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NASA NTRS2004

Ionic Liquids and New Proton Exchange Membranes for Fuel Cells

There is currently a great surge of activity in fuel cell research as laboratories across the world seek to take advantage of the high energy capacity provided by &el cells relative to those of other portable electrochemical power systems. Much of this activity is aimed at high temperature fie1 cells, and a vital component of such &el cells must be the availability of a high temperature stable proton-permeable membrane. NASA Glenn Research Center is greatly involved in developing this technology. Other approaches to the high temperature fuel cell involve the use of single- component or almost-single-component electrolytes that provide a path for protons through the cell. A heavily researched case is the phosphoric acid fuel cell, in which the electrolyte is almost pure phosphoric acid and the cathode reaction produces water directly. The phosphoric acid fie1 cell delivers an open circuit voltage of 0.9 V falling to about 0.7 V under operating conditions at 170 C. The proton transport mechanism is mainly vehicular in character according to the viscosity/conductance relation. Here we describe some Proton Transfer Ionic Liquids (PTILs) with low vapor pressure and high temperature stability that have conductivities of unprecedented magnitude for non-aqueous systems. The first requirement of an ionic liquid is that, contrary to experience with most liquids consisting of ions, it must have a melting point that is not much above room temperature. The limit commonly suggested is 100 C. PTILs constitute an interesting class of non-corrosive proton-exchange electrolyte, which can serve well in high temperature (T = 100 - 250 C) fuel cell applications. We will present cell performance data showing that the open circuit voltage output, and the performance of a simple H2(g)Pt/PTIL/Pt/O2(g) fuel cell may be superior to those of the equivalent phosphoric acid electrolyte fuel cell both at ambient temperature and temperatures up to and above 200 C. My work at NASA Glenn Research Center during this summer is to develop and characterize proton exchange membranes doped with ionic liquids. The main techniques used to characterize these materials are: Impedance Spectroscopy, NMR, DSC, TGA, DMA, IR, and SEM ...

Belieres, Jean-Philippe↗

NASA NTRS2004

High Temperature Polymers for use in Fuel Cells

NASA Glenn Research Center (GRC) is currently working on polymers for fuel cell and lithium battery applications. The desire for more efficient, higher power density, and a lower environmental impact power sources has led to interest in proton exchanges membrane fuels cells (PEMFC) and lithium batteries. A PEMFC has many advantages as a power source. The fuel cell uses oxygen and hydrogen as reactants. The resulting products are electricity, heat, and water. The PEMFC consists of electrodes with a catalyst, and an electrolyte. The electrolyte is an ion-conducting polymer that transports protons from the anode to the cathode. Typically, a PEMFC is operated at a temperature of about 80 C. There is intense interest in developing a fuel cell membrane that can operate at higher temperatures in the range of 80 C- 120 C. Operating the he1 cell at higher temperatures increases the kinetics of the fuel cell reaction as well as decreasing the susceptibility of the catalyst to be poisoned by impurities. Currently, Nafion made by Dupont is the most widely used polymer membrane in PEMFC. Nafion does not function well above 80 C due to a significant decrease in the conductivity of the membrane from a loss of hydration. In addition to the loss of conductivity at high temperatures, the long term stability and relatively high cost of Nafion have stimulated many researches to find a substitute for Nafion. Lithium ion batteries are popular for use in portable electronic devices, such as laptop computers and mobile phones. The high power density of lithium batteries makes them ideal for the high power demand of today s advanced electronics. NASA is developing a solid polymer electrolyte that can be used for lithium batteries. Solid polymer electrolytes have many advantages over the current gel or liquid based systems that are used currently. Among these advantages are the potential for increased power density and design flexibility. Automobiles, computers, and cell phones require highly efficient power density for lowering emissions and meeting increasing consumer demands. Many of the solutions can be provided by proton exchange membrane fuel cells and lithium batteries. NASA Glenn Research Center has recognized this need, and is presently engaged in a solution. The goals for the summer include mastering synthesis techniques, understanding the reactions occurring during the synthesis, and characterizing the resulting polymer membranes using NMR, DSC, and TGA for the PEMFC and lithium batteries.

