NASA Fuel Cell and Hydrogen Activities

Presented by: Ian Jakupca

Department of Energy Annual Merit Review 30 April 2019 1 Overview

• National Aeronautic and Space Administration • Definitions • NASA Near Term Activities • Energy Storage and Power • Batteries • Fuel Cells • Regenerative Fuel Cells • Electrolysis • ISRU • Cryogenics • Review

2 National Aeronautics and Space Administration

3 Acknowledgements

NASA has many development activities supported by a number of high quality people across the country. This list only includes the most significant contributors to the development of this presentation. Headquarters • Lee Mason, Space Technology Mission Directorate, Deputy Chief Engineer • Gerald (Jerry) Sanders, Lead for In-Situ Resource Utilization (ISRU) System Capability Leadership Team Jet Propulsion Laboratory • Erik Brandon, Ph.D, Electrochemical Technologies • Ratnakumar Bugga, Ph.D, Electrochemical Technologies Marshall Space Flight Center • Kevin Takada, Environmental Control Systems Kennedy Space Center • Erik Dirschka, PE, Propellant Management Glenn Research Center • William R. Bennett, Photovoltaic and Electrochemical Systems • Fred Elliott, Space Technology Project Office • Ryan Gilligan, Cryogenic and Fluid Systems • Wesley L. Johnson, Cryogenic and Fluid Systems • Lisa Kohout, Photovoltaic and Electrochemical Systems • Dianne Linne, ISRU Project Manager • Phillip J. Smith, Photovoltaic and Electrochemical Systems • Tim Smith, Chief, Space Technology Project Office

4 Electrochemical System Definitions

Primary Power Energy Storage Commodity Generation Discharge Power Only Charge + Store + Discharge Chemical Conversion Description Description Description • Energy conversion system that • Stores excess energy for later use • Converts supplied chemical feedstock supplies electricity to customer system • Supplies power when baseline power into useful commodities • Operation limited by initial stored supply (e.g. PV) is no longer available • Requires external energy source (e.g. energy • Tied to external energy source thermal, chemical, electrical, etc.)

Examples Examples Examples • Nuclear (e.g. RTG, KiloPower) • Rechargeable Batteries • ISS Oxygen Generators • Primary Batteries • Regenerative Fuel Cells (OGA, Elektron) • Primary Fuel Cells • ISRU Propellant Generation

NASA Applications: NASA Applications: NASA Applications: Missions without access to continuous Ensuring Continuous Power Life-support, ISRU power (e.g. PV) • Satellites (PV + Battery) • Oxygen Generation • All NASA applications require electrical • ISS (PV + Battery) • Propellant Generation power • Surface Systems • Material Processing • Each primary power solution fits a (exploration platforms, ISRU, crewed) • Recharging Regenerative Fuel Cells particular suite of NASA missions • Platforms to survive Lunar Night

5 Electrochemical System Definitions

Primary Fuel Cell Regenerative Fuel Cell Electrolysis Discharge Power Only Charge + Store + Discharge Chemical Conversion 2H + O → 2H O + 4e- + Heat - 2 2 2 2H2O + 4e → 2H2 + O2 + Heat ɳCycle = ~50%

O H O2 H2 2 2 O2 H2

ΔP ΔP ΔP ΔP

QTH Q TH QTH

H O 2 H2O Q ELE QELE QELE H2O QELE Discharging Discharging Charging Charging Regenerative Fuel Cell = Fuel Cell + Interconnecting Fluidic System + Electrolysis 6 Multiple power technologies comprise the Lunar Surface Power Architecture

Each power technology contributes to an integrated Regenerative Fuel Cells (RFCs) for Lunar Exploration • Batteries meet energy storage needs for low energy applications • RFCs address high energy storage requirements where nuclear power may not be an option (in locations near humans) • Nuclear and radio isotope power systems provide constant power independent of sunlight Energy Storage Options for Space Applications

Battery = TRL 9 Energy Options for Primary Fuel Cell = TRL 5 Space Applications Regenerative Fuel Cell = TRL 3

• Current energy storage technologies are insufficient for NASA exploration missions • Availability of flight-qualified fuel cells ended with the Space Shuttle Program • Terrestrial fuel cells not directly portable to space applications

• Different wetted material requirements (air vs. pure O2) • Different internal flow characteristics • No space-qualified high-pressure electrolyzer exists

