Design of direct methanol fuel cells for portable applications
The design requirements, stack power density and efficiency issues for mini fuel cells and micro fuel cells are discussed.
fuel↗
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Development of a High Reliability Compact Air Independent PEMFC Power System
Autonomous Underwater Vehicles (AUV's) have received increasing attention in recent years as military and commercial users look for means to maintain a mobile and persistent presence in the undersea world. Compact, neutrally buoyant power systems are needed for both small and large vehicles. Historically, batteries have been employed in these applications, but the energy density and therefore mission duration are limited with current battery technologies. Vehicles with stored energy requirements greater than approximately 10 kWh have an alternate means to get long duration power. High efficiency Proton Exchange Membrane (PEM) fuel cell systems utilizing pure hydrogen and oxygen reactants show the potential for an order of magnitude energy density improvement over batteries as long as the subsystems are compact. One key aspect to achieving a compact and energy dense system is the design of the fuel cell balance of plant (BOP). Recent fuel cell work, initially focused on NASA applications requiring high reliability, has developed systems that can meet target power and energy densities. Passive flow through systems using ejector driven reactant (EDR) circulation have been developed to provide high reactant flow and water management within the stack, with minimal parasitic losses compared to blowers. The ejectors and recirculation loops, along with valves and other BOP instrumentation, have been incorporated within the stack end plate. In addition, components for water management and reactant conditioning have been incorporated within the stack to further minimize the BOP. These BOP systems are thermally and functionally integrated into the stack hardware and fit into the small volumes required for AUV and future NASA applications to maximize the volume available for reactants. These integrated systems provide a compact solution for the fuel cell BOP and maximize the efficiency and reliability of the system. Designs have been developed for multiple applications ranging from less than 1 kWe to 70 kWe. These systems occupy a very small portion of the overall energy system, allowing most of the system volume to be used for reactants. The fuel cell systems have been optimized to use reactants efficiently with high stack efficiency and low parasitic losses. The resulting compact, highly efficient fuel cell system provides exceptional reactant utilization and energy density. Key design variables and supporting test data are presented. Future development activities are described.
Vasquez, Arturo↗
Development of a PEMFC Power System with Integrated Balance of Plant
Autonomous Underwater Vehicles (AUV s) have received increasing attention in recent years as military and commercial users look for means to maintain a mobile and persistent presence in the undersea world. Compact, neutrally buoyant power systems are needed for both small and large vehicles. Batteries are usually employed in these applications, but the energy density and therefore the mission duration are limited with current battery technology. At a certain energy or mission duration requirement, other means to get long duration power become feasible. For example, above 10 kW-hrs liquid oxygen and hydrogen have better specific energy than batteries and are preferable for energy storage as long as a compact system of about 100 W/liter is achievable to convert the chemical energy in these reactants into power. Other reactant forms are possible, such as high pressure gas, chemical hydrides or oxygen carriers, but it is essential that the power system be small and light weight. Recent fuel cell work, primarily focused on NASA applications, has developed power systems that can meet this target power density. Passive flow-through systems, using ejector driven reactant (EDR) flow, integrated into a compact balance of plant have been developed. These systems are thermally and functionally integrated in much the same way as are automotive, air breathing fuel cell systems. These systems fit into the small volumes required for AUV and future NASA applications. Designs have been developed for both a 21" diameter and a larger diameter (LD) AUV. These fuel cell systems occupy a very small portion of the overall energy system, allowing most of the system volume to be used for the reactants. The fuel cell systems have been optimized to use reactants efficiently with high stack efficiency and low parasitic losses. The resulting compact, highly efficient fuel cell system provides exceptional reactant utilization and energy density. Key design variables and supporting test data are presented. Future development activities are described.
Wynne, B.↗
Round Trip Energy Efficiency of NASA Glenn Regenerative Fuel Cell System
NASA Glenn Research Center (GRC) has recently demonstrated a Polymer Electrolyte Membrane (PEM) based hydrogen/oxygen regenerative fuel cell system (RFCS) that operated for a charge/discharge cycle with round trip efficiency (RTE) greater than 50 percent. The regenerative fuel cell system (RFCS) demonstrated closed loop energy storage over a pressure range of 90 to 190 psig. In charge mode, a constant electrical power profile of 7.1 kWe was absorbed by the RFCS and stored as pressurized hydrogen and oxygen gas. In discharge mode, the system delivered 3 to 4 kWe of electrical power along with product water. Fuel cell and electrolyzer power profiles and polarization performance are documented in this paper. Individual cell performance and the variation of cell voltages within the electrochemical stacks are also reported. Fuel cell efficiency, electrolyzer efficiency, and the system RTE were calculated from the test data and are included below.
