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CERDEC Bottom Line: THE WARFIGHTER NS9/03
US ARMY CERDECFuel Cell TechnologyUS ARMY CERDECFuel Cell Technology
Dr. Ashok PatilUS ARMY CERDEC
Chief, Environmental Systems and Fuel Cell BranchFort Belvoir, VA
2004 AAAS Symposium13 February 2004
Seattle, WA
CERDEC Bottom Line: THE WARFIGHTER NS9/03
THE AMERICAN WARFIGHTER:ARMY’S #1 CUSTOMER
THE AMERICAN WARFIGHTER:ARMY’S #1 CUSTOMER
The ARMY’S R&D programsare focused on developing critical, cutting edged equipment for the AMERICAN WARFIGHTERSso that they can accomplish their Mission quickly and effectively and return home safe.
The AMERICAN WARFIGHTERS are our BOTTOM LINE.
Copyright: Time Magazine, December 2003
CERDEC Bottom Line: THE WARFIGHTER NS9/03
OverviewOverview
1. Military Power Needs
2. Why Fuel Cells?
3. Military Applications
4. Soldier Power
5. Technology Evolution
6. Conclusions
CERDEC Bottom Line: THE WARFIGHTER NS9/03
American WarfightersAmerican Warfighters
“We had extreme difficulty moving with all our weight. If our movement would have been to relieve a unit in contact or a time sensitive mission we would not have been able to move in a timely manner. It took us 8 hours to move 5 clicks. [that's less than 1 mph]”
This is more than just a cartoon.
For our American Warfighters
CERDEC Bottom Line: THE WARFIGHTER NS9/03
Why Fuel Cells?Why Fuel Cells?
- Coalition Forces came within days of running out of batteries to power critical Army systems.
-Rechargeable batteries were encouraged but not used by troops.
-Warfighters need light-weight, high energy dense power systems.
CERDEC Bottom Line: THE WARFIGHTER NS9/03
Military Power SourcesMilitary Power Sources
Diesel Gen Sets
TPV
Fuel Cells
Microengines
Batteries
Hybrid Systems
Current Army Power Sources
Pacing Technologies
Future Army Power Sources
Power Users
Watts
MINI-UV
Power Sources
NO CURRENT SOLUTION:
CRITICAL GAP!
20W –3000W
NO CURRENT SOLUTION:
CRITICAL GAP!
20W –3000W
3-5kW
50W
CERDEC Bottom Line: THE WARFIGHTER NS9/03
Fuel Cell Technology forThe Modern Army
Fuel Cell Technology forThe Modern Army
Benefits of Fuel Cells in Military Applications
•Light WeightLight Weight •Longer, Lighter Missions
•Silent OperationSilent Operation •Stealth and ‘Silent Watch’ Ops
•Higher EfficiencyHigher Efficiency •Cogeneration Use, Improved Fuel Utilization
CERDEC Bottom Line: THE WARFIGHTER NS9/03
Army Vision for Military Fuel Cell Systems
Army Vision for Military Fuel Cell Systems
Soldier & Sensor Power (10-100W)
Combined Heat and Power ( >3000W )
Auxiliary Power Units (500-3000W)
Major Applications for Portable Fuel Cell Technology
CERDEC Bottom Line: THE WARFIGHTER NS9/03
Fuel Cells of Interest to the ArmyFuel Cells of Interest to the Army
Proton Proton Exchange Exchange MembraneMembrane
•Low Temperature Operation
•High Energy Density
•Efficient Operation (30-40% on reformed fuels).
