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NASA NTRS2005

Small Portable PEM Fuel Cell Systems for NASA Exploration Missions

Oxygen-Hydrogen PEM-based fuel cell systems are being examined as a portable power source alternative in addition to advanced battery technology. Fuel cell power systems have been used by the Gemini, Apollo, and Space Shuttle programs. These systems have not been portable, but have been integral parts of their spacecraft, and have used reactants from a separate cryogenic supply. These systems typically have been higher in power. They also have had significant ancillary equipment sections that perform the pumping of reactants and coolant through the fuel cell stack and the separation of the product water from the unused reactant streams. The design of small portable fuel cell systems will be a significant departure from these previous designs. These smaller designs will have very limited ancillary equipment, relying on passive techniques for reactant and thermal management, and the reactant storage will be an integral part of the fuel cell system. An analysis of the mass and volume for small portable fuel cell systems was done to evaluate and quantify areas of technological improvement. A review of current fuel cell technology as well as reactant storage and management technology was completed to validate the analysis and to identify technology challenges

Burke, Kenneth A.↗

NASA NTRS2011

NASA Non-Flow-Through PEM Fuel Cell System for Aerospace Applications

NASA is researching passive NFT Proton Exchange Membrane (PEM) fuel cell technologies for primary fuel cell power plants in air-independent applications. NFT fuel cell power systems have a higher power density than flow through systems due to both reduced parasitic loads and lower system mass and volume. Reactant storage still dominates system mass/volume considerations. NFT fuel cell stack testing has demonstrated equivalent short term performance to flow through stacks. More testing is required to evaluate long-term performance.

Araghi, Koorosh R.↗

NASA NTRS1989

Advanced space power PEM fuel cell systems

A model showing mass and heat transfer in proton exchange membrane (PEM) single cells is presented. For space applications, stack operation requiring combined water and thermal management is needed. Advanced hardware designs able to combine these two techniques are available. Test results are shown for membrane materials which can operate with sufficiently fast diffusive water transport to sustain current densities of 300 ma per square centimeter. Higher power density levels are predicted to require active water removal.

Vanderborgh, N. E.↗

NASA NTRS2004

Proton Exchange Membrane (PEM) Fuel Cells for Space Applications

This presentation will provide a summary of the PEM fuel cell development at the National Aeronautics and Space Administration, Johnson Space Center (NASA, JSC) in support of future space applications. Fuel cells have been used for space power generation due to their high energy storage density for multi-day missions. The Shuttle currently utilizes the alkaline fuel cell technology, which has highly safe and reliable performance. However, the alkaline technology has a limited life due to the corrosion inherent to the alkaline technology. PEM fuel cells are under development by industry for transportation, residential and commercial stationary power applications. NASA is trying to incorporate some of this stack technology development in the PEM fuel cells for space. NASA has some unique design and performance parameters which make developing a PEM fuel cell system more challenging. Space fuel cell applications utilize oxygen, rather than air, which yields better performance but increases the hazard level. To reduce the quantity of reactants that need to be flown in space, NASA also utilizes water separation and reactant recirculation. Due to the hazards of utilizing active components for recirculation and water separation, NASA is trying to develop passive recirculation and water separation methods. However, the ability to develop recirculation components and water separators that are gravity-independent and successfully operate over the full range of power levels is one of the greatest challenges to developing a safe and reliable PEM fuel cell system. PEM stack, accessory component, and system tests that have been performed for space power applications will be discussed.

Bradley, Karla↗

NASA NTRS2019

Thermal System Sizing Comparison of a PEM and Solid Oxide Fuel Cell Systems on Mars

Power production is a key aspect to any Mars mission. One method for providing power throughout the day/night cycle, or to satisfy short-duration high-output power needs, is to utilize a regenerative fuel cell system for providing energy storage and nighttime or supplemental power. This study compares the total system mass for two types of fuel cell systems, proton exchange membrane (PEM) and solid oxide (SO), sized to provide 10 kW of electrical output power in the Mars environment. Two operating locations were examined; one near the equator at 4 Â°S latitude and one the higher northern latitude of 48Â°N. The systems were sized to operate throughout the year at these locations, where the radiator was sized for the worst-case warm condition and the insulation was sized for the worst-case cold condition. Using the selected system parameters, the results for both latitudes showed that the lightest system was the SO fuel cell with a PEM electrolyzer. This was mainly due to the higher operational temperature of the SO system enabled a significantly smaller radiator mass compared to that of the PEM fuel cell system. However, there was a significant difference in mass for the PEM system when operated near the equator as compared to the higher northern latitude. For the 10-kW output system this difference in mass was just under 100 kg.

