Fuel Cell Electric Aircraft Energy Challenge New Era of Aviation
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Fuel Cell Electric Fuel Cell Electric Aircraft Aircraft Energy Challenge Energy Challenge New Era of Aviation New Era of Aviation James Dunn James Dunn Advanced Technology Products Advanced Technology Products Worcester, MA Worcester, MA Electric Aircraft Symposium Electric Aircraft Symposium San Fran – May 2007 San Fran – May 2007
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Fuel Cell Electric Aircraft Energy Challenge New Era of Aviation. James Dunn Advanced Technology Products Worcester, MA Electric Aircraft Symposium San Fran – May 2007. Fuel cells in Aviation. Electric UAV’s – Helios-NASA- Aerovironment Auxiliary Power – Boeing APU – Madrid + - PowerPoint PPT Presentation
Transcript of Fuel Cell Electric Aircraft Energy Challenge New Era of Aviation
Fuel Cell Electric Aircraft Fuel Cell Electric Aircraft Energy ChallengeEnergy Challenge
New Era of AviationNew Era of Aviation
James DunnJames Dunn
Advanced Technology Products Advanced Technology Products Worcester, MAWorcester, MA
Electric Aircraft SymposiumElectric Aircraft Symposium
San Fran – May 2007San Fran – May 2007
Fuel cells in Aviation Fuel cells in Aviation
Electric UAV’s – Helios-NASA- AerovironmentElectric UAV’s – Helios-NASA- Aerovironment
Auxiliary Power – Boeing APU – Madrid +Auxiliary Power – Boeing APU – Madrid +
Electric Airships – HAA – Lockheed MartinElectric Airships – HAA – Lockheed Martin
Electric Propulsion - Manned aircraft - E-PlaneElectric Propulsion - Manned aircraft - E-Plane
Aerovironment “HELIOS” UAVAerovironment “HELIOS” UAVRegenerative fuel cell systemRegenerative fuel cell system
High Altitude AirshipHigh Altitude AirshipSolar PV and Fuel CellsSolar PV and Fuel Cells
Electric GliderElectric GliderFuel Cell Powered Glider
Piloted Fuel Cell AircraftPiloted Fuel Cell Aircraft2-place Electric DynAero 2-place Electric DynAero
Benefits of Electric AircraftBenefits of Electric Aircraft
Increased Reliability – 1 moving part!Increased Reliability – 1 moving part! Improved SafetyImproved Safety QUIET - only propeller noiseQUIET - only propeller noise Improved Comfort and Easy MaintenanceImproved Comfort and Easy Maintenance No VibrationNo Vibration Reduced life-cycle costsReduced life-cycle costs
NO EMISSIONS !NO EMISSIONS !
Why Fuel CellsWhy Fuel Cells High Efficiency High Efficiency – 2.5 X Gasoline Engines– 2.5 X Gasoline Engines
(60% vs. 23%) (60% vs. 23%)
Zero Emissions Zero Emissions – Only Water Vapor– Only Water Vapor No odors or fumesNo odors or fumes
Hydrogen Fuel Hydrogen Fuel – Sustainable and Renewable– Sustainable and Renewable
High Energy DensityHigh Energy Density – 300 - 600 WH/kg – 300 - 600 WH/kg 2-3 X battery density2-3 X battery density
The Energy Challenge !The Energy Challenge !
Airplane needs 25kW Airplane needs 25kW PowerPower @ 100 mph @ 100 mph 300 Mi. flight requires 75 kWh of Energy300 Mi. flight requires 75 kWh of Energy Energy system Weight for 75kWh:Energy system Weight for 75kWh:
- Lead Acid Batteries = 3000 kg - Lead Acid Batteries = 3000 kg - NiMH Batteries = 1500 kg - NiMH Batteries = 1500 kg - LiIon Batteries - LiIon Batteries = 600 kg = 600 kg Fuel Cell system (+ 3 kg H2) = 165 kg Fuel Cell system (+ 3 kg H2) = 165 kg
(Gasoline Equivalent = 100 kg !)(Gasoline Equivalent = 100 kg !)
The ChallengeThe Challenge – Matching the energy – Matching the energy density of Gasoline and IC Engines? density of Gasoline and IC Engines?