•Quick Start
•Proven Reliability
•Low Acoustics and Vibration
•Pure Hydrogen Fuel
•Heat Rejection at Larger Sizes
•Sensitive to Contaminants
•Thermal Mismatch between reformers and stacks
•Soldier Power
•Sensors
•Silent Watch Auxiliary Power Units
Direct Direct MethanolMethanol
•Low Temperature Operation
•Direct Liquid Fuel
•High Energy Density
•Low Acoustics and Vibration
•Operation Below Freezing
•Longevity of Stack Materials
•Slow Start Time
•Methanol Crossover
•Soldier Power
•Sensors
Solid Solid OxideOxide
•Fuel Flexible Goal-Diesel/JP8
•Tolerance to Contaminants Except Sulfur
•Low Acoustics and Vibration
•High Temperature Operation
•Materials Problems
•On/Off Cycle Life
•Slow Start Time
•Only Early Prototype Exist
•Auxiliary Power Units
•Vehicle Power
•Combined Heat and power
Fuel Cell Advantages Challenges Applications
CERDEC Bottom Line: THE WARFIGHTER NS9/03
HydrogenHydrogen SourceSource
Diesel/ JP-8Diesel/ JP-8** (1300-5000Whr/kg) (1300-5000Whr/kg)
Gasoline/JP-4Gasoline/JP-4** (1200-5000Whr/kg) (1200-5000Whr/kg)
MethaneMethane** (2100-5600Whr/kg) (2100-5600Whr/kg)
Propane/ButanePropane/Butane** (1920-5000Whr/kg) (1920-5000Whr/kg)
EthanolEthanol** (1000-3000Whr/kg) (1000-3000Whr/kg)
MethanolMethanol** (800-2300Whr/kg) (800-2300Whr/kg)
Chemical/Metal Hydrides (1200Whr/kg)Chemical/Metal Hydrides (1200Whr/kg)
Hydrogen (1000-23,000Whr/kg)Hydrogen (1000-23,000Whr/kg)
Hydrogen DeliveryHydrogen Delivery
* Based on 15-40% Efficiency
CERDEC Bottom Line: THE WARFIGHTER NS9/03
Soldier and Sensor PowerSoldier and Sensor Power
Goal: Longer, Lighter Missions through Hybrid Systems.
Applications: Soldier Power, Robots\UAVs, Remote Sensors, Battery Chargers.
Technology:Direct Hydrogen Fed-Fuel CellsDirect Methanol Fuel CellsMethanol Reforming Fuel Cell Systems
Soldier Systems can use prepackaged liquid fuels such as Methanol
CERDEC Bottom Line: THE WARFIGHTER NS9/03
High Energy Dense FuelsHigh Energy Dense Fuels
High energy dense fuels, such as methanol, favor low-power systems over batteries for longer missions (12+ hours)!
Portable Power - Energy Density
0
10
20
30
40
50
60
0.00 12.00 24.00 36.00 48.00 60.00 72.00 84.00 96.00
Mission Length in Hours
Po
wer
Sys
tem
Wei
gh
t in
Po
un
ds
Rechargeable Battery
Primary Battery
PEM Fuel Cell w\ Chemical Hydride
Direct Methanol FC
CERDEC Bottom Line: THE WARFIGHTER NS9/03
CERDEC Goals for Soldier PowerCERDEC Goals for Soldier Power
Soldier Power SourceSoldier Power Source
PowerPower: 25W continuous: 25W continuous
Energy DensityEnergy Density: 1000Whr/kg for 72 : 1000Whr/kg for 72 hour mission.hour mission.
Portable Battery ChargerPortable Battery Charger
PowerPower: 150-500W: 150-500Wee , 28VDC , 28VDC
Weight:Weight: < 9.0kg, including 1000Whrs of fuel.
Hot-Swappable Fuel Cartridge
Temperature Range: 1C - 52C
Non-Detectable (aural) at 100 meters.
CERDEC Bottom Line: THE WARFIGHTER NS9/03
CERDEC Efforts in Soldier and Sensor Power
CERDEC Efforts in Soldier and Sensor Power
15W Monopolar DMFC
Present DMFC-20(Version 1.0):
• 20 W net power.
•1.75 kg (fuel cell and b.o.p.)
•460 Whr / kg system energy density
(including 1.0L ‘Neat’ Methanol).
Future DMFC-20(Version 1.1):
• 20 W net power, ruggedized housing.
•1.0 kg (fuel cell and b.o.p.)
