Chemical%20Hydride%20Based%20PEM%20Fuel%20Cells%20for%20%20for%20Portable%20Power%20Applications

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Chemical Hydride Based PEM Fuel Cells for for
Portable Power Applications
Joint Services Power Expo May 2-5, 2005
Millennium Cell, Inc. One Industrial Way West,
Eatontown, NJ 07724 shah_at_millenniumcell.com 732-54
4-5739
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Outline

• Millennium Cell (MCEL) company overview
• Hydrogen storage/generation via sodium
  borohydride
• Hydrogen on Demand Technology
• Gravimetric Energy Density Comparison
• Prototype Development
• P1 Cartridge Test Results

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Millennium Cell Company Overview

• We are developers of hydrogen energy systems for
  use primarily in portable electronics devices for
  consumer, military, medical, and industrial
  markets.
• 25 patents issued to date
• Over 40 patent applications submitted and still
  pending
• Public offering in August 2000 (Nasdaq MCEL),
  currently 40 people working in Eatontown, NJ and
  Washington DC.
• 23 in technical organization
• 9 Ph.D.s company wide
• Announced relationships

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Hydrogen Generation from Sodium Borohydride
(SBH)Hydrogen on Demand Reaction
NaBH4 (aq) 2 H2O ? 4 H2
NaBO2 (aq) heat
cat
An energy-dense water-based chemical hydride fuel
Borate can be recycled into NaBH4 or can be
disposed of
Proprietary catalyst induces rapid H2 production
High purity humidified H2
Exothermic reaction requires no heat
input

• Hydrogen is generated in a controllable,
  heat-releasing reaction
• Fuel is an ambient pressure, room-temperature,
  non-flammable liquid
• Hydrogen generated via this process is of high
  purity (no carbon monoxide or sulfur) and is
  humidified (heat generates some water vapor)
• U.S. Patent 6,534,033 System for Hydrogen
  Generation

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Hydrogen Generation from Sodium Borohydride
(NaBH4)Schematic of Hydrogen on Demand
Technology
Gas/Liquid Separator
Fuel Pump
Catalyst Reactor
Hydrogen Water Vapor
Fuel tank NaBH4 solution
H2
Discharged fuel area NaBO2
Water from Fuel Cell
Borate (NaBO2)
borate
H2O
Hydrogen Water Vapor
Coolant Loop (optional)
Fuel Cell
Pure Humidified H2
Heat Exchanger
Electric Power
Oxygen from Air
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Gravimetric Energy Density Comparison

• Zn/Air, today 300 Wh/kg
• Li/SO2, today 170 Wh/kg
• Li-Ion, today 110 Wh/kg
• DMFC
• fuel only, today (15) 900 Wh/kg
• fuel only, projected (25) 1500 Wh/kg
• RMFC (0.7 V fuel cell, 75 conversion)
• fuel only (64), projected 1440 Wh/kg
• HOD/PEM (0.7 V fuel cell, 95 conversion)
• Practical dry fuel for shipping, today 3900
  Wh/kg
• Practical fuel only (20) energy density today
  760 Wh/kg
• Practical fuel only (35) energy density
  projected 1330 Wh/kg

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Comparison of HOD PEM to Methanol-based Systems
HOD(NaBH4)/PEM DMFC Reformed MeOH/PEM
Heat Dissipation 1.5 Watts heat per Watt of net electrical output 3 to 5 Watts heat per Watt of net electrical output 1 Watt heat per Watt of net electrical output
Thermal Signature HOD reaction temperature lt 100 C High due to high heat dissipation needs Reformer temperatures of gt 250C
Design Characteristics Simple generator design, high efficiency over wide operating range Cross-over fluctuation affects turndown, complex concentration control and water recovery scheme Multiple Reactors and CO clean up
Stack Power Density 0.3 - 0.5 W/cc lt 0.1 W/cc PEM power density limited due to CO
Demonstrated Operating Life PEM gt 4000 hours Low 100s of hours PEM limited by CO poisoning
Capital Cost Low catalyst loadings in HOD system and simple design translate into low capital cost High due to catalyst loading Reformer cost high due to catalyst needs and CO clean-up step
Fuel Safety Non-flammable in solution Flammable Flammable
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M2 Consumer Electronics Demonstrator Prototype

• Demonstrated at Intel Developers Forum, Mar 2005
• 135 Wh/L and 130 Wh/kg fuel system
• Demonstration prototype fuel volume
  non-optimized
• NBPC scale power (20 W), 3 hr runtime _at_ 11 W nom
• 33 Wh scale system, 245 cc

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Protonex P1 Full SystemCartridge attachment