Peplowski, Katherine M.↗

NASA NTRS2004

Space Shuttle Upgrades: Long Life Alkaline Fuel Cell

NASA has utilized the alkaline fuel cell technology to provide electrical power for manned launch vehicles such as Gemini, Apollo, and the Space Shuttle. The current Shuttle alkaline fuel cells are procured from UTC Fuel Cells, a United Technologies Company. The alkaline fuel cells are very reliable but the operating life is limited to 2600 hours due to voltage degradation of the individual cells. The main limiting factor in the life of the cells is corrosion of the cell's fiberglass/epoxy frame by the aqueous potassium hydroxide electrolyte. To reduce operating costs, the orbiter program office approved the Long Life Alkaline Fuel Cell (LLAFC) program as a shuttle upgrade in 1999 to increase the operating life of the fuel cell powerplant to 5000 hours. The LLAFC program incorporates improving the cell by extending the length of the corrosion path, which reduces the cell frame corrosion. UTCFC performed analysis to understand the fundamental mechanisms that drive the cell frame corrosion. The analysis indicated that the corrosion path started along the bond line between the cathode and the cell frame. Analysis also showed that the oxygen available at the cathode, the catalyst on the electrode, and the electrode substrate all supported or intensified the corrosion. The new cell design essentially doubled the corrosion path to mitigate the problem. A 10-cell stack was tested for 5000 hours during the development phase of this program to verify improved cell performance. A complete 96-cell stack was then tested for 5000 hours during the full manned-space qualification phase of this program. Additional upgrades to the powerplant under this program are: replacing the aluminum body in the pressure regulator with stainless steel to reduce corrosion, improving stack insulator plate with improved resistance to stress failure and improved temperature capability, and replacing separator plate elastomer seals with a more durable material and improved seal retention.

Kerri McCurdy↗

NASA NTRS2005

The Development of Fuel Cell Technology for Electric Power Generation - From Spacecraft Applications to the Hydrogen Economy

The fuel cell uses a catalyzed reaction between a fuel and an oxidizer to directly produce electricity. Its high theoretical efficiency and low temperature operation made it a subject of much study upon its invention ca. 1900, but its relatively high life cycle costs kept it as "solution in search of a problem" for its first half century. The first problem for which fuel cells presented a cost effective solution was, starting in the 1960's that of a power source for NASA's manned spacecraft. NASA thus invested, and continues to invest, in the development of fuel cell power plants for this application. However, starting in the mid-1990's, prospective environmental regulations have driven increased governmental and industrial interest in "green power" and the "Hydrogen Economy." This has in turn stimulated greatly increased investment in fuel cell development for a variety of terrestrial applications. This investment is bringing about notable advances in fuel cell technology, but these advances are often in directions quite different from those needed for NASA spacecraft applications. This environment thus presents both opportunities and challenges for NASA's manned space program.

Scott, John H.↗

NASA NTRS2006

Fuel Cell Airframe Integration Study for Short-Range Aircraft: Aircraft Propulsion and Subsystems Integration Evaluation - Volume 1

The objective of this study is to define the functionality and evaluate the propulsion and power system benefits derived from a Solid Oxide Fuel Cell (SOFC) based Auxiliary Power Unit (APU) for a future short range commercial aircraft, and to define the technology gaps to enable such a system. United Technologies Corporation (UTC) Integrated Total Aircraft Power System (ITAPS) methodologies were used to evaluate a baseline aircraft and several SOFC architectures. The technology benefits were captured as reductions of the mission fuel burn, life cycle cost, noise and emissions. As a result of the study, it was recognized that system integration is critical to maximize benefits from the SOFC APU for aircraft application. The mission fuel burn savings for the two SOFC architectures ranged from 4.7 percent for a system with high integration to 6.7 percent for a highly integrated system with certain technological risks. The SOFC APU itself produced zero emissions. The reduction in engine fuel burn achieved with the SOFC systems also resulted in reduced emissions from the engines for both ground operations and in flight. The noise level of the baseline APU with a silencer is 78 dBA, while the SOFC APU produced a lower noise level. It is concluded that a high specific power SOFC system is needed to achieve the benefits identified in this study. Additional areas requiring further development are the processing of the fuel to remove sulfur, either on board or on the ground, and extending the heat sink capability of the fuel to allow greater waste heat recovery, resolve the transient electrical system integration issues, and identification of the impact of the location of the SOFC and its size on the aircraft.