•43% Less Weight
•620 Whr / kg system energy density
(including 1.0L ‘Neat’ Methanol).
CERDEC Bottom Line: THE WARFIGHTER NS9/03
Direct Methanol FuelCell Evolution
Direct Methanol FuelCell Evolution
11stst Generation (2001) Generation (2001)Smart Fuel Cell’s A-25 DMFC :25W, 22 lbs (10 kg) dry.2.5L ‘Neat’ Methanol Fuel Reservoir.
-55 hour Runtime.
22ndnd Generation (2003) Generation (2003)New Prototype C-25 DMFC: 25W, 2lbs (1.0kg) dry. -90% Weight Reduction!140Whr Internal Fuel Storage
-6 hour Runtime
CERDEC Bottom Line: THE WARFIGHTER NS9/03
Equivalent Power Sourcesfor 72 Hour, 20W MissionEquivalent Power Sourcesfor 72 Hour, 20W Mission
For 72 hour mission, current DMFC Technology shows vast weight savingsvast weight savings over military batteries.
• BA-5590 Lithium Sulfur Dioxide Batteries
• 17.6 Pounds (8kg)
• $0.56 per Watt-hour
• Ball DMFC 20W
Direct Methanol Fuel Cell
with two fuel canisters.
• 6.4 Pounds (2.9 kg)• $0.34 per Watt-hour*
*($10,000/unit, 3000 hour lifetime)
(0.75kg, 800Whr per methanol canister).
CERDEC Bottom Line: THE WARFIGHTER NS9/03
Lifetime Cost Estimates20W Continuous Load
Lifetime Cost Estimates20W Continuous Load
Estimates do not reflect reduced shipping and logistics costs!
BA5590 Battery Ball DMFC 20
Unit Cost 75.00$ Unit Cost 10,000.00$ Disposal Cost 25.00$ Lifetime 3000
Watt-Hour 180 Energy Produced 60000
$/Watt-Hour 0.56$ Fuel Canister Energy Density 800 Watt-Hour
Fuel Canisters Needed 75
333 batteries needed Unit Fuel Cost 10.00$ per canister
for 60,000 Whr Lifetime Fuel Costs 750.00$
Canister Disposal Costs 5.00$
Total Battery Cost 33,300.00$ Lifetime Canister Displ. Cost 375.00$
for 3000 Hours Unit Disposal Cost 30.00$
Maintenance Hours 450 15% of lifetime
Maintenace Cost 20.00$ $/hr
Total Maintenance Cost 9,000.00$
Spare Parts Package 500.00$ 5% total cost
Total Cost 20,655.00$ per unit
$ / Watt-Hour 0.34$
38% Cost SavingsFor 3000 Hours!
CERDEC Bottom Line: THE WARFIGHTER NS9/03
Microchannel Reactors• Enhanced Heat Transfer• Enhanced Mass Transfer• Economics of Mass Production• High Surface Area to Volume Ratio• Low pressure Drop Through Channels
Future Directions in Reformer DesignFuture Directions
in Reformer Design
CERDEC Bottom Line: THE WARFIGHTER NS9/03
Fuel Reformer SystemsFuel Reformer Systems
Innovatek Design Goals:
• 1000 We nominal
• Diesel Fuel
• Process: Steam Reforming
• Weight: < 30 kg; Volume < 50 Lfor entire Fuel Processing System
Diesel Reformer
Battelle Design Goals:
• 100-200 We nominal system
• Weight < 3.5 kg (dry); Volume < 2.5 L
• Including Fuel Cell Stack and BOP
• Fuel: Methanol
• Process: Steam Reforming
Methanol Reformer
CERDEC Bottom Line: THE WARFIGHTER NS9/03
C3 On-The-MoveCombat Vehicle
C3 On-The-MoveCombat Vehicle
Mobile Power Pac2kW Methanol Reforming
Fuel Cell System
•Weight: 265 lbs (120 kg)•Fuel: Methanol-Water •3.5 Gallon Fuel Capacity -6 hours operation time•Voltage: 24-28VDC•Noise: < 55dBA at 7 metersNoise: < 55dBA at 7 metersFuel Cell APU mounted on the roof of a C3 On-The-
Move Combat Vehicle. This APU provides power to electronic equipment during stealth operations.
