US Army CERDEC Development of Battlefield Fuel Cell Power

1
US Army CERDEC Development of Battlefield Fuel
Cell Power

• Beth Bostic
• US Army CERDEC Fuel Cell Team
• elizabeth.bostic_at_us.army.mil
• 703-704-1027

2
Agenda

• Current Power Problem
• What is a Fuel Cell?
• Army Areas of Focus
• Benefits and Technical Challenges
• The Fuel Issue
• The Path Forward

3
The Power Problem

• FACT Over Half of todays Highly digitized
  C4ISR Force is powered by 1980s Generators.
  They are outdated and unreliable.

4
Battlefield Power
SOLDIER
MOBILE
POWER GAP
Tactical Operation Center

• Brigade
• Disposable batteries are costly
• Available energy NOT fully utilized
• No Recharge capability
• Too many battery types

No non-battery power away from vehicles, gensets,
or wall plugs

• SBCT I
• 1,200 gals fuel/day to theater costs vary (13
  - 133/gal)
• 133 Generators ( MTOE )
• Too Large, Too Noisy, Not Efficient
• Redundant Generators
• No Smart Power Distribution

• 700K for 72 hrs
• 7 TONS of batteries!

• 68 TONS of generators!
• 45K-465K (72 hrs)
• 12 TONS Fuel!

5
Potential Power Solutions

• Advanced Disposable Batteries
• Lithium Ion Pouch/Polymer Batteries
• Fuel Cells
• Stirling Engines
• Flexible Solar Panels
• Metal-Air Batteries
• Advanced Internal-Combustion Generators

Soldier Sensor Power Battery Recharging Auxiliar
y Power Units Fuel Reforming Component
RD Vehicle Applications
6
What is a Fuel Cell?
Electrochemical Energy Conversion Device PEM Fuel
Cells take in Hydrogen and Air (Oxygen) and,
through a chemical reaction, make Water and
Electricity.
7
CERDEC Focus Areas
Located at Fort Belvoir, VA approximately 20
miles south of Washington, DC
Soldier and Sensor Power (0-100W)
Battery Charging (100-500W)
Auxiliary Power Units (500W-10kW)
Goal Transition Technology to areas where it is
needed most.
8
Army Fuel Cell Structure
9
DoD Fuel Cell Efforts
10
Benefits of Fuel Cell Technology

• Decreased acoustic signature
• Decreased thermal signature
• Longer, Lighter missions
• Improved Efficiency
• Increased Power Density
• Significant Fuel Savings
• Hybrid systems offer the best solution

11
Technical Challenges

• Rugged System, durability in harsh environments
• Reduce System Size and Weight
• Reliability
• Balance of Plant Components
• Air side contamination
• Water Management
• Reduce Acoustic and Thermal Signatures
• Orientation independent operation
• Power Quality
• Unit Cost

12
The Fuel Policy

• 1999 DoD One Fuel Forward Policy states that
  the military can only develop or acquire power
  technologies that utilize currently supported
  military logistic fuels.
• kerosene-based fuels such as JP-8 and JP-5 for
  land and ground forces

Larger power fuel cell power systems (gt500W) must
be logistically fueled.
PROBLEM Logistic Fuels are not easily reformed
into a hydrogen rich stream compatible with fuel
cells.
13
Fuel Reforming Issues

• What is the target fuel cell?
• Sulfur Removal
• Regenerable Approach is preferred
• Sulfur levels are variable in logistics fuel up
  to 3000ppm
• Carbon Formation
• Function of operating parameters
• Sensitive trade off of performance
• Water Management
• Prefer NO external water source needed
• System Performance
• Efficiency
• Start-up Time
• Transient response
• Thermal cycling

14
Silent Tactical Power Efforts
Logistics Fuel Reforming is critical

• FY 08 Target ? 2-5kW Quiet Power Source
• lt 150 kgs, lt 69dBA noise
• TRL 5
• JP-8 Fueled

• System Specs
• Two 1kW Methanol Reforming PEM units
• 1kW Prototype Liquid Hydrocarbon fuel reforming
  system
• 85-100 kg
• 29 x 27 x 25

15
Tactical Power Benefits

• 2kW Fuel Cell for C3OTM
• 2003 Demonstration
• Provided Silent Watch Capability
• Thermally undetectable from three sides.

16
The Path Forward

• Reduce logistic footprint for power!
• Focus on Near-Term Military Applications
• Soldier Sensor Power
• Auxiliary Power Units
• Portable Battery Chargers
• Fuel cells have the potential to significantly
  reduce weight costs over traditional military
  power sources
• Main Technology Barriers to Military Adaptation
• Fuel Supply
• Affordability, and Reliability/Durability in the
  Field
• Large Systems (500W) must use Logistics Fuels

17
Questions?

• Beth Bostic
• US Army CERDEC Fuel Cell Team
• elizabeth.bostic_at_us.army.mil
• 703-704-1027