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Fuel Cell Research and Development for Earth and Space Applications

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Fuel Cell Research and Development for Earth and Space Applications National Aeronautics and Space Administration Fuel Cell Research and Development for Earth and Space Applications Ian Jakupca, NASA Glenn Research Center 17 July 2018 1 National Aeronautics and Space Administration Presentation Outline • NASA – Overview and Scope • Background • Power and Energy Systems • Applicable Types of Electrochemical Systems • Energy Storage: Batteries vs. Regenerative Fuel Cells (RFC) • Comparison of Fuel Cell Technologies: Aerospace vs. Terrestrial • Active NASA Fuel Cell research • Power Generation • Energy Storage • Commodity Generation • Review 2 NASA Centers and Facilities 3 LUNAR EXPLORATION CAMPAIGN 4 5 NASA's Lunar Reconnaissance Orbiter (LRO) Data • The average temperature on the Moon (at the equator and mid latitudes) varies from 90 Kelvin (-298 degrees Fahrenheit or -183 degrees Celsius), at night, to 379 Kelvin (224 degrees Fahrenheit or 106 degrees Celsius) during the day. • Extremely cold temperatures within the permanently shadowed regions of large polar impact craters in the south polar region during the daytime is at 35 Kelvin (-397 degrees Fahrenheit or -238 degrees Celsius) • Lunar day/night cycle lasts between 27.32 and 29.53 Earth days (655.7 to 708.7 hours) • Regulating hardware in this environment requires both power and energy 6 Power and Energy Systems Power Generation Energy Storage Discharge Power Only Charge + Store + Discharge Description Description • Energy conversion system that • Stores excess energy for later use supplies electricity to customer • Supplies power when baseline system power supply (e.g. PV) is no longer • Operation limited by initial available stored energy • Tied to external energy source Examples Examples • Nuclear (e.g. RTG, KiloPower) • Rechargeable Batteries • Primary Batteries • Regenerative Fuel Cells • Primary Fuel Cells • Photovoltaics NASA Applications: NASA Applications: Missions without access to Ensuring Continuous Power continuous power (e.g. PV) • Satellites (PV + Battery) • All NASA applications require • ISS (PV + Battery) electrical power • Surface Systems • Each primary power solution fits (exploration platforms, ISRU, crewed) a particular suite of NASA • Platforms to survive Lunar Night missions 7 Summary of Applicable Electrochemical Chemistries Low Temperature Moderate Temperature High Temperature Proton Exchange Phosphoric Acid Molten Carbonate Cell Type Alkaline (AEM) Alkaline (AFC) Solid Oxide (SOFC) Membrane (PEM) (PAFC) (MCFC) Ionic Polymer Anionic Polymer KOH in asbestos Phosphoric Acid in Liquid carbonate in Anionic Conducting Electrolyte Membrane Membrane matrix SiC structure LiAlO2 structure Ceramic Operating 10 – 80 °C 20 – 70 °C 70 – 225 °C 200 – 250 °C ~650 °C 600 – 1,000 °C Temperature + - - + 2- 2- Charge Carrier H OH OH H CO3 O Load Slew Rate Very High High High High Low to Medium Low Capability (> 1k’s mA/cm2/s) (~ 1k’s mA/cm2/s) (~ 1k’s mA/cm2/s) (~ 1k’s mA/cm2/s) (~100’s mA/cm2/s) (~10’s mA/cm2/s) Fuel Pure H Pure H H , CO, Short Hydrocarbons 2 Feasible for2 2 Product Water Cavity Oxygen Hydrogen Hydrogen Oxygen Hydrogen Product Water Liquid ProductAerospace Operation defines Applications product water state Vapor, externally separated CO Tolerance < 2 ppm < 2 ppm < 5 ppm < 50 ppm Fuel Reformer Very High High High Minimal Complexity No longer in Aerospace Viability Promising TBR (Low TRL) Not Viable Not Viable Promising production Terrestrial High Developmental Moderate Moderate High N/A Availability (Increasing) (Increasing) (Stable) (Increasing) (Increasing) Terrestrial Markets Transportation, Transportation, Co-generation and Co-generation and C = Commercial Logistics, Stationary Logistics N/A Stationary Power (C) Stationary Power Stationary Power I = Industrial R = Residential Power (C, I, & R) (C) (C & l) (C, I, & R) 8 Summary of Applicable Electrochemical Chemistries PEM AEM Alkaline Solid Oxide • Commonly used in mobile • Solid polymer electrolyte • Liquid electrolyte suspended in • Commonly used in stationary terrestrial applications • Developing technology not yet asbestos structure terrestrial applications • Terrestrial systems vent Oxygen to deployed • Hydrogen recirculates to remove • Terrestrial systems vent hydrogen remove product water from stack product water from stack to remove product water from stack • Mature for terrestrial applications, • Used in Space Shuttle • Mature for terrestrial applications, Key NotesKey needs development for Aerospace needs development for Aerospace • Rapid reaction kinetics support • Reaction kinetics support transient • Reaction kinetics support