1. US Army CERDEC Development of Battlefield Fuel Cell Power
Beth Bostic
US Army CERDEC Fuel Cell Team

2. Agenda Current Power Problem What is a Fuel Cell? Army Areas of Focus
Benefits and Technical Challenges
The Fuel Issue
The Path Forward
9/22/2018

3. The Power Problem
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: Over Half of today’s “Highly digitized C4ISR” Force is powered by 1980’s Generators. They are outdated and unreliable.
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.
9/22/2018

4. Tactical Operation Center
Battlefield Power
MOBILE
SOLDIER
POWER GAP
Tactical Operation Center
Forward Area Environment
Brigade
Disposable batteries are costly
Available energy NOT fully utilized
No Recharge capability
Too many battery types
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
No non-battery power away from vehicles, gensets, or wall plugs
68 TONS of generators!
$45K-$465K (72 hrs)
12 TONS Fuel!
~$700K for 72 hrs
7 TONS of batteries!
9/22/2018

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
9/22/2018

6. Electrochemical Energy Conversion Device
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. H2
Fuel
H2O & Heat Exhaust O2
Air
+ IONS
Electrolyte
Anode
(- electrode)
Cathode
(+ electrode)
Electrons = Electricity IN
OUT
9/22/2018

7. Soldier and Sensor Power
CERDEC Focus Areas
Located at Fort Belvoir, VA
approximately 20 miles south of Washington, DC
Soldier and Sensor Power
(0-100W)
Battery Charging
( W)
Auxiliary Power Units
(500W-10kW)
Goal: Transition Technology to areas where it is needed most.
9/22/2018

8. Army Fuel Cell Structure
Soldier & Sensor Power
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)
Stationary Power
Focus on System Development, Test, Demonstration, and Transition
Focus on Basic Materials R&D, Components, and Testing
Army Research Laboratory (ARL)
Army Research Office (ARO)
Portable Power Generation
Size: ~12 inches x 17 inches Mounted on Black Foam Core
9/22/2018

9. DoD Fuel Cell Efforts Air Force Navy Army DARPA 9/22/2018
More Electric Aircraft
Distributed Ship Power & Propulsion
Auxiliary Power Units
Light Vehicle Propulsion
Administrative FCV Demonstrations
Backup Stationary Power
Ground Support Equipment
FUEL CELL
Unmanned Vehicles & Sensor Power
DARPA
Soldier Power
Logistics Fuel Reforming
Battery Recharging
9/22/2018

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
9/22/2018

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
9/22/2018

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.
9/22/2018

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
9/22/2018

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 kg
29” x 27” x 25”
9/22/2018

15. Tactical Power Benefits
Acoustic Signature
53 dBA
72 dBA
79 dBA
1kW Idatech FCS-1200
3kW TQG
2kW MTG
Acoustic and Thermal Signature
2kW Fuel Cell for C3OTM
2003 Demonstration
Provided Silent Watch Capability
Thermally undetectable from three sides.
9/22/2018

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
9/22/2018

17. US Army CERDEC Fuel Cell Team
Questions?
Beth Bostic
US Army CERDEC Fuel Cell Team