Gasoline =13,200 WH/kgGasoline =13,200 WH/kg @ 20% effic. Net = 2600 WH/kg @ 20% effic. Net = 2600 WH/kg
Best LiIon Batts = 200 WH/kgBest LiIon Batts = 200 WH/kg
Still a Still a 13:1 advantage for Gas!!13:1 advantage for Gas!!
(H(H22 = 30,000 WH/kg) = 30,000 WH/kg)
IssuesIssues – – Weight, Volume, HEAT, (+$$)Weight, Volume, HEAT, (+$$)
Hurdles & IssuesHurdles & Issues
System Weight – Power Density/Effic. System Weight – Power Density/Effic. Support Components – Power & WeightSupport Components – Power & Weight Hydrogen Storage/Generation SystemHydrogen Storage/Generation System Heat Transfer methods & HEX System Heat Transfer methods & HEX System Safety Issues – FAA + OngoingSafety Issues – FAA + Ongoing Customer AcceptanceCustomer Acceptance Costly TechnologyCostly Technology
Hydrogen SourcesHydrogen Sources
H2 Gas - High Pressure Tank – 5000 psiH2 Gas - High Pressure Tank – 5000 psi Liquid Hydrogen – Cryo issuesLiquid Hydrogen – Cryo issues Reformed Gasoline – CO, CO2Reformed Gasoline – CO, CO2 Methanol/Ethanol – Direct or reformateMethanol/Ethanol – Direct or reformate Ammonia Ammonia (dissociated) – high yield(dissociated) – high yield Sodium borohydride – safe, costlySodium borohydride – safe, costly Magnesium HydrideMagnesium Hydride Other ??Other ??
NASA Fuel Cell Study NASA Fuel Cell Study Elements:Elements:
Selected Aircraft for ConversionSelected Aircraft for Conversion
AGA Lafayette IIIAGA Lafayette III All Carbon Kit - 28’ WingAll Carbon Kit - 28’ Wing WWee/W/Woo = .31 = .31
80 hp. Rotax 912< 12 kW to CruiseVne of 180+ kts
Aircraft Modeling for Hydrogen PEM Aircraft Modeling for Hydrogen PEM Fuel Cell Motor ConversionFuel Cell Motor Conversion
NASA GRCNASA GRC
MCR01 ULM Kit PlaneMCR01 ULM Kit PlaneAirbreathing Systems Analysis Office (NASA GRC)Airbreathing Systems Analysis Office (NASA GRC)
Systems Analysis Branch (NASA LaRC)Systems Analysis Branch (NASA LaRC)
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MCR01 ULM Fuel Cell ConversionMCR01 ULM Fuel Cell Conversion Power Density Technology Sensitivity: PDPower Density Technology Sensitivity: PDPMADPMAD = 1.06 kW/kg = 1.06 kW/kg
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Further performance gains possible only if PMAD weight is
reduced!
Advanced TechnologyFuel Cell Stack Power Density: 2.50 kW/kgElectric Motor Power Density: 2.30 kW/kg
PMAD Power Density: 1.06 kW/kgRange = 336 nm
Applied State-of-the-Art TechnologyFuel Cell Stack Power Density: 1.57 kW/kgElectric Motor Power Density: 1.35 kW/kg
PMAD Power Density: 1.06 kW/kgRange = 58 nm
MCR01/Rotax 912> 800 nm Range
1.3
1.5
1.7
1.82.0
2.3
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1.9
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PDMotor (kW/kg)PDStack (kW/kg)
Aircraft Structures
Aircraft Systems & Equipment
FAR 23.25 Pilot
Propeller, Cowl & Mounts
Propeller Electric Motor
Supercharger Electric Motor
Fuel Cell System
PMAD
Fuel Delivery
H2 Tank
H2 Fuel
Aircraft Structures
Aircraft Systems & Equipment
FAR 23.25 Pilot
Propeller, Cowl & Mounts
Propeller Electric Motor
Supercharger Electric Motor
Fuel Cell System
PMAD
Fuel Delivery
H2 Tank
H2 Fuel
Gross weight constantat 992 lb limit
MCR01 ULM Fuel Cell Conversion MCR01 ULM Fuel Cell Conversion Power Density Technology Sensitivity: PDPower Density Technology Sensitivity: PDPMADPMAD = 2.60 kW/kg = 2.60 kW/kg
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Aircraft Structures
Aircraft Systems & Equipment
FAR 23.25 Pilot
Propeller, Cowl & Mounts
Propeller Electric Motor
Supercharger Electric Motor
Fuel Cell System
PMAD
Fuel Delivery
H2 Tank
H2 Fuel
1.31.5
1.71.8
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Advanced TechnologyFuel Cell Stack Power Density: 2.50 kW/kgElectric Motor Power Density: 2.30 kW/kg
PMAD Power Density: 2.60 kW/kgRange = 644 nm
Diminishing returns on range – The heavy compressed hydrogen tank limits further gains.