Garcia, Christopher P.↗
Evaluation Studies of a 800W Solid Oxide-Based Fuel Cells Stack for Electrical Power in Aviation
As both NASA and the aeronautics industry recognize the need for higher fuel efficiency and lower carbon emissions in both commercial airline and private aviation applications, development of all-electric or hybrid electric aircraft have garnered renewed interest in the aviation community. For the particular example of the hybrid-electric option, the solid oxide fuel cell (SOFC) is an attractive option for the power source, due to its potential to utilize aviation fuels thereby having minimal impact to aviation infrastructure. SOFC stack performance depends upon many factors, one of the most important is the way the oxidant and fuel gases are delivered to the fuel cells. System modeling of various aircraft configurations for FUELEAP (Fostering Ultra-Efficient, Low-Emitting Aviation Power) point to the need to operate SOFC stacks at high current densities. This creates challenges in the thermal profile of the stacks with potential to create large thermal gradients and hot spots. This study investigates two types of commercial solid oxide fuel cell stacks, the cross flow and co-flow gas designs, both convectively cooled with cathode air. High fuel utilization factors were also employed under varying electrical loads expected from the demands of flight. In addition, performance, range of operation and endurance were investigated under conditions of high current loads and thermal cycling. Evaluations include the study of gas kinetic using electrochemical spectroscopy. Testing took place at the facilities of NASA Glenn using a commercial test system (FuelCon AG, Magdeburg Germany). These studies are crucial to the Glenn Research Center's ability to conduct research, evaluation and development of the next-generation SOFC based stacks for cutting-edge energy technologies for aerospace applications. This study supports NASA's Convergent Aeronautics Solutions' (CAS) FUELEAP project.
Goldsby, Jon C.↗
NASA Tech Briefs, August 2004
Topics covered include: Data Relay Board with Protocol for High-Speed, Free-Space Optical Communications; Software and Algorithms for Biomedical Image Data Processing and Visualization; Rapid Chemometric Filtering of Spectral Data; Prioritizing Scientific Data for Transmission; Determining Sizes of Particles in a Flow from DPIV Data; Faster Processing for Inverting GPS Occultation Data; FPGA-Based, Self-Checking, Fault-Tolerant Computers; Ultralow-Power Digital Correlator for Microwave Polarimetry; Grounding Headphones for Protection Against ESD; Lightweight Stacks of Direct Methanol Fuel Cells; Highly Efficient Vector-Inversion Pulse Generators; Estimating Basic Preliminary Design Performances of Aerospace Vehicles; Framework for Development of Object-Oriented Software; Analyzing Spacecraft Telecommunication Systems; Collaborative Planning of Robotic Exploration; Tools for Administration of a UNIX-Based Network; Preparing and Analyzing Iced Airfoils; Evaluating Performance of Components; Fuels Containing Methane of Natural Gas in Solution; Direct Electrolytic Deposition of Mats of MnxOy Nanowires; Bubble Eliminator Based on Centrifugal Flow; Inflatable Emergency Atmospheric-Entry Vehicles; Lightweight Deployable Mirrors with Tensegrity Supports; Centrifugal Adsorption Cartridge System; Ultrasonic Apparatus for Pulverizing Brittle Material; Transplanting Retinal Cells using Bucky Paper for Support; Using an Ultrasonic Instrument to Size Extravascular Bubbles; Coronagraphic Notch Filter for Raman Spectroscopy; On-the-Fly Mapping for Calibrating Directional Antennas; Working Fluids for Increasing Capacities of Heat Pipes; Computationally-Efficient Minimum-Time Aircraft Routes in the Presence of Winds; Liquid-Metal-Fed Pulsed Plasma Thrusters; Personal Radiation Protection System; and Attitude Control for a Solar-Sail Spacecraft.
