2. CERDEC Bottom Line: THE WARFIGHTER NS9/03 US ARMY CERDEC Fuel Cell Technology Dr. Ashok Patil US ARMY CERDEC Chief, Environmental Systems and Fuel Cell Branch Fort Belvoir, VA 2004 AAAS Symposium 13 February 2004 Seattle, WA

3. CERDEC Bottom Line: THE WARFIGHTER NS9/03 THE AMERICAN WARFIGHTER: ARMY’S #1 CUSTOMER The ARMY’S R&D programs are focused on developing critical, cutting edged equipment for the AMERICAN WARFIGHTERS so that they can accomplish their Mission quickly and effectively and return home safe. The AMERICAN WARFIGHTERS are our BOTTOM LINE. Copyright: Time Magazine, December 2003

4. CERDEC Bottom Line: THE WARFIGHTER NS9/03 Overview 1.Military Power Needs 2.Why Fuel Cells? 3.Military Applications 4.Soldier Power 5.Technology Evolution 6.Conclusions

5. CERDEC Bottom Line: THE WARFIGHTER NS9/03 American Warfighters “We had extreme difficulty moving with all our weight. If our movement would have been to relieve a unit in contact or a time sensitive mission we would not have been able to move in a timely manner. It took us 8 hours to move 5 clicks. [that's less than 1 mph]” This is more than just a cartoon. For our American Warfighters

6. CERDEC Bottom Line: THE WARFIGHTER NS9/03 Why Fuel Cells? - Coalition Forces came within days of running out of batteries to power critical Army systems. -Rechargeable batteries were encouraged but not used by troops. -Warfighters need light-weight, high energy dense power systems.

7. CERDEC Bottom Line: THE WARFIGHTER NS9/03 Military Power Sources Diesel Gen Sets TPV Fuel Cells Microengines Batteries Hybrid Systems Current Army Power Sources Pacing Technologies Future Army Power Sources Power Users Watts MINI-UV Power Sources NO CURRENT SOLUTION: CRITICAL GAP! 20W –3000W NO CURRENT SOLUTION: CRITICAL GAP! 20W –3000W 3-5kW 50W

8. CERDEC Bottom Line: THE WARFIGHTER NS9/03 Fuel Cell Technology for The Modern Army Benefits of Fuel Cells in Military Applications Light WeightLight Weight Longer, Lighter Missions Silent OperationSilent Operation Stealth and ‘Silent Watch’ Ops Higher EfficiencyHigher Efficiency Cogeneration Use, Improved Fuel Utilization

9. CERDEC Bottom Line: THE WARFIGHTER NS9/03 Army Vision for Military Fuel Cell Systems Soldier & Sensor Power (10-100W) Combined Heat and Power ( >3000W ) Auxiliary Power Units (500-3000W) Major Applications for Portable Fuel Cell Technology

10. CERDEC Bottom Line: THE WARFIGHTER NS9/03 Fuel Cells of Interest to the Army Proton Exchange Membrane Low Temperature Operation High Energy Density Efficient Operation (30-40% on reformed fuels). Quick Start Proven Reliability Low Acoustics and Vibration Pure Hydrogen Fuel Heat Rejection at Larger Sizes Sensitive to Contaminants Thermal Mismatch between reformers and stacks Soldier Power Sensors Silent Watch Auxiliary Power Units Direct Methanol Low Temperature Operation Direct Liquid Fuel High Energy Density Low Acoustics and Vibration Operation Below Freezing Longevity of Stack Materials Slow Start Time Methanol Crossover Soldier Power Sensors Solid Oxide Fuel Flexible Goal-Diesel/JP8 Tolerance to Contaminants Except Sulfur Low Acoustics and Vibration High Temperature Operation Materials Problems On/Off Cycle Life Slow Start Time Only Early Prototype Exist Auxiliary Power Units Vehicle Power Combined Heat and power Fuel CellAdvantagesChallenges Applications