Gross weight constantat 992 lb limit
Program ObjectivesProgram Objectives
Demonstrate viability of Fuel Cell powered Demonstrate viability of Fuel Cell powered electric propelled aircraftelectric propelled aircraft
Determine the optimum energy sourceDetermine the optimum energy source Analyze performance parameters & rangeAnalyze performance parameters & range Design/develop High efficiency HDesign/develop High efficiency H22 PEM fuel cell PEM fuel cell Integrate all components into Airframe and TestIntegrate all components into Airframe and Test Provide educational vehicle for studentsProvide educational vehicle for students
Basic Schematic of Basic Schematic of ComponentsComponents
MOTOR
THROTTLE AVIONICS, BATTERY
MONITORING AND
TELEMETRY
H2
AIR/O2 SURGE ENERGY,
ULTRA-CAPS, FLYWHEEL,
OR THIN METAL FILM BATTERIES
MAIN BATTERY STORAGE
POWER GENERATION FOR RANGE EXTENSION
FUEL CELL
MOTOR CONTROLLER
Students at Oshkosh Students at Oshkosh
Energy DistributionEnergy Distribution
Battery + Fuel Cell System Rqmts.Battery + Fuel Cell System Rqmts.
Max Power - Batteries + Fuel Cell 75 kw Max Power - Batteries + Fuel Cell 75 kw Bus voltageBus voltage 270 DC 270 DC Net Stack power - cont.Net Stack power - cont. 17 kw 17 kw No. of CellsNo. of Cells 180 180EfficiencyEfficiency 60 % 60 %Fuel Cell sys. Wt. (w/sgl.H2 tank)Fuel Cell sys. Wt. (w/sgl.H2 tank) 80 kg 80 kg Battery + Master Power Xtrol Wt.Battery + Master Power Xtrol Wt. 50 kg 50 kg Total Energy System WeightTotal Energy System Weight 130 kg130 kg
Fuel Cell System target weightFuel Cell System target weight
Stack (10-18kW)Stack (10-18kW) 25 kg25 kg Blower (Compressor)+ ductBlower (Compressor)+ duct 5 kg 5 kg Misc. BOP, plumbing, sensors Misc. BOP, plumbing, sensors 4 kg 4 kg HEX System w/RadiatorsHEX System w/Radiators 9 kg 9 kg DC-DC Up-convertorDC-DC Up-convertor 7 kg 7 kg Fuel Cell Controller/mon.Fuel Cell Controller/mon. 5 kg 5 kg Dynatech Tank/Reg.Dynatech Tank/Reg. 18 kg18 kg Mounting + Misc.Mounting + Misc. 5 kg 5 kg TOTAL fuel Cell System WeightTOTAL fuel Cell System Weight 78 kg78 kg
New Lynntech Stack DesignNew Lynntech Stack Design
Ultrahigh EfficiencyUltrahigh Efficiency (60%)(60%)
LightWeight – Metal (NoLightWeight – Metal (No Graphite) Bipolar PlatesGraphite) Bipolar Plates
Ambient Air OpsAmbient Air Ops No CompressorNo Compressor No Hydrators No Hydrators
10 kW Fuel Cell Stack10 kW Fuel Cell Stack
DESIGN SPECIFICATIONSDESIGN SPECIFICATIONS
180 cells180 cells
300 cm300 cm22 active area active area
Generation 3 endplatesGeneration 3 endplates
10.25 kW @ 16 psia10.25 kW @ 16 psia
137 V137 V
75 A75 A
50 ˚C50 ˚C
25 kg (hydrated)25 kg (hydrated)
400 W/kg (@ 250 mA/cm400 W/kg (@ 250 mA/cm22))
720 W/kg (@500 mA/cm720 W/kg (@500 mA/cm22) 18KW) 18KW
Specific Energy Equivalent Specific Energy Equivalent Total Fuel Cell SystemTotal Fuel Cell System
Sgl. Tank - 78 kg System - 1 kg H2 = 24 kWHSgl. Tank - 78 kg System - 1 kg H2 = 24 kWH
Net Energy Density = 24/78 = Net Energy Density = 24/78 = 307 WH/kg307 WH/kg
Dbl. Tank – 96 kg system – 2 kg H2 = 48 kWHDbl. Tank – 96 kg system – 2 kg H2 = 48 kWH