transient • Wide range of fuels (Anode) transient load response capability load response capability load response capability • Can be configured to internally • Support wide range of current • Relatively high tolerance to • Relatively high tolerance to reform hydrocarbons densities contaminant gases contaminant gases • Relatively high tolerance to • Minimal start times • Solid polymer eliminates migration • Higher pH enables larger selection contaminant gases in Hydrogen (typ. < 1 min) of corrosive electrolyte for wetted materials • Resistant to freezing when stored • Demonstrated high pressure • Higher pH enables larger selection operation for wetted materials Advantages • Solid polymer electrolyte eliminates migration of acidic electrolyte • Very sensitive to CO or Sulfur • Limited operational life • No longer available as company • Ceramic electrolyte limits transient contaminants in Hydrogen stream • Limited pressure capability divested both IP and fabrication load response capability • Water-based system limits capability • Ceramic electrolyte limits start-up temperature regimes • EPA restricted use of asbestos times to 10’s of minutes to hours • Liquid electrolyte migrates • Seals need development for throughout fluid system requiring Aerospace applications frequent and expensive servicing • Limited to low-pressure Disadvantages applications 9 Aerospace Electrochemical Systems Fuel Cell Regenerative Fuel Cell Electrolysis Power Generation Energy Storage Commodity Generation Discharging Only Discharging 2 H2O 2 H2+ O2 Discharging or Solar Array Load Hydrogen Charging Electrolyzer Fuel Cell Oxygen 2 CO2 2 CO + O2 Description • Converts supplied reactant to Water Description DC electricity Description • Converts chemical feedstock • Operation limited by supplied • Stores supplied energy as gaseous reactants into useful commodities reactants • Discharges power as requested by external load • Tied to external energy source • Not tied to external energy • Tied to external energy source source NASA Applications: NASA Applications: Life-support, ISRU NASA Applications: Ensuring Continuous Power • Oxygen Generation Sustained High-Power • Surface Systems • Propellant Generation • Crewed transit vehicles (exploration platforms, ISRU, crewed) • Material Processing (Apollo, Gemini, STS, etc.) • Platforms to survive Lunar Night • Power-intense rovers/landing platforms 10 Example H2/O2 Aerospace Fuel Cell Systems Fuel Cell Regenerative Fuel Cell Electrolysis Power Generation Energy Storage Commodity Generation - - 2H2 + O2 → 2H2O + 4e + Heat 2H2O + 4e → 2H2 + O2 + Heat ɳCycle = ~50% O2 H2 O2 H2 O2 H2 ΔP ΔP ΔP ΔP QTH QTH QTH H2O H2O QELE QELE QELE H2O QELE DischargingDischarging Charging Charging Interconnecting Regenerative Fuel Cell = Fuel Cell + + Electrolysis Fluidic System 11 Definitions: Power and Energy System Metrics Fuel Cell Regenerative Fuel Cell Electrolysis Power Generation Energy Storage Commodity Generation Primary Metrics Primary Metrics Primary Metrics • Specific Power (W/kg) • Specific Energy (W•hrs/kg) • Production Rate (kg/day) • Output Power (Watts) • Reliability (Years) • Reliability (Months/Years) • Mass (kg) • Stored Energy (kW•hrs) • System Pressure (Atm) • Volume (L) • Mass (kg) • Mass (kg) • Reliability (Hours/Days) • Volume (L) • Volume (L) Technical Challenges Technical Challenges Technical Challenges • Water Management • Component Reliability • System Pressure • Reactant Purity • Corrosion/Chemical Compatibility • Component Reliability • Thermal Control • Reactant Purity • Corrosion/Chemical • Con-Ops • Water Management Compatibility • Shelf-life • Con-Ops • Fluid Purity • Thermal • Con-Ops • EZ System Pressure • Maintenance • Maintenance • Shelf-life 12 Comparison of Fuel Cell Technologies Aerospace Terrestrial Space Shuttle Fuel Cell Stack 1 (1979 - 2014) Toyota Mirai Fuel Cell Differentiating Characteristics Differentiating Characteristics Pure Oxygen (stored, stoichiometric) Atmospheric Air (conditioned, excess flow) Water Separation in µg High air flow drives water removal Fluid management issues and environmental conditions make aerospace and terrestrial fuel cells functionally dissimilar Notes: 1 = http://www.toyota-global.com/innovation/environmental_technology/technology_file/fuel_cell_hybrid/fcstack.html 13 Cross-Cutting Technologies: Fuel Cells, Electrolyzers, and RFCs Aerospace Portability of Terrestrial Technology Remaining Technical Component TRL Level to Aerospace Applications 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 Technology 2 Electrochemistry 5+ Low O2 vs air, Performance Water Management 5+ Low Flow Rate, µg Fluidic Components 8+ Moderate O vs air Reactant 2 Procedures 5 Moderate O vs air, Performance Storage 2 Thermal 8+ Moderate µg, Vacuum and
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