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@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. FACT: Inadequate supplies of military batteries almost led U.S. forces to cease operations during Operation Iraqi Freedom. The power supply dictates mission tempo. FACT: A soldier normally carries about 65 pounds worth of equipment and supplies in his or her rucksack. Currently, some soldiers are carrying upwards of 95 pounds. The Power Problem FACT: Over Half of today’s “Highly digitized C4ISR” Force is powered by 1980’s Generators. They are outdated and unreliable.

4. Forward Area Environment 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 Auxiliary Power Units Fuel Reforming Component R&D Vehicle Applications

6. Electrons = Electricity H2O & Heat Exhaust OUT IN H2 Fuel + IONS IN O2 Air Electrolyte Cathode (+ electrode) Anode (- electrode) 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. Portable Power Generation Stationary Power Soldier & Sensor Power Focus on System Development, Test, Demonstration, and Transition Communications-Electronics, Research Development and Engineering Center (CERDEC) Tank & Automotive Research Development and Engineering Center (TARDEC) Army Corps of Engineers Construction Engineering Research Laboratory (CERL) Focus on Basic Materials R&D, Components, and Testing Army Research Laboratory (ARL) Army Research Office (ARO) Army Fuel Cell Structure

9. Air Force Navy More Electric Aircraft DARPA FUEL CELL Distributed Ship Power & Propulsion Unmanned Vehicles & Sensor Power Ground Support Equipment Soldier Power Logistics Fuel Reforming Battery Recharging Auxiliary Power Units Light Vehicle Propulsion Backup Stationary Power Administrative FCV Demonstrations Army 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 (>500W) 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 • < 150 kgs, < 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. Acoustic and Thermal Signature 2kW MTG 3kW TQG 1kW Idatech FCS-1200 Acoustic Signature 79 dBA 72 dBA 53 dBA 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@us.army.mil 703-704-1027