11. CERDEC Bottom Line: THE WARFIGHTER NS9/03 Hydrogen Source Diesel/ JP-8 * (1300-5000Whr/kg) Gasoline/JP-4 * (1200-5000Whr/kg) Methane * (2100-5600Whr/kg) Propane/Butane * (1920-5000Whr/kg) Ethanol * (1000-3000Whr/kg) Methanol * (800-2300Whr/kg) Chemical/Metal Hydrides (1200Whr/kg) Hydrogen (1000-23,000Whr/kg) Hydrogen Delivery * Based on 15-40% Efficiency

12. CERDEC Bottom Line: THE WARFIGHTER NS9/03 Soldier and Sensor Power Goal : Longer, Lighter Missions through Hybrid Systems. Applications : Soldier Power, Robots\UAVs, Remote Sensors, Battery Chargers. Technology :  Direct Hydrogen Fed-Fuel Cells  Direct Methanol Fuel Cells  Methanol Reforming Fuel Cell Systems Soldier Systems can use prepackaged liquid fuels such as Methanol

13. CERDEC Bottom Line: THE WARFIGHTER NS9/03 High Energy Dense Fuels High energy dense fuels, such as methanol, favor low-power systems over batteries for longer missions (12+ hours)! Direct Methanol FC

14. CERDEC Bottom Line: THE WARFIGHTER NS9/03 CERDEC Goals for Soldier Power Soldier Power Source Power: 25W continuous Energy Density: 1000Whr/kg for 72 hour mission. Portable Battery Charger Power: 150-500W e, 28VDC Weight: Weight: < 9.0kg, including 1000 Whrs of fuel. Hot-Swappable Fuel Cartridge Temperature Range: 1C - 52C Non-Detectable (aural) at 100 meters.

15. CERDEC Bottom Line: THE WARFIGHTER NS9/03 CERDEC Efforts in Soldier and Sensor Power 15W Monopolar DMFC Present DMFC-20(Version 1.0): 20 W net power. 1.75 kg (fuel cell and b.o.p.) 460 Whr / kg system energy density (including 1.0L ‘Neat’ Methanol). Future DMFC-20(Version 1.1): 20 W net power, ruggedized housing. 1.0 kg (fuel cell and b.o.p.) 43% Less Weight 620 Whr / kg system energy density (including 1.0L ‘Neat’ Methanol).

16. CERDEC Bottom Line: THE WARFIGHTER NS9/03 Direct Methanol Fuel Cell Evolution 1 st Generation (2001) Smart Fuel Cell’s A-25 DMFC :  25W, 22 lbs (10 kg) dry.  2.5L ‘Neat’ Methanol Fuel Reservoir. -55 hour Runtime. 2 nd Generation (2003) New Prototype C-25 DMFC:  25W, 2lbs (1.0kg) dry. -90% Weight Reduction!  140Whr Internal Fuel Storage -6 hour Runtime

17. CERDEC Bottom Line: THE WARFIGHTER NS9/03 Equivalent Power Sources for 72 Hour, 20W Mission vast weight savings For 72 hour mission, current DMFC Technology shows vast weight savings over military batteries. BA-5590 Lithium Sulfur Dioxide Batteries 17.6 Pounds (8kg) $0.56 per Watt-hour Ball DMFC 20W Direct Methanol Fuel Cell with two fuel canisters. 6.4 Pounds (2.9 kg) $0.34 per Watt-hour * *($10,000/unit, 3000 hour lifetime) (0.75kg, 800Whr per methanol canister).

18. CERDEC Bottom Line: THE WARFIGHTER NS9/03 Lifetime Cost Estimates 20W Continuous Load Estimates do not reflect reduced shipping and logistics costs! 38% Cost Savings For 3000 Hours!