Fuel Cells↗

NASA NTRS2018

Fuel Cell Model Validation with Power Module Test Data

The AES Modular Power Systems (AMPS) Fuel Cell team at the NASA Glenn Research Center (GRC) has created a Microsoft Excel model of a regenerative fuel cell (RFC) system for potential lunar and Martian applications. Due to some limitations of this model, including the ability to predict transient effects in the thermal and fluidic performance of the system, a system-level transient thermal/fluids model was desired. GT-SUITE is a transient multi-physics simulation tool that is popular in the automotive industry and has a built-in template for proton exchange membrane (PEM) fuel cells. However, terrestrial fuel cells used in the automotive industry vary significantly from aerospace fuel cells. A validation effort was undertaken to compare GT SUITE model results to actual data collected during the 2015 AMPS (Advanced Exploration Systems (AES) Modular Power Systems) Power Module Demonstration in which the AMPS team used a PEM fuel cell system to power a 478 kilogram rover assembly at the Dunes test site located at GRC. The purpose of the model was to evaluate the efficacy of using GT SUITE to model a non-flow through PEM fuel cell system. The validation effort examined electrochemical performance including fuel cell stack voltage and power supplied, the thermal performance of the stack namely stack temperature and heat rejection rates, and the fluidic performance of the system including pressures, reactant consumption, and water production rates.

Model Validation↗

NASA NTRS2018

GT SUITE Fuel Cell Model Validation with Power Module Test Data

The AES Modular Power Systems (AMPS) Fuel Cell team at the NASA Glenn Research Center (GRC) has created a Microsoft Excel model of a regenerative fuel cell (RFC) system for potential lunar and Martian applications. Due to some limitations of this model, including the ability to predict transient effects in the thermal and fluidic performance of the system, a system-level transient thermal/fluids model was desired. GT-SUITE is a transient multi-physics simulation tool that is popular in the automotive industry and has a built in template for proton exchange membrane (PEM) fuel cells. However, terrestrial fuel cells used in the automotive industry vary significantly from aerospace fuel cells. A validation effort was undertaken to compare GT SUITE model results to actual data collected during the 2015 AMPS Power Module Demonstration in which the AMPS team used a PEM fuel cell system to power a 478 kg rover assembly at the Dunes test site located at GRC. The purpose of the model was to evaluate the efficacy of using GT SUITE to model a non-flow through PEM fuel cell system. The validation effort examined electrochemical performance including fuel cell stack voltage and power supplied, the thermal performance of the stack namely stack temperature and heat rejection rates, and the fluidic performance of the system including pressures, reactant consumption, and water production rates.

Gilligan, Ryan↗

NASA NTRS2013

Development of a High Reliability Compact Air Independent PEMFC Power System

Autonomous Underwater Vehicles (AUV's) have received increasing attention in recent years as military and commercial users look for means to maintain a mobile and persistent presence in the undersea world. Compact, neutrally buoyant power systems are needed for both small and large vehicles. Historically, batteries have been employed in these applications, but the energy density and therefore mission duration are limited with current battery technologies. Vehicles with stored energy requirements greater than approximately 10 kWh have an alternate means to get long duration power. High efficiency Proton Exchange Membrane (PEM) fuel cell systems utilizing pure hydrogen and oxygen reactants show the potential for an order of magnitude energy density improvement over batteries as long as the subsystems are compact. One key aspect to achieving a compact and energy dense system is the design of the fuel cell balance of plant (BOP). Recent fuel cell work, initially focused on NASA applications requiring high reliability, has developed systems that can meet target power and energy densities. Passive flow through systems using ejector driven reactant (EDR) circulation have been developed to provide high reactant flow and water management within the stack, with minimal parasitic losses compared to blowers. The ejectors and recirculation loops, along with valves and other BOP instrumentation, have been incorporated within the stack end plate. In addition, components for water management and reactant conditioning have been incorporated within the stack to further minimize the BOP. These BOP systems are thermally and functionally integrated into the stack hardware and fit into the small volumes required for AUV and future NASA applications to maximize the volume available for reactants. These integrated systems provide a compact solution for the fuel cell BOP and maximize the efficiency and reliability of the system. Designs have been developed for multiple applications ranging from less than 1 kWe to 70 kWe. These systems occupy a very small portion of the overall energy system, allowing most of the system volume to be used for reactants. The fuel cell systems have been optimized to use reactants efficiently with high stack efficiency and low parasitic losses. The resulting compact, highly efficient fuel cell system provides exceptional reactant utilization and energy density. Key design variables and supporting test data are presented. Future development activities are described.

