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DoD End User Perspective and DARPA Palm Power Program
DOE Fuel Cell Portable Power WorkshopJanuary 15-17, 2002
Phoenix, Arizona
Dr. Robert NowakDr. Robert NowakDARPA Defense Sciences OfficeDARPA Defense Sciences [email protected]@darpa.mil 703 696703 696--74917491
Dr. Karen Swider LyonsDr. Karen Swider LyonsNaval Research LabNaval Research Lab
Advanced Energy TechnologiesAdvanced Energy Technologies
DoD Compact Fuel Cell Evolution
1996 - H2 System (metal hydride)• 40 W / 90 Wh; 1.6 kg
1992 –H2 Stack• 15 W; 2.3 kg
1998 - H2 System (compressed hydrogen• 50 W/ 2 kW-hr; 3.4 kg
2001 – DMFC - System• 60 W; 6.8 kg; 30% efficiency SOFC –Hydrocarbon – System
• 20 W; 0.72 kg; 28% efficiency (Goals)“It’s the fuel stupid!”“It’s the fuel stupid!”
The Future?
Marine Corps Air Ground Combat Center29 Palms, CA, Fall 1999
MILITARY EXERCISETRAINING
Fuel Cells aboard Humvee
PRC-119 Radios
Retransmission Site
COST ESTIMATE FOR ONE RETRANS SITE
• BA5590 BATTERIES = $8000• FUEL CELLS = $250
Ball Aerospace & Technologies Corpand H-Power Corp
• Operates directly on methanol (no fuel processing required)• Very low temperature operation (case and cooling air is cool to the touch)• One gallon of methanol ( < $0.50) equivalent to 100 lbs. batteries ($4000)• Technology easily scaled – cellular telephones (1 Watt on up)• Several distributed units could replace unreliable, noisy generators• Future technology goal - operate on logistics fuels
Direct Methanol Fuel Cell
60 Watt Packaged System
LANL and Ball Aerospace & Technologies Corporation
Brassboard
Direct Methanol Fuel Cells for Cellular Phones
•One Month Operation?•No Battery Chargers•Scaleable Technology for More Power Hungry Devices
PolyFuel
NEC
Motorola
Manhattan Scientifics
Performance Shortfall of Today’s Portable Power Sources for DoD Applications
1600 2000 4000 60000 200 400 600 800 1000 1200 14000
100
200
300
400
500
600Micro Air Vehicles
Robots
Micro ClimateCooling
Exoskeletons
Soldier Power
2005
Specific Energy, Whr/kg
Spec
ific
Pow
er, W
/kg
Batteries
2018-252008
! Develop a 20 W power source in a hand-held package having 15 times the energy content of the best battery to meet future power requirements in 2010 and beyond
Idea:
Technical Challenges:
Impact:Highlights:
! For…Objective Force Warrior, SOCOM
! To…Enable Future Missions! via…Energy Conversion of High
Energy Fuels! Scale Up Option for Cooling, EXO,
etc.
" New Start in FY01; Five Year Program. Phase I – 3 Years
" Multidisciplinary teams: Large Corporations, Small Businesses, Universities, Non-profits
" Transition Partners: PM Soldier, Natick, CECOM, SOCOM, Marine Corps, Navy
! Highly efficient energy conversion ofliquid fuels
! New materials for thermal management, catalysis! Novel fabrication tools for highly compact, complex
systems
Palm PowerResource Allocation
Materials8% Materials
Processing6%
Components25%
Systems61%
10
100
1,000
10,000
0 50 100 150 200 250
Syst
em S
peci
fic E
nerg
y, W
h/kg
Discharge Time at 20W, hours
3 Hours 3 days 10 days
2,000 Wh/kg goal for 3 day system 3,000 Wh/kg goal for 10 day system
1,000 Wh/kg goal for 3 hour system
Current SOA Batteries (Primary & Secondary)
HighSpecific
Power
HighSpecificEnergy
Mission Energy Goals
Program StructureMaterials (8%)! Membranes
" U of Colorado! Electroactive Polymers
" SRI! Thermionics
" Vanderbuilt" ENECO
! Thermophotovoltaics" Draper Laboratory
! Thermoelectrics" RTI
Materials Processing (6%)! Ceramic Extrusion
" Georgia Tech" Adaptive Materials
Components (25%)!Small Engine
" U of Michigan! AMTEC
" AMPS! Micro Fuel Processing
" RTI" Altex
! SOFC" MSRI
! Combustion" Yale U
Integrated Systems (61%)! DMFC
" Ball Aerospace" Creare
! SOFC" ITN Energy Systems" Honeywell/General Electric
Program Philosophy• Multiple Technologies• Cross-fertilization of Materials andComponents
• Flexible Integration Into Systems
AlN
Si
Thin-filmTE AlN
Si
MicroChannelsfor Heat-TransferFluids
20 µµµµm
YSZElectrolyte
NI-YSZAnode
Anode Supported Tubule(SEM Fracture Surface)
Approach:• Steam reforming of hydrocarbon fuels
and thermal decomposition of ammonia in a H2 selective membrane reactor
• Integrated micro-channel reactor, auxiliary fuel combustor, H2membrane, gas/gas heat exchanger heat recovery, and insulation panels for low heat loss.