Net Energy Density = 48/96 = Net Energy Density = 48/96 = 500 WH/kg500 WH/kg
Boeing Fuel Cell Glider Activities
System Integration
System Lay – out Design
•Motor and Drive
•Fuel Cell Systems•Compressor•Heat exchanger•Pumps•Controller
•Battery
•Controllers and Converters
•H2 System
Hydrogen storage
Liquid to air heat exchanger
Batteries Hydrogen delivery/regulati
on
Fuel Cell Stack
Power Conditioner, Regulation, Battery
charger
Motor Controller
Motor
Fuel Cell Controller
Electric controlled propeller
Legend
Fuel
Electricity
Liquid Coolant
Control
Prop Control
“Throttle”
Outside Air
Boeing Activities
Electrical Subsystem
Electrical Subsystem Configuration
Power Balance
•Power Demand•Motor & Drive•Controllers•Converters
•Power Generation•Fuel Cells•Battery•Ground Auxiliary Power
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Time 6 13 20 27 34 41 48
Mission Time [min]
Fuel Cell
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Safety and Flight TestingSafety and Flight Testing
Major concern on all new Aircraft Major concern on all new Aircraft
Pilot and Airframe issuesPilot and Airframe issues
Safety and Flight TestingSafety and Flight Testing(Whoops – wrong button !)(Whoops – wrong button !)
Energy System ChallengesEnergy System Challenges
Energy DensityEnergy Density Thermal ManagementThermal Management Recharge or RefuelRecharge or Refuel Integration of Solar PVIntegration of Solar PV CostCost LifeLife ReliabilityReliability
Technology EvolutionTechnology Evolution
AreaArea TodayToday Future (2020)Future (2020) Motor/XtrolMotor/Xtrol 2kw/kg2kw/kg 8-10 kw/kg8-10 kw/kg Fuel Cell Sys.Fuel Cell Sys. 2kw/kg2kw/kg 5-6 kw/kg5-6 kw/kg Fuel/H2 StorageFuel/H2 Storage 7% H2 – Wt.7% H2 – Wt. 12-15 %12-15 % Energy StorageEnergy Storage 200 WH/kg200 WH/kg 5-800 WH/kg5-800 WH/kg Energy ProducedEnergy Produced 150 kWH150 kWH 1000 kWH1000 kWH RangeRange 100 Mi100 Mi 1000 mi.1000 mi.
Emerging Energy SolutionsEmerging Energy Solutions
Advanced Batteries – Lithium Ion + Advanced Batteries – Lithium Ion + High Density UltraCaps – EEStor – OtherHigh Density UltraCaps – EEStor – Other
NanoStructured Electrodes – 500-2000 WH/kgNanoStructured Electrodes – 500-2000 WH/kg
High Temp Fuel Cells – Higher power densityHigh Temp Fuel Cells – Higher power density Advanced H2 Storage – New mat’ls + tanksAdvanced H2 Storage – New mat’ls + tanks
New Energy Gen. Sources - ManyNew Energy Gen. Sources - Many
Future Technology OptionsFuture Technology Options
Airframe Weight reductionAirframe Weight reduction Improved Airframe/Propulsion EfficiencyImproved Airframe/Propulsion Efficiency Energy/Fuel Storage optionsEnergy/Fuel Storage options Higher Energy Density Storage TechsHigher Energy Density Storage Techs New Designs with integrated storageNew Designs with integrated storage Improved Solar PV Design - IntegrationImproved Solar PV Design - Integration
Future Electric PAV ?Future Electric PAV ?
CarterCopter Hi-Speed Electric CarterCopter Hi-Speed Electric GyroCopterGyroCopter
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