CERDEC Bottom Line: THE WARFIGHTER NS9/03
Cogeneration Power and CoolingCogeneration Power and Cooling
Heat Actuated Heat Actuated CoolingCooling
HeatHeat
CoolingCooling
Export PowerExport Power
Fuel CellFuel Cell
2 to 3 kW Electric Power-2 to 3 kW Electric Power-12 to 18 kBTUh Cooling12 to 18 kBTUh Cooling
FeaturesFeatures•Silent Operation
•Power On-The-Move
• Cooling
• Exportable Power
•Reduced Fuel ConsumptionJP-8JP-8
CERDEC Bottom Line: THE WARFIGHTER NS9/03
Hybrid Fuel Cell Technology Challenges
Hybrid Fuel Cell Technology Challenges
Challenges
Lightweight
Compact
Rugged NBC SurvivableNon Detectable
Affordable
Commercial Off-the-Shelf
Hydrogen Supply
Reliable,Maintainable, Sustainable
Military TemperatureOperation
Environmentally Safe
Military SpecificMilitary Specific
CERDEC Bottom Line: THE WARFIGHTER NS9/03
1998 2002 2004 2006 2010+
Soldier & Sensor Power
PEMFC with Hydrogen TankPEMFC Hybrid System
100W PEMFCWith Tank H2.
20W PEMFCHybrid
Demonstrated During Field Exercises
2004 Status:
Diesel Solid Oxide Fuel CellsLogistic Fuel Reformers for PEMFC Systems
Diesel Reformer for PEMFC
Solid OxideFuel Cell APU
Component Development/Basic Research
Soldier & Sensor Power, Portable APU
Roadmap (to TRL 6) for Military Fuel Cell DemonstrationsRoadmap (to TRL 6) for Military Fuel Cell Demonstrations
Soldier & Sensor Power, Portable APU
PEMFC with Chemical Hydride Direct Methanol Fuel Cells
Methanol Reforming PEMFC System
20W DMFC
2kW Methanol Reforming PEMFC
system
Early Prototypes
CERDEC Bottom Line: THE WARFIGHTER NS9/03
ConclusionsConclusions
Main Military Applications for Portable Fuel Cells Are:•Soldier & Sensor Power, Auxiliary Power Units, and Cogeneration.
US Army CERDEC is at the forefront of cutting edge fuel cell technology for the military.
Fuel cells offer significant weight and cost savings over traditional military power sources
Main Technology Barriers to Military are:•Fuel Supply, Affordability, and Reliability/Durability in the Field.
Prepackaged Liquid Fuels (Methanol) Ideal for Low-Power Applications.
CERDEC Bottom Line: THE WARFIGHTER NS9/03
Back-UpBack-Up
CERDEC Bottom Line: THE WARFIGHTER NS9/03
Past CERDEC EffortsPast CERDEC Efforts
Soldier PowerCooling Module
1996
Snorkler - 1996
Methanol PoweredGenerator Set – 1984
DMFC 60W SystemDARPA Palm Power
2002
PPS 100W - 1998
CERDEC Fuel Cell Timeline
25W DMFC2002-2003
20W DMFC 20031000W Methanol
Reforming PEM - 2001
CERDEC Bottom Line: THE WARFIGHTER NS9/03
Absorption Cooling Efforts
• Microchannel flow/chemical mixing• Porous membrane technology• Better Efficiency• Smaller Size• Heat Actuated Breadboard System
Current Cogeneration EffortsCurrent Cogeneration Efforts
Fuel Cell Efforts •2 kW fuel cell auxiliary power unitfor mobile power generation.
•1 kW integrated fuel cell system with low sulfur diesel reformer.
• 1 kW low sulfur diesel fuel reformer.
1kW PEM Fuel cell with fuel reformer.
Expander/compressor Refrigerant Desorber