Vasquez, Arturo↗

NASA NTRS2011

The Advantages of Non-Flow-Through Fuel Cell Power Systems for Aerospace Applications

NASA has been developing proton-exchange-membrane (PEM) fuel cell power systems for the past decade, as an upgraded technology to the alkaline fuel cells which presently provide power for the Shuttle Orbiter. All fuel cell power systems consist of one or more fuel cell stacks in combination with appropriate balance-of-plant hardware. Traditional PEM fuel cells are characterized as flow-through, in which recirculating reactant streams remove product water from the fuel cell stack. NASA recently embarked on the development of non-flow-through fuel cell systems, in which reactants are dead-ended into the fuel cell stack and product water is removed by internal wicks. This simplifies the fuel cell power system by eliminating the need for pumps to provide reactant circulation, and mechanical water separators to remove the product water from the recirculating reactant streams. By eliminating these mechanical components, the resulting fuel cell power system has lower mass, volume, and parasitic power requirements, along with higher reliability and longer life. These improved non-flow-through fuel cell power systems therefore offer significant advantages for many aerospace applications.

Hoberecht, Mark↗

NASA NTRS2005

Hydrogen-Oxygen PEM Regenerative Fuel Cell Energy Storage System

An introduction to the closed cycle hydrogen-oxygen polymer electrolyte membrane (PEM) regenerative fuel cell (RFC), recently constructed at NASA Glenn Research Center, is presented. Illustrated with explanatory graphics and figures, this report outlines the engineering motivations for the RFC as a solar energy storage device, the system requirements, layout and hardware detail of the RFC unit at NASA Glenn, the construction history, and test experience accumulated to date with this unit.

Bents, David J.↗

NASA NTRS2000

Analysis and Test of a Proton Exchange Membrane Fuel Cell Power System for Space Power Applications

An effort is underway to develop a prototype Proton Exchange Membrane (PEM) Fuel Cell breadboard system for fuhlre space applications. This prototype will be used to develop a comprehensive design basis for a space-rated PEM fuel cell powerplant. The prototype system includes reactant pressure regulators, ejector-based reactant pumps, a 4-kW fuel cell stack and cooling system, and a passive, membranebased oxygen / water separator. A computer model is being developed concurrently to analytically predict fluid flow in the oxidant reactant system. Fuel cells have historically played an important role in human-rated spacecraft. The Gemini and Apollo spacecraft used fuel cells for vehicle electrical power. The Space Shuttle currently uses three Alkaline Fuel Cell Powerplants (AFCP) to generate all of the vehicle's 15-20kW electrical power. Engineers at the Johnson Space Center have leveraged off the development effort ongoing in the commercial arena to develop PEM fuel cel ls for terrestrial uses. The prototype design originated from efforts to develop a PEM fuel cell replacement for the current Space Shuttle AFCP' s. In order to improve on the life and an already excellent hi storical record of reliability and safety, three subsystems were focused on. These were the fuel cell stack itself, the reactant circulation devices, and reactant / product water separator. PEM fuel cell stack performance is already demonstrating the potential for greater than four times the useful life of the current Shuttle's AFCP. Reactant pumping for product water removal has historically been accomplished with mechanical pumps. Ejectors offer an effective means of reactant pumping as well as the potential for weight reduction, control simplification, and long life. Centrifugal water separation is used on the current AFCP. A passive, membrane-based water separator offers compatibility with the micro-gravity environment of space, and the potential for control simplification, elimination of moving parts in an oxygen environment, and long life. The prototype system has been assembled from components that have previously been tested and evaluated at the component level. Preliminary data obtained from tests performed with the prototype system, as well as other published data, has been used to validate the analytical component models. These components have been incorporated into an integrated oxidant fluid system model. Results obtained from both the performance tests and the analytical model are presented.