• Maximized thermal efficiency and hydrogen yield
• Integrated Micro-channel reactor/ combustor for hydrogen generation by thermal decomposition of NH3
• High-flux, high-selectivity Pd-based composite membranes
• Micro-channel gas/gas heat exchangers for high thermal efficiency
• “Additive” manufacturing for light-weight fuel processor components
Status of Current Technologies:
• To develop lightweight, fuel processors to convert liquid logistic fuels to high purity on-demand hydrogen
Overall Objective:
Compact Integrated Multi-Fuel ProcessorsAshok S. Damle, Research Triangle Institute
Charles J. Call, MesoSystems Technology, Inc.
Hydrogen Generator Targets:• Capacity - 1.5 to 5 kW-hr• Specific Energy - 2 to 3 kWh/kg
Conceptual NH3-based Hydrogen Generator
Valve
Reactor andHeat Exchanger Butane
Canister
AmmoniaAdsorbentCanister
AmmoniaTank
11.5 cm
8.5 cm
20 cm
Proposed SOFC Palm Power System
Thermal ManagementAir Delivery
Fuel Delivery
CPOXfor startup(pre-reformingif necessary)
High Performance
Direct OxidationSOFC
Exhaust
• Power: 20 W, 12 VDC• Estimated dimension: 8.5 x 11.5 x 20 cm (10-day
mission)• Estimated weight (excluding fuel): 0.5 kg• Estimated energy density (JP-8 fuel):
• 2000 Wh/kg (3-day mission)• 3700 Wh/kg (10-day mission)
• Fuel: JP-8Honeywell/GE
Honeywell/GE SOFC Performance
0
0.2
0.4
0.6
0.8
1
1.2
1.4
0 0.5 1 1.5 2 2.5
Current Density (A/cm²)
Volta
ge (V
)
0
0.2
0.4
0.6
0.8
1
1.2
1.4
Pow
er D
ensi
ty (W
/cm
²)
Voltage in Syngas
Power Density in Syngas19% H2, 24% CO, 1% CO2, Bal N2
Power Density in H2
Voltage in H2 • 800°C operation• Open circuit voltages in
agreement with theoretical values
• Peak power density:– 1.3 W/cm² in
hydrogen– 0.85 W/cm² in JP-8
syngas
0.0
0.2
0.4
0.6
0.0
0.2
0.4
0.6
Diesel
Toluene
Decane
0.0
0.2
0.4
0.6
0.0
0.2
0.4
0.6
Volta
ge (V
)
Cur
rent
den
sity
(A/c
m2 )
0 2 4 6 8 10 120.0
0.2
0.4
0.6
0.0
0.2
0.4
0.6
Time(hr)
Direct Oxidation of Liquid Hydrocarbons
• Performance on liquid hydrocarbon fuels at 700°C
• Stable operation
Gorte, Vohs, Worrell
Direct Oxidation ofHydrocarbons in SOFCs
Diesel – Performance vs. Time
0.0 0.2 0.4 0.6 0.80.0
0.2
0.4
0.6
0.8
1.0
Pow
er D
ensi
ty (W
/cm
2 )
Volta
ge (V
)
Current Density (A/cm2)
0.00
0.05
0.10
0.15
0.20
I-V for Diesel Fuel at 700°C
0 2 4 6 8 10 120.0
0.2
0.4
0.6
0.8
1.0
Voltage Current Density
Volta
ge (V
) and
Cur
rent
Den
sity
(A/c
m2 )
Time (hr)
Gorte, Vohs, Worrell
CPOX for Processing Hydrocarbon Fuels
• Fuels: propane, butane, octane, JP-8, and diesel
• Duration: 700 hours to date
• Thermal cycles: 10
• Sulfur tolerance: 1000 ppm dibenzothiophenein JP-8
• Yield: 70-80% of LHV in JP-8
0%
20%
40%
60%
80%
100%
0 40 80 120 160 200 240 280 320
Time (Hours)
Perc
ent Y
ield
%
H2
COThermal Cycle
Honeywell/GE