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REDOX electrochemical energy storage
Reservoirs of chemical solutions can store electrical energy with high efficiency. Reactant solutions are stored outside conversion section where charging and discharging reactions take place. Conversion unit consists of stacks of cells connected together in parallel hydraulically, and in series electrically. Stacks resemble fuel cell batteries. System is 99% ampere-hour efficient, 75% watt hour efficient, and has long projected lifetime. Applications include storage buffering for remote solar or wind power systems, and industrial load leveling. Cost estimates are $325/kW of power requirement plus $51/kWh storage capacity. Mass production would reduce cost by about factor of two.
Thaller, L. H.↗
Solid Oxide Fuel Cell/Gas Turbine Hybrid Cycle Technology for Auxiliary Aerospace Power
A notional 440 kW auxiliary power unit has been developed for 300 passenger commercial transport aircraft in 2015AD. A hybrid engine using solid-oxide fuel cell stacks and a gas turbine bottoming cycle has been considered. Steady-state performance analysis during cruise operation has been presented. Trades between performance efficiency and system mass were conducted with system specific energy as the discriminator. Fuel cell performance was examined with an area specific resistance. The ratio of fuel cell versus turbine power was explored through variable fuel utilization. Area specific resistance, fuel utilization, and mission length had interacting effects upon system specific energy. During cruise operation, the simple cycle fuel cell/gas turbine hybrid was not able to outperform current turbine-driven generators for system specific energy, despite a significant improvement in system efficiency. This was due in part to the increased mass of the hybrid engine, and the increased water flow required for on-board fuel reformation. Two planar, anode-supported cell design concepts were considered. Designs that seek to minimize the metallic interconnect layer mass were seen to have a large effect upon the system mass estimates.
Steffen, Christopher J., Jr.↗
Proton exchange membrane fuel cells for space and electric vehicle applications: From basic research to technology development
The proton exchange membrane fuel cell (PEMFC) is one of the most promising electrochemical power sources for space and electric vehicle applications. The wide spectrum of R&D activities on PEMFC's, carried out in our Center from 1988 to date, is as follows (1) Electrode Kinetic and Electrocatalysis of Oxygen Reduction; (2) Optimization of Structures of Electrodes and of Membrane and Electrode Assemblies; (3) Selection and Evaluation of Advanced Proton Conducting Membranes and of Operating Conditions to Attain High Energy Efficiency; (4) Modeling Analysis of Fuel Cell Performance and of Thermal and Water Management; and (5) Engineering Design and Development of Multicell Stacks. The accomplishments on these tasks may be summarized as follows: (1) A microelectrode technique was developed to determine the electrode kinetic parameters for the fuel cell reactions and mass transport parameters for the H2 and O2 reactants in the proton conducting membrane. (2) High energy efficiencies and high power densities were demonstrated in PEMFCs with low platinum loading electrodes (0.4 mg/cm(exp 2) or less), advanced membranes and optimized structures of membrane and electrode assemblies, as well as operating conditions. (3) The modeling analyses revealed methods to minimize mass transport limitations, particularly with air as the cathodic reactant; and for efficient thermal and water management. (4) Work is in progress to develop multi-kilowatt stacks with the electrodes containing low platinum loadings.
Srinivasan, Supramaniam↗
Analysis of a 100-W Regenerative Fuel Cell Demonstration
A 100-W regenerative fuel cell (RFC) demonstration was successfully completed at the NASA Glenn Research Center on December 11, 2014. This effort was funded by Advanced Space Power Systems milestone and represented the first demonstration of passive laboratory-scale stacks arranged as an RFC, consisting of a non-flow-through fuel cell and a static-feed electrolyzer. Once developed, these stacks present the potential to minimize system mass, volume, and parasitic power in comparison to existing terrestrial electrochemical systems and nonnuclear power generation options. Testing involved the fuel cell powering a simulated load then recycling fuel cell product water by subsequently electrolyzing it to regenerate hydrogen and oxygen gases for fuel cell operations. A total of five cycles were completed over a 2-week period, yielding cell voltage data for stack performance and quality measures for regenerated reactants. Overall, round-trip efficiency was calculated to be 47.4 percent. Gas crossover was observed in electrolyzer gas products, as residual gas analysis showed 1.1 percent hydrogen in oxygen and 0.4 percent oxygen in hydrogen. Fuel cell product water was determined to be more acidic and conductive and have a higher fluoride content when compared to deionized water.