Vasquez, Arturo↗

NASA NTRS1994

Space power systems technology

Reported here is a series of studies which examine several potential catalysts and electrodes for some fuel cell systems, some materials for space applications, and mathematical modeling and performance predictions for some solid oxide fuel cells and electrolyzers. The fuel cell systems have a potential for terrestrial applications in addition to solar energy conversion in space applications. Catalysts and electrodes for phosphoric acid fuel cell systems and for polymer electrolyte membrane (PEM) fuel cell and electrolyzer systems were examined.

Coulman, George A.↗

NASA NTRS2011

Development Status of PEM Non-Flow-Through Fuel Cell System Technology for NASA Applications

Today s widespread development of proton-exchange-membrane (PEM) fuel cell technology for commercial users owes its existence to NASA, where fuel cell technology saw its first applications. Beginning with the early Gemini and Apollo programs, and continuing to this day with the Shuttle Orbiter program, fuel cells have been a primary source of electrical power for many NASA missions. This is particularly true for manned missions, where astronauts are able to make use of the by-product of the fuel cell reaction, potable water. But fuel cells also offer advantages for unmanned missions, specifically when power requirements exceed several hundred watts and primary batteries are not a viable alternative. In recent years, NASA s Exploration Technology Development Program (ETDP) funded the development of fuel cell technology for applications that provide both primary power and regenerative fuel cell energy storage for planned Exploration missions that involved a return to the moon. Under this program, the Altair Lunar Lander was a mission requiring fuel cell primary power. There were also various Lunar Surface System applications requiring regenerative fuel cell energy storage, in which a fuel cell and electrolyzer combine to form an energy storage system with hydrogen, oxygen, and water as common reactants. Examples of these systems include habitat modules and large rovers. In FY11, the ETDP has been replaced by the Enabling Technology Development and Demonstration Program (ETDDP), with many of the same technology goals and requirements applied against NASA s revised Exploration portfolio.

Hoberecht, Mark A.↗

NASA NTRSDate not supplied

Regenerative Fuel Cell Systems for Lunar Surface Applications

A discrete Regenerative Fuel Cell (RFC), comprised of a Proton Exchange Membrane (PEM) Fuel Cell (FC) system integrated with a PEM Electrolyzer (EZ) system, can provide energy conversion and storage options for applications where batteries are not practical. This includes missions on the lunar surface where long charge and discharge periods result in extremely high battery system mass for sufficient energy storage. While both PEM FC and PEM EZ are mature terrestrial technologies, there is still a lot of development needed for aerospace applications. Integrating the PEM FC and PEM EZ systems together requires the integration of multiple thermal, fluid, and electrical subsystems, increasing the complexity of the overall RFC system. Additionally, Balance of Plant (BoP) components and subsystems play a crucial role in the effective performance to maximize the RFC round trip efficiency. This presentation will give a high-level overview of RFCs, select BoP components including a catalytic recombiner and gas drying equipment, and the current testing that is being done on the RFC project at NASA GRC.

Jessica Cashman↗

NASA NTRS2010

A Comparison of Flow-Through Versus Non-Flow-Through Proton Exchange Membrane Fuel Cell Systems for NASA's Exploration Missions

As part of the Exploration Technology Development Program (ETDP) under the auspices of the Exploration Systems Mission Directorate (ESMD), NASA is developing both primary fuel cell power systems and regenerative fuel cell (RFC) energy storage systems within the fuel cell portion of the Energy Storage Project. This effort is being led by the NASA Glenn Research Center (GRC) in partnership with the NASA Johnson Space Center (JSC), Jet Propulsion Laboratory (JPL), NASA Kennedy Space Center (KSC), and industrial partners. The development goals are to improve fuel cell and electrolysis stack electrical performance, reduce system mass, volume, and parasitic power requirements, and increase system life and reliability. A major focus of this effort has been the parallel development of both flow-through and non-flow-through proton exchange membrane (PEM) primary fuel cell power systems. The plan has been, at the appropriate time, to select a single primary fuel cell technology for eventual flight hardware development. Ideally, that appropriate time would occur after both technologies have achieved a technology readiness level (TRL) of six, which represents an engineering model fidelity PEM fuel cell system being successfully tested in a relevant environment. Budget constraints in fiscal year 2009 and beyond have prevented NASA from continuing to pursue the parallel development of both primary fuel cell options. Because very limited data exists for either system, a toplevel, qualitative assessment based on engineering judgement was performed expeditiously to provide guidance for a selection. At that time, the non-flow-through technology was selected for continued development because of potentially major advantages in terms of weight, volume, parasitic power, reliability, and life. This author believes that the advantages are significant enough, and the potential benefits great enough, to offset the higher state of technology readiness of flow-through technology. This paper summarizes the technical considerations which helped form the engineering judgement that led to the final decision.