Gummalla, Mallika↗

NASA NTRS2007

Development of High Fidelity, Fuel-Like Thermal Simulators for Non-Nuclear Testing

Non-nuclear testing can be a valuable tool in development of a space nuclear power or propulsion system. In a non-nuclear test bed, electric heaters are used to simulate the heat from nuclear fuel. Work at the NASA Marshall Space Flight Center seeks to develop high fidelity thermal simulators that not only match the static power profile that would be observed in an operating, fueled nuclear reactor, but to also match the dynamic fuel pin performance during feasible transients. Comparison between the fuel pins and thermal simulators is made at the fuel clad surface, which corresponds to the sheath surface in the thermal simulator. Static and dynamic fuel pin performance was determined using SINDA-FLUINT analysis, and the performance of conceptual thermal simulator designs was compared to the expected nuclear performance. Through a series of iterative analysis, a conceptual high fidelity design will be developed, followed by engineering design, fabrication, and testing to validate the overall design process. Although the resulting thermal simulator will be designed for a specific reactor concept, establishing this rigorous design process will assist in streamlining the thermal simulator development for other reactor concepts.

Bragg-Sitton, S. M.↗

NASA NTRS2007

Fuel Cell Development for NASA's Human Exploration Program: Benchmarking with "The Hydrogen Economy"

The theoretically high efficiency and low temperature operation of hydrogen-oxygen fuel cells has motivated them to be the subject of much study since their invention in the 19th Century, but their relatively high life cycle costs kept them as a "solution in search of a problem" for many years. The first problem for which fuel cells presented a truly cost effective solution was that of providing a power source for NASA's human spaceflight vehicles in the 1960 s. NASA thus invested, and continues to invest, in the development of fuel cell power plants for this application. This development program continues to place its highest priorities on requirements for minimum system mass and maximum durability and reliability. These priorities drive fuel cell power plant design decisions at all levels, even that of catalyst support. However, since the mid-1990's, prospective environmental regulations have driven increased governmental and industrial interest in "green power" and the "Hydrogen Economy." This has in turn stimulated greatly increased investment in fuel cell development for a variety of commercial applications. This investment is bringing about notable advances in fuel cell technology, but, as these development efforts place their highest priority on requirements for minimum life cycle cost and field safety, these advances are yielding design solutions quite different at almost every level from those needed for spacecraft applications. This environment thus presents both opportunities and challenges for NASA's Human Exploration Program

Scott, John H.↗

NASA NTRS2001

Combustor with fuel preparation chambers

An annular combustor having fuel preparation chambers mounted in the dome of the combustor. The fuel preparation chamber comprises an annular wall extending axially from an inlet to an exit that defines a mixing chamber. Mounted to the inlet are an air swirler and a fuel atomizer. The air swirler provides swirled air to the mixing chamber while the atomizer provides a fuel spray. On the downstream side of the exit, the fuel preparation chamber has an inwardly extending conical wall that compresses the swirling mixture of fuel and air exiting the mixing chamber.

Zelina, Joseph↗

NASA NTRS1983

Fuel control for gas turbine with continuous pilot flame

An improved fuel control for a gas turbine engine having a continuous pilot flame and a fuel distribution system including a pump drawing fuel from a source and supplying a line to the main fuel nozzle of the engine, the improvement being a control loop between the pump outlet and the pump inlet to bypass fuel, an electronically controlled throttle valve to restrict flow in the control loop when main nozzle demand exists and to permit substantially unrestricted flow without main nozzle demand, a minimum flow valve in the control loop downstream of the throttle valve to maintain a minimum pressure in the loop ahead of the flow valve, a branch tube from the pilot flame nozzle to the control loop between the throttle valve and the minimum flow valve, an orifice in the branch tube, and a feedback tube from the branch tube downstream of the orifice to the minimum flow valve, the minimum flow valve being operative to maintain a substantially constant pressure differential across the orifice to maintain constant fuel flow to the pilot flame nozzle.

Swick, Robert M.↗

NASA NTRS2003

Method for providing concentricity of pilot fuel assembly in a combustor

Concentric installation of a pilot fuel assembly in an opening in a gas turbine combustor casing is achieved by providing a boss having at least two flat surfaces which are perpendicular to each other on the combustor casing surrounding the opening and a mounting flange having at least two flat surfaces which are perpendicular to each other on the pilot fuel assembly. The pilot fuel assembly is concentrically installed to the combustor casing by inserting the assembly into the combustor casing opening, and moving the pilot fuel assembly as far as it will go in a first direction substantially parallel to one of the flat boss surfaces. The distance between the other flat boss surface and one of the flat flange surfaces is then taken. Next, the pilot fuel assembly is moved in the direction opposite the first direction, at which point, the distance between the same two flat surfaces is again measured. Lastly, the pilot fuel assembly is located at a position where the distance between the two measuring surfaces is equal to the average of the first and second measurements. If desired, these steps can be repeated back and forth along an axis perpendicular to the first and second directions.

