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The development of a fuel cell energy storage system for the Space Station Extravehicular Mobility Unit (EMU) is discussed. The ion-exchange membrane fuel cell uses hydrogen stored as a metal hydride. Several features of the hydrogen-oxygen fuel cell are examined, including its construction, hydrogen storage, hydride recharge, water heat, water removal, and operational parameters.
The International Space Station (ISS) Program requires that there always be a 45 calendar day contingency supply of breathing oxygen. In the early assembly stages, there is only one flight system, the Russian Solid Fuel Oxygen Generator (SFOG), that can meet that requirement. To better ensure the contingency oxygen supply, the Crew and Thermal Systems Division was directed to develop a flight hardware system that can meet all contingency oxygen requirements for ISS. Such a system, called the Backup Oxygen Candle System (BOCS), has been built and tested. The BOCS consists of 33 chlorate candles, a thermal containment apparatus, support equipment and packaging. The thermal containment apparatus utilizes the O2 produced by the candle as the motive stream in an ejector to passively cool the candle during operation.
The results of a 12 month study to identify high performance regenerative hydrogen-oxygen fuel cell concepts for geosynchronous satellite application are summarized. Emphasis was placed on concepts with the potential for high energy density and passive means for water and heat management to maximize system reliability. Both polymer membrane and alkaline electrolyte fuel cells were considered, with emphasis on the alkaline cell because of its high performance, advanced state of development, and proven ability to operate in a launch and space environment. Three alkaline system concepts were studied. Results indicate that using near term technology energy densities between 46 and 52 watt-hour/lb can be achieved at efficiencies of 55 percent. Using advanced light weight cell construction which was achieved in experimental cells, composite tankage material for the reactant gases and the reversible stack concept, system energy densities of 115 watt-hours/lb can be projected.
The results of a 12 month study to identify high performance regenerative hydrogen-oxygen fuel cell concepts for geosynchronous satellite application are summarized. Emphasis was placed on concepts with the potential for high energy density and passive means for water and heat management to maximize system reliability. Both polymer membrane and alkaline electrolyte fuel cells were considered, with emphasis on the alkaline cell because of its high performance, advanced state of development, and proven ability to operate in a launch and space environment. Three alkaline system concepts were studied. Results indicate that using near term technology energy densities between 46 and 52 watt-hour/lb can be achieved at efficiencies of 55 percent. Using advanced light weight cell construction which was achieved in experimental cells, composite tankage material for the reactant gases and the reversible stack concept, system energy densities of 115 watt-hours/lb can be projected.
A fuel cell technology program was established to advance the state-of-the art of hydrogen oxygen fuel cells using low temperature, potassium hydroxide electrolyte technology as the base. Cell and component testing confirmed that low temperature, potassium hydroxide electrolyte technology is compatible with the requirements of the space shuttle Phase B contractors. Testing of the DM-1 powerplant demonstrated all of the important requirements of the shuttle except operating life. Testing also identified DM-1 powerplant life limiting mechanisms; hydrogen pump gear wear and pressurization of the cell stack over its design limits.
Cathodic electrocatalysts for use in low temperature hydrogen-oxygen fuel cells with an alkaline electrolyte-corrosion resistance and activity testing of materials and elements
Cathodic electrocatalysts development for use in low temperature hydrogen-oxygen fuel cells with alkaline electrolyte
Discharge characteristics of pulsed hydrogen- oxygen fuel cells and galvanostatic reactions in nonsteady state operation
Cathodic electrocatalyst materials studied for use in low temperature hydrogen oxygen fuel cells with alkaline electrolyte
Summarized are the results of a 12-month study to identify high performance regenerative hydrogen-oxygen fuel cell concepts for geosynchronous satellite application. Emphasis was placed on concepts with the potential for high energy density (W-hr/lb) and passive means for water and heat management to maximize system reliability. Both polymer membrane and alkaline electrolyte fuel cells were considered, with emphasis on the alkaline cell because of its high performance, advanced state of development, and proven ability to operate in a launch and space environment. Three alkaline system concepts were studied. The first, the integrated design, utilized a configuration in which the fuel cell and electrolysis cells are alternately stacked inside a pressure vessel. Product water is transferred by diffusion during electrolysis and waste heat is conducted through the pressure wall, thus using completely passive means for transfer and control. The second alkaline system, the dedicated design, uses a separate fuel cell and electrolysis stack so that each unit can be optimized in size and weight based on its orbital operating period. The third design was a dual function stack configuration, in which each cell can operate in both fuel cell and electrolysis mode, thus eliminating the need for two separate stacks and associated equipment. Results indicate that using near term technology energy densities between 46 and 52 W-hr/lb can be achieved at efficiencies of 55 percent. System densities of 115 W-hr/lb are contemplated.