fuel cell↗
Regenerative Performance of the NASA Symmetrical Solid Oxide Fuel Cell Design
The NASA Glenn Research Center is developing both a novel cell design (BSC) and a novel ceramic fabrication technique to produce fuel cells predicted to exceed a specific power density of 1.0 kW/kg. The NASA Glenn cell design has taken a completely different approach among planar designs by removing the metal interconnect and returning to the use of a thin, doped LaCrO3 interconnect. The cell is structurally symmetrical. Both electrodes support the thin electrolyte and contain micro-channels for gas flow-- a geometry referred to as a bi-electrode supported cell or BSC. The cell characteristics have been demonstrated under both SOFC and SOE conditions. Electrolysis tests verify that this cell design operates at very high electrochemical voltage efficiencies (EVE) and high H2O conversion percentages, even at the low flow rates predicted for closed loop systems encountered in unmanned aerial vehicle (UAV) applications. For UAVs the volume, weight and the efficiency are critical as they determine the size of the water tank, the solar panel size, and other system requirements. For UAVs, regenerative solid oxide fuel cell stacks (RSOFC) use solar panels during daylight to generate power for electrolysis and then operate in fuel cell mode during the night to power the UAV and electronics. Recent studies, performed by NASA for a more electric commercial aircraft, evaluated SOFCs for auxiliary power units (APUs). System studies were also conducted for regenerative RSOFC systems. One common requirement for aerospace SOFCs and RSOFCs, determined independently in each application study, was the need for high specific power density and volume density, on the order of 1.0 kW/kg and greater than 1.0 kW/L. Until recently the best reported performance for SOFCs was 0.2 kW/kg or less for stacks. NASA Glenn is working to prototype the light weight, low volume BSC design for such high specific power aerospace applications.
Cable, Thomas L.↗
Fuel Cell Auxiliary Power Study Volume 1: RASER Task Order 5
This study evaluated the feasibility of a hybrid solid oxide fuel cell (SOFC) auxiliary power unit (APU) and the impact in a 90-passenger More-Electric Regional Jet application. The study established realistic hybrid SOFC APU system weight and system efficiencies, and evaluated the impact on the aircraft total weight, fuel burn, and emissions from the main engine and the APU during cruise, landing and take-off (LTO) cycle, and at the gate. Although the SOFC APU may be heavier than the current conventional APU, its weight disadvantage can be offset by fuel savings in the higher SOFC APU system efficiencies against the main engine bleed and extraction during cruise. The higher SOFC APU system efficiency compared to the conventional APU on the ground can also provide considerable fuel saving and emissions reduction, particularly at the gate, but is limited by the fuel cell stack thermal fatigue characteristic.
Mak, Audie↗
Primary and secondary electrical space power based on advanced PEM systems
For new space ventures, power continues to be a pacing function for mission planning and experiment endurance. Although electrochemical power is a well demonstrated space power technology, current hardware limitations impact future mission viability. In order to document and augment electrochemical technology, a series of experiments for the National Aeronautics and Space Administration Lewis Research Center (NASA LeRC) are underway at the Los Alamos National Laboratory that define operational parameters on contemporary proton exchange membrane (PEM) hardware operating with hydrogen and oxygen reactants. Because of the high efficiency possible for water electrolysis, this hardware is also thought part of a secondary battery design built around stored reactants - the so-called regenerative fuel cell. An overview of stack testing at Los Alamos and of analyses related to regenerative fuel cell systems are provided in this paper. Finally, this paper describes work looking at innovative concepts that remove complexity from stack hardware with the specific intent of higher system reliability. This new concept offers the potential for unprecedented electrochemical power system energy densities.
Vanderborgh, N. E.↗
Regenerative fuel cell study for satellites in GEO orbit
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.
Levy, Alexander↗
High Performance Fuel Cell and Electrolyzer Membrane Electrode Assemblies (MEAs) for Space Energy Storage Systems
Regenerative fuel cells provide a pathway to energy storage system development that are game changers for NASA missions. The fuel cell/ electrolysis MEA performance requirements 0.92 V/ 1.44 V at 200 mA/cm2 can be met. Fuel Cell MEAs have been incorporated into advanced NFT stacks. Electrolyzer stack development in progress. Fuel Cell MEA performance is a strong function of membrane selection, membrane selection will be driven by durability requirements. Electrolyzer MEA performance is catalysts driven, catalyst selection will be driven by durability requirements. Round Trip Efficiency, based on a cell performance, is approximately 65%.