Halila, Ely E.↗

NASA NTRS2008

Intelligent Engine Systems: Alternate Fuels Evaluation

The performance and gaseous emissions were measured for a well-stirred reactor operating under lean conditions for two fuels: JP8 and a synthetic Fisher-Tropsch fuel over a range of equivalence ratios from 0.6 down to the lean blowout. The lean blowout characteristics were determined in LBO experiments at loading parameter values from 0.7 to 1.4. The lean blowout characteristics were then explored under higher loading conditions by simulating higher altitude operation with the use of nitrogen as a dilution gas for the air stream. The experiments showed that: (1) The lean blowout characteristics for the two fuels were close under both low loading and high loading conditions. (2) The combustion temperatures and observed combustion efficiencies were similar for the two fuels. (3) The gaseous emissions were similar for the two fuels and the differences in the H2O and CO2 emissions appear to be directly relatable to the C/H ratio for the fuels.

Ballal, Dilip↗

NASA NTRS2008

Unitized regenerative fuel cell system

A Unitized Regenerative Fuel Cell system uses heat pipes to convey waste heat from the fuel cell stack to the reactant storage tanks. The storage tanks act as heat sinks/sources and as passive radiators of the waste heat from the fuel cell stack. During charge up, i.e., the electrolytic process, gases are conveyed to the reactant storage tanks by way of tubes that include dryers. Reactant gases moving through the dryers give up energy to the cold tanks, causing water vapor in with the gases to condense and freeze on the internal surfaces of the dryer. During operation in its fuel cell mode, the heat pipes convey waste heat from the fuel cell stack to the respective reactant storage tanks, thereby heating them such that the reactant gases, as they pass though the respective dryers on their way to the fuel cell stacks retrieve the water previously removed.

Burke, Kenneth A.↗

NASA NTRS1946

Flight Investigation of the Knock-Limited Performance of a Triptane Blend, a Toluene Blend, and 28-R Fuel in an R-1830-75 Engine

Knock-limited performance data were obtained for three fuels on an R-1830-75 engine in a B-24D airplane at engine speeds of 1800, 2250, and 2600 rpm, a spark advance of 25 degrees B.T.C., and carburetor-air temperatures of 85 F for 1800 and 2250 rpm and 100 F for 2600 rpm. The test fuels were a blend of 80 percent 28-R plus 20 percent triptane (leaded to 4.5 ml TEL/gal), a blend of 80 percent 28-R plus 15 percent toluene (leaded to 4.5 ml TEL / gal), and 28-R fuel. The knock-limited manifold pressure of the toluene blend depreciated more in the lean region than the triptane blend or 28-R fuel. The knock-limited brake horsepower for the triptane blend varied from 16 to 25 percent higher than 28-R in the lean region and 18 to 30 percent higher in the rich region. The knock-limited brake horsepower of the toluene blend was approximately 15 percent higher than that of 28-R in the rich region and varied from 2 to 10 percent higher in the lean region. Knock limits of the triptane blend and 28-R fuel tested in the R-1830-75 engine agreed with limits for the same fuels determined with the R-1830-94 engine for engine speeds of 1800 and 2250 rpm.

Blackman, Calvin C.↗

NASA NTRS2009

Synthetic and Biomass Alternate Fueling in Aviation

Worldwide, aviation alone uses 85 to 95 billion gallons of nonrenewable fossil fuel per year (2008). General transportation fueling can accommodate several different fuels; however, aviation fuels have very specific requirements. Biofuels have been flight demonstrated, are considered renewable, have the capacity to become "drop-in" replacements for Jet-A fuel, and solve the CO2 climate change problem. The major issue is cost; current biomass biofuels are not economically competitive. Biofuel feedstock sources being researched are halophytes, algae, cyanobacteria, weeds-to-crops, wastes with contingent restraints on use of crop land, freshwater, and climate change. There are five major renewable energy sources: solar thermal, solar photovoltaic, wind, drilled geothermal and biomass, each of which have an order of magnitude greater capacity to meet all energy needs. All five address aspects of climate change; biomass has massive potential as an energy fuel feedstock.

Hendricks, R.C.↗

NASA NTRS2010

Thermal Stability Testing of a Fischer-Tropsch Fuel and Various Blends with Jet A

Fischer-Tropsch (F-T) jet fuel composition differs from petroleum-based, conventional commercial jet fuel because of differences in feedstock and production methodology. Fischer-Tropsch fuel typically has a lower aromatic and sulfur content and consists primarily of iso and normal parafins. The ASTM D3241 specification for Jet Fuel Thermal Oxidation Test (JFTOT) break point testing method was used to test the breakpoint of a baseline conventional Jet A, a commercial grade F-T jet fuel, and various blends of this F-T fuel in Jet A. The testing completed in this report was supported by the NASA Fundamental Aeronautics Subsonics Fixed Wing Project.