• ISS O2 Generators are low pressure electrolyzers • Terrestrial electrolyzers have demonstrated >200 ATM operation 8 Battery Activities in Support of NASA Missions

• Low temperature electrolytes to extend operating temperatures for outer planetary missions

• High temperature batteries for Venus missions

• Non-flammable separator/electrolyte systems

• Solid-state high specific energy, high power batteries

• Li-air batteries for aircraft applications Improved cathode and electrolyte stability in Lithium-Oxygen batteries

• Multi-functional load-bearing energy storage

• X-57 Maxwell distributed electric propulsion flight demonstration

• Safe battery designs and assessments for aerospace applications

9 Energy Storage System Needs for Future Planetary Missions

• Primary Batteries/Fuel Cells for Surface Probes: High Temperature Operation (> 465C) High Specific Energy (>400 Wh/kg) Operation in Corrosive Environments • Rechargeable Batteries for Aerial Platforms: High Temperature Operation (300-465C) Operation in Corrosive Environments Low-Medium Cycle Life High Specific Energy (>200 Wh/kg) Operation in High Pressures Inner Planets • Primary Batteries/Fuel cells for planetary landers/probes: Outer Planets High Specific Energy (> 500 Wh/kg), Icy Giants Long Life (> 15 years), Radiation Tolerance & Sterilizable by heat or radiation • Rechargeable Batteries for flyby/orbital missions: High Specific Energy (> 250 Wh/kg) Long Life (> 15 years) Radiation Tolerance & Sterilizable by heat or radiation. Uranus/Neptune missions • Low temperature Batteries for Probes and Landers: Low Temperature Primary batteries (< -80C) Europa Orbiter Europa Lander Low Temperature Rechargeable Batteries (< -60 C) All images are Artist’s Concepts 10 Lunar RFC Trade Study Results

10 kW H2/O2 RFC Energy Storage System for Lunar Outpost /kg Reactants Everything

else W•hr

Volume (m3) Everything

else Batteries RFC System System RFC Mass, kg

Reactants

RFC RFC RFC RFC

Batteries

Batteries RFC System Specific Energy, System RFC Specific Energy,

Mass (kg) RFC specific energy dependent on location. RFCs enable missions to survive the lunar night Battery specific energy independent of location.

11 Venus Interior Probe Using In-situ Power and Propulsion (VIP-INSPR) Venus Power Concept for Variable Altitude Balloon

High Altitude Balloon Above the clouds • Abundant solar power Solar power Electrolyze H2O • SOEC recharges H2 & O2 from H2O • Bring stored H2O (Harvesting may be challenging) • Consumes stored H2O 60 km • Solar array powers probe

d e d H from balloon into H from hydride into Electrolyze H O to generate H and O s 2 2 2 2 2 c n e e c hydride to descend balloon to ascend n s d a below the clouds above the clouds

Descend below clouds Below the clouds • Store ~200 g H2 from balloon in metal hydride • SOFC generates power from H & O H /O Fuel cell 2 2 • Operate on solid oxide fuel cell (SOFC) 2 2 to power probe • Store H2O byproduct 10-20 km • Store H2O byproduct Ascend above clouds • Release H back into balloon 2 • A solar array powers the probe at high altitude and generates H and O with Solid Oxide Electrolysis • Operate on solar power 2 2 • Electrolyze H2O back into H2 and O2 Cell (SOEC) using water carried from ground as a closed-system. • Metal hydride H2 storage and compressed gas O2 storage • Solid Oxide Fuel Cell (SOFC) will powers the probe at low altitudes from the stored H2 and O2. jp l.n asa .g o v • H2-filled balloon will be used for buoyancy and altitude control (60-15 km). 12 Electrolysis within NASA

Fundamental Process • Electrochemically dissociating water into gaseous hydrogen and oxygen • Multiple chemistries – Polymer Electrolyte Membrane (PEM), Alkaline, Solid Oxide • Multiple pressure ranges o ISRU & Life support = low pressure o Energy storage = high pressure

Life Support: Process recovered H2O to release oxygen to source breathing oxygen • Redesign ISS Oxygen Generator assembly for increased safety, pressure, reliability, and life • Evaluate Hydrogen safety sensors

Energy Storage: Recharge RFC system by processing fuel cell product H2O into H2 fuel and O2 oxidizer for fuel cell operation

ISRU: Process recovered H2O to utilizing the resulting H2 and O2 • Hydrogen Reduction – Hydrogen for material processing • Life Support – Oxygen to source breathing oxygen • Propellant Generation – Oxygen for liquefaction and storage 13 In-situ Resource Utilization (ISRU)