19. CERDEC Bottom Line: THE WARFIGHTER NS9/03  Microchannel Reactors Enhanced Heat Transfer Enhanced Mass Transfer Economics of Mass Production High Surface Area to Volume Ratio Low pressure Drop Through Channels Future Directions in Reformer Design

20. CERDEC Bottom Line: THE WARFIGHTER NS9/03 Fuel Reformer Systems Innovatek Design Goals: 1000 We nominal Diesel Fuel Process: Steam Reforming Weight: < 30 kg; Volume < 50 L for entire Fuel Processing System Diesel Reformer Battelle Design Goals: 100-200 We nominal system Weight < 3.5 kg (dry); Volume < 2.5 L Including Fuel Cell Stack and BOP Fuel: Methanol Process: Steam Reforming Methanol Reformer

21. CERDEC Bottom Line: THE WARFIGHTER NS9/03 C3 On-The-Move Combat Vehicle Mobile Power Pac 2kW Methanol Reforming Fuel Cell System Weight: 265 lbs (120 kg) Fuel: Methanol-Water 3.5 Gallon Fuel Capacity -6 hours operation time Voltage: 24-28VDC Noise: < 55dBA at 7 metersNoise: < 55dBA at 7 meters Fuel Cell APU mounted on the roof of a C3 On-The- Move Combat Vehicle. This APU provides power to electronic equipment during stealth operations.

22. CERDEC Bottom Line: THE WARFIGHTER NS9/03 Cogeneration Power and Cooling Heat Actuated Cooling Heat Heat Cooling Export Power Fuel Cell 2 to 3 kW Electric Power- 12 to 18 kBTUh Cooling Features Silent Operation Power On-The-Move Cooling Exportable Power Reduced Fuel Consumption JP-8

23. CERDEC Bottom Line: THE WARFIGHTER NS9/03 Hybrid Fuel Cell Technology Challenges Challenges Lightweight Compact Rugged NBC SurvivableNon Detectable Affordable Commercial Off-the-Shelf Hydrogen Supply Reliable, Maintainable, Sustainable Military Temperature Operation Environmentally Safe Military Specific

24. CERDEC Bottom Line: THE WARFIGHTER NS9/03 1998 20022004 20062010+ Soldier & Sensor Power PEMFC with Hydrogen Tank PEMFC Hybrid System 100W PEMFC With Tank H2. 20W PEMFC Hybrid Demonstrated During Field Exercises 2004 Status: Diesel Solid Oxide Fuel Cells Logistic Fuel Reformers for PEMFC Systems Diesel Reformer for PEMFC Solid Oxide Fuel Cell APU Component Development/Basic Research Soldier & Sensor Power, Portable APU Roadmap (to TRL 6) for Military Fuel Cell Demonstrations Soldier & Sensor Power, Portable APU PEMFC with Chemical Hydride Direct Methanol Fuel Cells Methanol Reforming PEMFC System 20W DMFC 2kW Methanol Reforming PEMFC system Early Prototypes

25. CERDEC Bottom Line: THE WARFIGHTER NS9/03 Conclusions  Main Military Applications for Portable Fuel Cells Are: Soldier & Sensor Power, Auxiliary Power Units, and Cogeneration.  US Army CERDEC is at the forefront of cutting edge fuel cell technology for the military.  Fuel cells offer significant weight and cost savings over traditional military power sources  Main Technology Barriers to Military are: Fuel Supply, Affordability, and Reliability/Durability in the Field.  Prepackaged Liquid Fuels (Methanol) Ideal for Low-Power Applications.

26. CERDEC Bottom Line: THE WARFIGHTER NS9/03 Back-Up

27. CERDEC Bottom Line: THE WARFIGHTER NS9/03 Past CERDEC Efforts Soldier Power Cooling Module 1996 Snorkler - 1996 Methanol Powered Generator Set – 1984 DMFC 60W System DARPA Palm Power 2002 PPS 100W - 1998 CERDEC Fuel Cell Timeline 25W DMFC 2002-2003 20W DMFC 2003 1000W Methanol Reforming PEM - 2001

28. CERDEC Bottom Line: THE WARFIGHTER NS9/03 Absorption Cooling Efforts Microchannel flow/chemical mixing Porous membrane technology Better Efficiency Smaller Size Heat Actuated Breadboard System Current Cogeneration Efforts Fuel Cell Efforts 2 kW fuel cell auxiliary power unit for mobile power generation. 1 kW integrated fuel cell system with low sulfur diesel reformer. 1 kW low sulfur diesel fuel reformer. 1kW PEM Fuel cell with fuel reformer. Expander/compressor Refrigerant Desorber