A fuel cell technology program was established to advance the state-of-the-art of hydrogen-oxygen fuel cells using low temperature, potassium hydroxide electrolyte technology as the base. Program tasks are described consisting of baseline cell design and stack testing, hydrogen pump design and testing, and DM-2 powerplant testing and technology extension efforts. A baseline cell configuration capable of a minimum of 2000 hours of life was defined. A 6-cell prototype stack, incorporating most of the scheme cell features, was tested for a total of 10,497 hours. A 6-cell stack incorporating all of the design features was tested. The DM-2 powerplant with a 34 cell stack, an accessory section packaged in the basic configuration anticipated for the space shuttle powerplant and a powerplant control unit, was defined, assembled, and tested. Cells were used in the stack and a drag-type hydrogen pump was installed in the accessory section. A test program was established, in conjunction with NASA/JSC, based on space shuttle orbiter mission. A 2000-hour minimum endurance test and a 5000-hour goal were set and the test started on August 8, 1972. The 2000-hour milestone was completed on November 3, 1972. On 13 March 1973, at the end of the thirty-first simulated seven-day mission and 5072 load hours, the test was concluded, all goals having been met. At this time, the DM-2 was in excellent condition and capable of additional endurance.
Development of cathodic electrocatalysts for use in low temperature hydrogen-oxygen fuel cells with alkaline electrolyte
The theoretically high efficiency and low temperature operation of hydrogen-oxygen fuel cells has motivated them to be the subject of much study since their invention in the 19th Century, but their relatively high life cycle costs kept them as a "solution in search of a problem" for many years. The first problem for which fuel cells presented a truly cost effective solution was that of providing a power source for NASA's human spaceflight vehicles in the 1960 s. NASA thus invested, and continues to invest, in the development of fuel cell power plants for this application. This development program continues to place its highest priorities on requirements for minimum system mass and maximum durability and reliability. These priorities drive fuel cell power plant design decisions at all levels, even that of catalyst support. However, since the mid-1990's, prospective environmental regulations have driven increased governmental and industrial interest in "green power" and the "Hydrogen Economy." This has in turn stimulated greatly increased investment in fuel cell development for a variety of commercial applications. This investment is bringing about notable advances in fuel cell technology, but, as these development efforts place their highest priority on requirements for minimum life cycle cost and field safety, these advances are yielding design solutions quite different at almost every level from those needed for spacecraft applications. This environment thus presents both opportunities and challenges for NASA's Human Exploration Program
A fuel cell technology program which was established to advance the state-of-the-art of hydrogen-oxygen fuel cells using the P and WA PC8B technology as the base is reported. The major tasks of this program consisted of (1) fuel cell system studies of a space shuttle powerplant conceptual design (designated engineering model -1, EM-1) supported by liaison with the space shuttle prime contractors; (2) component and subsystem technology advancement and; (3) a demonstrator powerplant test. Fuel cell system studies, with the EM-1 as the focal point of design activities, included determination of voltage regulation, specific reactant consumption, weight, voltage level and performance characteristics. These studies provided the basis for coordination activities with the space shuttle vehicle prime contractor. Interface information, on-board checkout and in-flight monitoring requirements, and development cost data were also provided as part of this activity. Even though the two vehicles primes had different voltage requirements (115 volts in one case and 28 volts in the other), it was concluded that either option could be provided in the fuel cell power system by the electrical hook-up of the cells in the stack.
Metal theory is used to study the role of metal catalysts in electrocatalysis, with particular reference to alkaline hydrogen-oxygen fuel cells. Use is made of a simple model, analogous to that used to interpret field emission in vacuum. Theoretical values for all the quantities in the Tafel equation are obtained in terms of bulk properties of the metal catalysts (such as free electron densities and Fermi level). The reasons why some processes are reversible (H-electrodes) and some irreversible (O-electrodes) are identified. Selection rules for desirable properties of catalytic materials are established.
An extensive research and development program has been carried out to devise an improved method of removing waste heat of reaction from a developmental 2 kW hydrogen-oxygen fuel cell.
Micro-tubular fuel cells that would operate at power levels on the order of hundreds of watts or less are under development as alternatives to batteries in numerous products - portable power tools, cellular telephones, laptop computers, portable television receivers, and small robotic vehicles, to name a few examples. Micro-tubular fuel cells exploit advances in the art of proton-exchange-membrane fuel cells. The main advantage of the micro-tubular fuel cells over the plate-and-frame fuel cells would be higher power densities: Whereas the mass and volume power densities of low-pressure hydrogen-and-oxygen-fuel plate-and-frame fuel cells designed to operate in the targeted power range are typically less than 0.1 W/g and 0.1 kW/L, micro-tubular fuel cells are expected to reach power densities much greater than 1 W/g and 1 kW/L. Because of their higher power densities, micro-tubular fuel cells would be better for powering portable equipment, and would be better suited to applications in which there are requirements for modularity to simplify maintenance or to facilitate scaling to higher power levels. The development of PEMFCs has conventionally focused on producing large stacks of cells that operate at typical power levels >5 kW. The usual approach taken to developing lower-power PEMFCs for applications like those listed above has been to simply shrink the basic plate-and-frame configuration to smaller dimensions. A conventional plate-and-frame fuel cell contains a membrane/electrode assembly in the form of a flat membrane with electrodes of the same active area bonded to both faces. In order to provide reactants to both electrodes, bipolar plates that contain flow passages are placed on both electrodes. The mass and volume overhead of the bipolar plates amounts to about 75 percent of the total mass and volume of a fuel-cell stack. Removing these bipolar plates in the micro-tubular fuel cell significantly increases the power density.
X ray diffraction analysis of matrices of hydrogen-oxygen electrolytic regenerative fuel cells