Klettlinger, Jennifer Suder↗

NASA NTRS2011

Alternative Aviation Fuel Experiment (AAFEX)

The rising cost of oil coupled with the need to reduce pollution and dependence on foreign suppliers has spurred great interest and activity in developing alternative aviation fuels. Although a variety of fuels have been produced that have similar properties to standard Jet A, detailed studies are required to ascertain the exact impacts of the fuels on engine operation and exhaust composition. In response to this need, NASA acquired and burned a variety of alternative aviation fuel mixtures in the Dryden Flight Research Center DC-8 to assess changes in the aircraft s CFM-56 engine performance and emission parameters relative to operation with standard JP-8. This Alternative Aviation Fuel Experiment, or AAFEX, was conducted at NASA Dryden s Aircraft Operations Facility (DAOF) in Palmdale, California, from January 19 to February 3, 2009 and specifically sought to establish fuel matrix effects on: 1) engine and exhaust gas temperatures and compressor speeds; 2) engine and auxiliary power unit (APU) gas phase and particle emissions and characteristics; and 3) volatile aerosol formation in aging exhaust plumes

Anderson, B. E.↗

NASA NTRS2011

Evaluating and Addressing Potential Hazards of Fuel Tanks Surviving Atmospheric Reentry

In order to ensure reentering spacecraft do not pose an undue risk to the Earth's population it is important to design satellites and rocket bodies with end of life considerations in mind. In addition to considering the possible consequences of deorbiting a vehicle, consideration must also be given to the possible risks associated with a vehicle failing to become operational or reach its intended orbit. Based on recovered space debris and numerous reentry survivability analyses, fuel tanks are of particular concern in both of these considerations. Most spacecraft utilize some type of fuel tank as part of their propulsion system. These fuel tanks are most often constructed using stainless steel or titanium and are filled with potentially hazardous substances such as hydrazine and nitrogen tetroxide. For a vehicle which has reached its scheduled end of mission the contents of the tanks are typically depleted. In this scenario the use of stainless steel and titanium results in the tanks posing a risk to people and property do to the high melting point and large heat of ablation of these materials leading to likely survival of the tank during reentry. If a large portion of the fuel is not depleted prior to reentry, there is the added risk of hazardous substance being released when the tank impact the ground. This paper presents a discussion of proactive methods which have been utilized by NASA satellite projects to address the risks associated with fuel tanks reentering the atmosphere. In particular it will address the design of a demiseable fuel tank as well as the evaluation of off the shelf designs which are selected to burst during reentry.

Kelley, Robert L.↗

NASA NTRS2012

Imidazolium-Based Polymeric Materials as Alkaline Anion-Exchange Fuel Cell Membranes

Polymer electrolyte membranes that conduct hydroxide ions have potential use in fuel cells. A variety of polystyrene-based quaternary ammonium hydroxides have been reported as anion exchange fuel cell membranes. However, the hydrolytic stability and conductivity of the commercially available membranes are not adequate to meet the requirements of fuel cell applications. When compared with commercially available membranes, polystyrene-imidazolium alkaline membrane electrolytes are more stable and more highly conducting. At the time of this reporting, this has been the first such usage for imidazolium-based polymeric materials for fuel cells. Imidazolium salts are known to be electrochemically stable over wide potential ranges. By controlling the relative ratio of imidazolium groups in polystyrene-imidazolium salts, their physiochemical properties could be modulated. Alkaline anion exchange membranes based on polystyrene-imidazolium hydroxide materials have been developed. The first step was to synthesize the poly(styrene-co-(1-((4-vinyl)methyl)-3- methylimidazolium) chloride through a free-radical polymerization. Casting of this material followed by in situ treatment of the membranes with sodium hydroxide solutions provided the corresponding hydroxide salts. Various ratios of the monomers 4-chloromoethylvinylbenzine (CMVB) and vinylbenzine (VB) provided various compositions of the polymer. The preferred material, due to the relative ease of casting the film, and its relatively low hygroscopic nature, was a 2:1 ratio of CMVB to VB. Testing confirmed that at room temperature, the new membranes outperformed commercially available membranes by a large margin. With fuel cells now in use at NASA and in transportation, and with defense potential, any improvement to fuel cell efficiency is a significant development.

Narayan, Sri R.↗