ISRU Resources & Processing Modular Power Resource & Site Regolith/Soil Excavation Modular Power Functions/ Elements Characterization & Sorting . Power Generation Systems . Power Distribution Life Support

. Energy Storage (O2 & H2) & EVA

Support Functions Regolith/Soil Transport /Elements Solar & Nuclear . ISRU Water/Volatile Pressurized Rover . Life Support & EVA Extraction

. O2, H2, and CH4 Storage and Transfer Regolith for O2 & Metals Regenerative CO2 & Habitats Fuel Cell Regolith Crushing & Trash/ Shared Hardware to Waste H2O, CO2 from Processing Reduce Mass & Cost Soil/Regolith . Solar arrays/nuclear reactor . Water Electrolysis CO from Mars 2 CH . Reactant Storage Atmosphere 4 O2 Surface Hopper . Cryogenic Storage H2O Used Descent Stage . Mobility

Propellant Depot Lander/Ascent Consumable Storage Lander/Ascent Civil Engineering, Shielding, & Construction Parts, Repair, & Assembly

In-Space Construction In-Space Manufacturing 14 Lunar ISRU Mission Capability Concepts

Excavation & Regolith

Processing for O2 Production

Resource Prospecting – Looking for Polar Ice Carbothermal Processing with Altair Lander Assets

Thermal Energy Storage Construction

Consumable Depots for Crew & Power Landing Pads, Berm, and Road Construction 15 ISRU is Similar to Establishing Remote Mining Infrastructure and Operations on Earth

Communications Planned, Mapped, and Coordinated Mining Ops: • To/From Site Transportation to/from Site: Areas for: i) Excavation, ii) Processing, and iii) Tailings • Local • Navigation Aids • Loading & Off-loading Aids • Fuel & Support Services

Power: • Generation • Storage • Distribution

Maintenance Roads & Repair Living Quarters & Crew Support Services Logistics Management Construction and Emplacement 16 Reactant Processing and Storage

Oxygen Hydrogen Oxygen MOXIE O Generator Tank-to-Tank Transfer Zero Boil-Off Tank (ZBOT) Experiment 2 Concentrators

CryoFILL Liquefaction and Storage Radio Frequency Mass Gauge (RFMG) Purification and Recovery

H2

He

17 Zero Boil-off Cryogenics

Zero Boil-Off Tank (ZBOT) Experiment: 1g (1W), 90%, Self-Pressurization Hardware in MSG Aboard ISS

Micro-g (0.5W), 70%, Self-Pressurization

ZBOT Experiment During Jet Mixing

18 Thank you for your attention.

Questions?

19 Major Challenges of Solar System Missions

Extreme Environments in Planetary Missions • Some missions require high radiation

resistant power systems 100 • Outer planetary surface missions require low temperature power Io Io-Volcano 10 systems Europa Inner planetary missions require • Some outer planetary missions require power systems that can operate in 1.0 power systems that can operate in very high temperature deep space and in dense or tenuous environments

atmospheres 0.1 Radiation MRads in Dose Radiation Triton Mercury Pluto Titan Mars Earth 0.01 Venus Limit of Limit of Military Military NASA Interest NASA Interest Interest Interest

-250 -200 -150 -100 -50 0,0 100 200 300 400 o Temperature C 20 Representative Examples of Aeronautics Mission Requirements

Number of Typical Mission Power Level Specific Energy EAP Configurations Passengers Range Urban ≤ 4 < 50 miles 200-500 kW 250 – 400 Whr/kg • All electric Mobility • Hybrid Electric

Thin Haul ≤ 9 < 600 miles 200-500 kW 300 – 600 Whr/kg • Hybrid Electric

Short Haul 40-80 < 600 miles 500-1500 kW 300 – 600 Whr/kg • Hybrid Electric Aircraft

Single 150-190 900 mile typical 1000-5000 kW 750 – 1000 • Hybrid Electric Aisle mission, Whr/kg minimum • Turbo Electric 3500 mile maximum range