Plastic Encapsulated Microelectronics (PEM)↗
Fuel-Cell Reactant-Gas Purifier
Catalytic purifier removes oxygen from hydrogen feedlines just upstream of fuel-cell stack. Purifier consists of layer of platinum sandwiched between two sheets of porous polytetrafluoroethylene (PTFE). Platinum and PTFE elements stacked and ready for pressing. Purifier cut to size, pleated and inserted into convenient length of metal tubing. Purifier is 90 percent efficient in removing oxygen from gas stream containing 2 percent oxygen in hydrogen.
Mcbryar, H.↗
Thermal management of advanced fuel cell power systems
It is shown that fuel cell devices are particularly attractive for the high-efficiency, high-reliability space hardware necessary to support upcoming space missions. These low-temperature hydrogen-oxygen systems necessarily operate with two-phase water. In either PEMFCs (proton exchange membrane fuel cells) or AFCs (alkaline fuel cells), engineering design must be critically focused on both stack temperature control and on the relative humidity control necessary to sustain appropriate conductivity within the ionic conductor. Water must also be removed promptly from the hardware. Present designs for AFC space hardware accomplish thermal management through two coupled cooling loops, both driven by a heat transfer fluid, and involve a recirculation fan to remove water and heat from the stack. There appears to be a certain advantage in using product water for these purposes within PEM hardware, because in that case a single fluid can serve both to control stack temperature, operating simultaneously as a heat transfer medium and through evaporation, and to provide the gas-phase moisture levels necessary to set the ionic conductor at appropriate performance levels. Moreover, the humidification cooling process automatically follows current loads. This design may remove the necessity for recirculation gas fans, thus demonstrating the long-term reliability essential for future space power hardware.
Vanderborgh, N. E.↗
Fuel Cell Power Plant Initiative: Preliminary Design of a Fixed-Base LFP/SOFC Power System - Volume 2
This report documents the preliminary design for a military fixed-base power system of 3 MWe nominal capacity using Westinghouse's tubular Solid Oxide Fuel Cell [SOFC] and Haldor Topsoe's logistic fuels processor [LFP]. The LFP provides to the fuel cell a methane rich sulfur free fuel stream derived from either DF-2 diesel fuel, or JP-8 turbine fuel. Fuel cells are electrochemical devices that directly convert the chemical energy contained in fuels such as hydrogen, natural gas, or coal gas into electricity at high efficiency with no intermediate heat engine or dynamo. The SOFC is distinguished from other fuel cell types by its solid state ceramic structure and its high operating temperature, nominally 1000'C. The SOFC pioneered by Westinghouse has a tubular geometry closed at one end. A power generation stack is formed by aggregating many cells in an ordered array. The Westinghouse stack design is distinguished from other fuel cell stacks by the complete absence of high integrity seals between cell elements, cells, and between stack and manifolds. Further, the reformer for natural gas [predominantly methane] and the stack are thermally and hydraulically integrated with no requirement for process water. The technical viability of combining the tubular SOFC and a logistic fuels processor was demonstrated at 27 kWe scale in a test program sponsored by the Advanced Research Projects Agency [ARPA) and carried out at the Southern California Edison's [SCE] Highgrove generating station near San Bernardino, California in 1994/95. The LFP was a breadboard design supplied by Haldor Topsoe, Inc. under subcontract to Westinghouse. The test program was completely successful. The LFP fueled the SOFC for 766 hours on JP-8 and 1555 hours of DF-2. In addition, the fuel cell operated for 3261 hours on pipeline natural gas. Over the 5582 hours of operation, the SOFC generated 118 MVVH of electricity with no perceptible degradation in performance. The LFP processed military specification JP-8 and DF-2 removing the sulfur and reforming these liquid fuels to a methane rich gaseous fuel. Results of this program are documented in a companion report titled 'Final Report-Solid Oxide Fuel Cell/ Logistic Fuels Processor 27 kWe Power System'.
Veyo, S.E.↗