Hydrogen Fuel Cartridges for Portable Applications

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Hydrogen Fuel Cartridges for Portable Applications
NCMS Hydrogen Energy Systems Manufacturing Issues
Workshops March 9, 2005
Millennium Cell, Inc. One Industrial Way West,
Eatontown, NJ 07724 mohring_at_millenniumcell.com
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Outline

• Millennium Cell (MCEL) company overview
• Hydrogen storage/generation via sodium
  borohydride
• Hydrogen on Demand Technology
• Features and Benefits for Portable Power Markets
• Portable Prototypes
• Manufacturing Issues
• Summary

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Millennium Cell Company Overview

• We are developers of hydrogen energy systems for
  use primarily in portable electronics devices for
  consumer, military, medical, and industrial
  markets.
• 25 patents issued to date
• Over 40 patent applications submitted and still
  pending
• Public offering in August 2000 (Nasdaq MCEL),
  currently 40 people working in Eatontown, NJ and
  Washington DC.
• 23 in technical organization
• 9 Ph.D.s company wide
• Announced relationships

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Hydrogen Generation from Sodium Borohydride
(SBH)Hydrogen on Demand Reaction
NaBH4 (aq) 2 H2O ? 4 H2
NaBO2 (aq) heat
cat
An energy-dense water-based chemical hydride fuel
Borate can be recycled into NaBH4 or can be
disposed of
Proprietary catalyst induces rapid H2 production
High purity humidified H2
Exothermic reaction requires no heat
input

• Hydrogen is generated in a controllable,
  heat-releasing reaction
• Fuel is an ambient pressure, room-temperature,
  non-flammable liquid
• Hydrogen generated via this process is of high
  purity (no carbon monoxide or sulfur) and is
  humidified (heat generates some water vapor)
• U.S. Patent 6,534,033 System for Hydrogen
  Generation

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Hydrogen Generation from Sodium Borohydride
(NaBH4)Schematic of Hydrogen on Demand
Technology
Gas/Liquid Separator
Fuel Pump
Catalyst Reactor
Hydrogen Water Vapor
Fuel tank NaBH4 solution
H2
Discharged fuel area NaBO2
Water from Fuel Cell
Borate (NaBO2)
borate
H2O
Hydrogen Water Vapor
Coolant Loop (optional)
Fuel Cell
Pure Humidified H2
Heat Exchanger
Electric Power
Oxygen from Air
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MCELs HOD systems have been demonstrated at
multiple power levels

• Primary propulsion (50 kW)
• Chrysler Natrium minivan
• Electric vehicle range extension (5 kW)
• Duffy Electric Boat
• Peugeot H2O
• Battery chargers, standby power (1.5 kW)
• Telecom-Rack Mount System (RM-1500)
• Battery replacement, Portable Power (lt100 W)

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HOD Powered Soldier of the FutureSaving our
Soldiers 20 Pounds!
13 BA5590 BatteriesWeight 29 lbs
1 HODTM/PEM Fuel Cell System and 6-360 Wh
Cartridges Weight 10 lbs w/ H2O Weight 4.5 lbs
w/out H20
Photo by Sarah Underhill, US
Army Soldier Systems Center.
.
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HOD Technology Features And Benefits

• High Energy Density Fuel System
• Can deliver up to 3 times Li-ion run time within
  the same volume with hydrogen fuel cell
• High Power Density
• Allows for in-device design of the power system
• High Purity Hydrogen
• Hydrogen fuel cells deliver greater power at a
  higher efficiency and last longer than with
  reformed hydrogen streams
• High Consumer Value
• Longer run times and low-cost fuel cartridge
  makes a compelling case for consumer preference
  over rechargeables
• Safety Advantages
• Hydrogen is not stored under pressure
• Liquid NaBH4 solution is non-flammable

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Soldier Power 30 Watt Power SystemCartridge
attachment
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Millennium Cell Lap-Top Prototype
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Manufacturing Technology Issues

• To meet the demands of the portable electronic
  market, there are a number of manufacturing
  technology issues that must be addressed
• Fuel Delivery
• Provide a consistent delivery of the fluid and
  gas streams
• Fuel Handling
• Optimal use of the available volumes and
  effectively managing the fluid and gas streams

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Hydrogen Generation from Sodium Borohydride
(NaBH4)Schematic of Hydrogen on Demand
Technology
Gas/Liquid Separator
Fuel Pump
Catalyst Reactor
Hydrogen Water Vapor
Fuel tank NaBH4 solution
H2
Discharged fuel area NaBO2
Water from Fuel Cell
Borate (NaBO2)
borate
H2O
Hydrogen Water Vapor
Coolant Loop (optional)
Fuel Cell
Pure Humidified H2
Heat Exchanger
Electric Power
Oxygen from Air
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Manufacturing Technology Issues - Fuel Delivery

• Main issue is the need for a micro liquid pump
• Requirements
• Low cost
• Materials compatibility
• Reliability
• Robustness to media
• Operating life
• Omni-directional operation
• Minimal volume
• Design lends itself to the portable power market
  needs
• Low electrical parasitic load
• Operating flows and pressures
• Pump type
• Diaphragm
• Peristaltic
• Gear

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Manufacturing Technology Issues - Fuel Handling

• Separation membrane sealing/bonding
• Permits liquids and gases to be consistently
  separated within the system where it is required
• Bladder sealing/bonding
• Provides a flexible containment of all system
  liquids and change shape and volume as required
• Fitments and Interconnects
• Provides the mechanical link between flexible
  bladders and rigid walls of the container

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Hydrogen Generation from Sodium Borohydride
(NaBH4)Schematic of Hydrogen on Demand
Technology
Gas/Liquid Separator
Fuel Pump
Catalyst Reactor
Hydrogen Water Vapor
Fuel tank NaBH4 solution
H2
Discharged fuel area NaBO2
Water from Fuel Cell
Borate (NaBO2)
borate
H2O
Hydrogen Water Vapor
Coolant Loop (optional)
Fuel Cell
Pure Humidified H2
Heat Exchanger
Electric Power
Oxygen from Air
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Separation membrane sealing/bonding

• Manufacturing barriers
• Low cost, high quality materials
• Low cost/high volume assembly technology
• Processes
• RF welding, heat sealing, ultrasonic welding, etc
• Adhesive bonding
• Performance issues
• Quality of membrane
• Pore size, backing bond
• Bonding to base material
• Leak testing
• Adhesive quality

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Bladder sealing/bonding

• Manufacturing barriers
• Low cost, high quality materials
• Low cost/high volume assembly technology
• Processes
• RF welding, heat sealing, ultrasonic welding, etc
• Adhesive bonding
• Performance issues
• Quality of film
• Pin holes, thickness variations
• Quality of sealed bladder
• Low cycle time leak testing

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Fitments and Interconnects

• Manufacturing barriers
• Low cost/high volume assembly technology
• Processes
• RF welding, heat sealing for bonding to bladder
• Unique assembly technology for connecting to
  cartridge
• Performance issues
• Quality of fitment bonding
• Low cycle time leak testing
• Quality of assembled interconnects
• Non destructive testing

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Summary

• Millennium Cells HOD technology is strongly
  positioned to meet near term commercialization
  targets in the portable power markets
• Manufacturing issues that will transition the
  technology from prototype to commercial product
  have wide range applicability in other industries