21 In-situ Venus Missions

The Need for In-Situ missions: The Problem Despite years of exploration, major • Hostile environment of high temperature and pressure (465°C and 92 questions remain: atm of CO2) makes surface and low-altitude missions challenging. • What is the precise chemical composition of • Cloud opacity limits orbital/balloon observations the atmosphere and how does it vary with • Conventional power sources, PV or RTG may not be applicable. New location and altitude? power technologies desired to enable missions • When and How did the Greenhouse effect occur on Venus • How did the atmosphere of Venus form and Battery Options Non-Existent evolve? • What are the morphology, chemical make-up, and variability of the Venusian clouds and their impact on the climate? • What are the processes controlling the atmospheric super-rotation? • What are the processes governing Venus seismicity and its interior structure? • How have the interior, surface, and atmosphere interacted as a coupled system over time? Fig. 1 Venus temperature/pressure vs. altitude. Fig. 1 Venus temperature/pressure vs. altitude 22 New Power Concept for Variable Altitude Venus Balloon Operation

Altitude Control Solar array powers the

• H2-filled balloon for probe at high altitude buoyancy and and generates H2 and altitude control O2 with Solid Oxide (60-15 km) Electrolysis Cell (SOEC)

• To Ascend: move H2 from stored H2O from hydride into balloon • To Descend: move

H2 from balloon into hydride At low altitudes, the SOEC operates reversibly as a Fuel Cell to power the probe from

the stored H2 and O2 and stores the

byproduct H2O

23 Portability of Terrestrial Technology to Aerospace Applications Aerospace Portability of Terrestrial Technology Remaining Component TRL Level to Aerospace Applications Technical Challenge Electrochemistry 9 High Electrolyzer Materials 5+ High High Pressure, Mass Technology Seals 5+ High High Pressure, Mass Gas Management 5+ Moderate High Pressure, Mass Flow Fields 5+ High Bipolar Plates 5+ Moderate O vs air Fuel Cell 2 Materials 5+ Moderate O vs air NOTE: Not all relevant Technology 2 Electrochemistry 5+ Low O2 vs air, Performance technologies exist Water Management 5+ Low Flow Rate, µg within the same Fluidic Components 8+ Moderate O vs air application nor are at Reactant 2 Procedures 5 Moderate O vs air, Performance the same TRL. Storage 2 Thermal 8+ Moderate µg, Vacuum and Elements of multiple Materials 8+ Low O2 vs air Management terrestrial applications Water Management 5+ Low O2 vs air, µg Hardware/PCB 8+ High are required to meet FC / EZ / RFC Power Management 8+ High specific NASA mission System Structure 8+ High requirements. Avionics Thermal 8+ High Instrumentation 8+ Moderate

4 In-situ Resource Utilization (ISRU)

Water Moon Mars Asteroids Uses (Hydrogen) Icy Regolith in Hydrated Soils/Minerals: Zypsum, Subsurface Regolith on . Drinking, radiation Permanently Shadowed Jarosite, Phylosilicates, C-type Carbonaceous shielding, plant growth, Regions (PSR) Polyhdrated Sulfates Chondrites cleaning & washing . Making Oxygen and Solar wind hydrogen with Subsurface Icy Soils in Mid- Hydrogen Oxygen Oxygen latitudes to Poles Minerals in Lunar Regolith: Carbon Dioxide in the Minerals in Regolith on S- . Breathing Ilmenite, Pyroxene, Olivine, atmosphere (~96%) type Ordinary and . Oxidizer for Propulsion Anorthite Enstatite Chondrites and Power Carbon (Gases) . CO, CO2, and HC’s in Carbon Dioxide in the Hydrocarbons and Tars . Fuel Production for PSR atmosphere (~96%) (PAHs) in Regolith on C- Propulsion and Power . Solar Wind from Sun type Carbonaceous . Plastic and Petrochemical (~50 ppm) Chondrites Production Minerals in Lunar Regolith Minerals in Mars Soils/Rocks Minerals in . In situ fabrication of parts Metals . Iron/Ti: Ilmenite . Iron: Ilmenite, Hematite, Regolith/Rocks on S-type . Electical power . Silicon: Pyroxene, Magnetite, Jarosite, Smectite Stony Iron and M-type generation and Olivine, Anorthite . Silicon: Silica, Phyllosilicates Metal Asteroids transmission . Magnesium: Mg-rich . Aluminum: Laterites, Silicates Aluminosilicates, Plagioclase . Al: Anorthitic Plagioclase . Magnesium: Mg-sulfates, Carbonates, & Smectites, Mg-rich Olivine Note: Rare Earth Elements (REE) and Platinum Group Metals (PGM) are not driving Resources of interest for Human Exploration 25