Hoberecht, Mark A.↗

NASA NTRS2004

Performance of a Fuel-Cell-Powered, Small Electric Airplane Assessed

Rapidly emerging fuel-cell-power technologies may be used to launch a new revolution of electric propulsion systems for light aircraft. Future small electric airplanes using fuel cell technologies hold the promise of high reliability, low maintenance, low noise, and - with the exception of water vapor - zero emissions. An analytical feasibility and performance assessment was conducted by NASA Glenn Research Center's Airbreathing Systems Analysis Office of a fuel-cell-powered, propeller-driven, small electric airplane based on a model of the MCR-01 two-place kitplane (Dyn'Aero, Darois, France). This assessment was conducted in parallel with an ongoing effort by the Advanced Technology Products Corporation and the Foundation for Advancing Science and Technology Education. Their project - partially funded by a NASA grant - is to design, build, and fly the first manned, continuously propelled, nongliding electric airplane. In our study, an analytical performance model of a proton exchange membrane (PEM) fuel cell propulsion system was developed and applied to a notional, two-place light airplane modeled after the MCR-01 kitplane. The PEM fuel cell stack was fed pure hydrogen fuel and humidified ambient air via a small automotive centrifugal supercharger. The fuel cell performance models were based on chemical reaction analyses calibrated with published data from the fledgling U.S. automotive fuel cell industry. Electric propeller motors, rated at two shaft power levels in separate assessments, were used to directly drive a two-bladed, variable-pitch propeller. Fuel sources considered were compressed hydrogen gas and cryogenic liquid hydrogen. Both of these fuel sources provided pure, contaminant-free hydrogen for the PEM cells.

Berton, Jeffrey J.↗

NASA NTRS2011

NASA PEMFC Development Background and History

NASA has been developing proton-exchange-membrane (PEM) fuel cell power systems for the past decade, as an upgraded technology to the alkaline fuel cells which presently provide power for the Shuttle Orbiter. All fuel cell power systems consist of one or more fuel cell stacks in combination with appropriate balance-of-plant hardware. Traditional PEM fuel cells are characterized as flow-through, in which recirculating reactant streams remove product water from the fuel cell stack. NASA recently embarked on the development of non-flow-through fuel cell systems, in which reactants are dead-ended into the fuel cell stack and product water is removed by internal wicks. This simplifies the fuel cell power system by eliminating the need for pumps to provide reactant circulation, and mechanical water separators to remove the product water from the recirculating reactant streams. By eliminating these mechanical components, the resulting fuel cell power system has lower mass, volume, and parasitic power requirements, along with higher reliability and longer life. Four vendors have designed and fabricated non-flow-through fuel cell stacks under NASA funding. One of these vendors is considered the "baseline" vendor, and the remaining three vendors are competing for the "alternate" role. Each has undergone testing of their stack hardware integrated with a NASA balance-of-plant. Future Exploration applications for this hardware include primary fuel cells for a Lunar Lander and regenerative fuel cells for Surface Systems.

Hoberecht, Mark↗

NASA NTRS2011

Teledyne Energy Systems, Inc., Proton Exchange Member (PEM) Fuel Cell Engineering Model Powerplant. Test Report: Initial Benchmark Tests in the Original Orientation

Proton Exchange Membrane (PEM) fuel cell technology is the leading candidate to replace the alkaline fuel cell technology, currently used on the Shuttle, for future space missions. During a 5-yr development program, a PEM fuel cell powerplant was developed. This report details the initial performance evaluation test results of the powerplant.

Loyselle, Patricia↗