• Demonstrated
• gt 350 Wh/L and gt 350 Wh/kg complete system
• 30 W Net Power, gt15 Hour Runtime per cartridge
• 465 Wh net single cartridge only ? 1.1 L, 1.25 kg

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Energy Cartridge Interface detail
7.9 cm
8.8 cm
Fuel/borate area
Electrical Interface
Air Filter
Catalyst Reactor
16.8 cm
Hydrogen Interface
Pressure Relief Valve
Fill Port
Fuel Pump Interface
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Cartridge Testing

• Fuel Cell Simulator
• Mimics FC interface
• Adjusts H2 demand
• Monitors cartridge metrics
• Over 250 hours of test

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Cartridge Testing Typical Data
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Cartridge Testing Start Up

• Fuel Cell Simulator Start up 60 s
• Fuel Cell System Start up 20 s

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Cold Temperature Cartridge Operation

• Operation at 20 C and 5 C
• No change in conversion
• No change in fuel utilization
• Startup time increased to 120 s

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Protonex P1 Status and P2 Technology Improvements
Achieved!

• P1 energy density goal for 72 h/30 W mission
  350 - 380 Wh/kg
• P2 energy density goal for 72 h/30 W mission
  425 - 500 Wh/kg
• Packaging efficiency
• Water recovery
• Custom components
• Dry SBH fuel cartridges can be mixed on-site as
  needed
• Indefinite storage life
• Ability to use field water to be studied
• Substantial energy density increase when shipping
  dry cartridges

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Fuel Cell Portable Power Systemsfor Military
ApplicationsJoint Services Power ExpoMay 2-5,
2005Greg CiprianoVP Marketing Military
Development
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Protonex Facts

• MISSION
• Focus on apps where fuel cells make sense
• Where batteries IC engines do not work well
• Design for performance, manufacturability and
  cost
• TARGET MARKET
• Portable and remote applications
• High-performance power, 10 500 Watts
• RESULT
• Best-in-class power systems vs. alternatives
• Leading metrics and fieldable costs
• Functional prototypes exist today

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Power Range Focus
Battery Curve
Protonex Fuel Cell Curve
Cell Phone
Fuel cells do well here
PDA
Cost/Watt-hr
IC Engine Curve
Laptop
Soldier Power
Small Generator
UPS
Residential
Auto
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Fuel Cell Benefits

• Reduced weight
• Extended runtimes
• Reduced size
• Lower life cycle cost
• Greater fuel efficiency
• Reduced emissions
• Lower noise level
• Lower heat signature

VALUE POINTS for Protonex fuel cell based power
solutions
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Potential Military Applications
NGen Portable Power Family NGen Portable Power Family NGen Portable Power Family
10-100W 100-300W 300-500W
Soldier Power Battery Charger Silent Watch
Remote Monitoring Small APU Small APU
Electronic Warfare Mobile Robots Mobile Robots
UAV UAV Fwd Area Charger
External PowerPack External PowerPack Shelter Power
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Protonex Military Activity

• Army Research Office
• Development program for next generation sub-kW
  stacks, 18 months
• Army Research Lab
• Development program for advanced DMFC fuel cell
  stacks, 2 yrs
• Air Force Research Lab
• Dual Use Science Technology, 18 months
• BAO kit power system using chemical hydride fuel
• Naval Research Lab
• Feasibility demonstrated on UAV power system,
  ongoing work
• TARDEC
• Prototype development for mobile robots
• SOCOM
• Silent Auxiliary Power Unit just awarded
• Military Primes
• Multiple joint development programs starting and
  in discussion

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Protonex Stack Breakthrough
20 W 1992
20 W 2003
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Protonex Stacks Best-in-Class

• H2 PEM technology
• Compact
• Lightweight
• Low Cost
• Robust
• Reliable
• Injection Moldable
• Patents Pending

3000 Series Family 50-200 Watts
Protonex Stacks are Highly Durable
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Stack Life Test 4000 hrs

• Man portable target system lifetime 2000 hrs
  operation, Phase I
• Degradation corresponds to loss of 1.5
  efficiency at 2000 hours

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NGen Systems

• Fuel Cell Power Systems
• Fuel Cell Stack
• Balance of Plant
• Air, Cooling, Controls
• Fuel System (HW and fuel)
• Chemical Hydrides
• Methanol Reformers
• H2 or Metal Hydrides
• Protonex Systems are
• Small lightweight
• Efficient durable
• Manufacturable
• Easy to embed in apps

30 Watt System Prototype
Stack superiority and simplicity enable the use
of available balance of plant components. Strong
systems knowledge and capabilities allow
selection, integration and commercialization of
best-in-class fuel technologies to deliver
complete power systems to applications.
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System Examples 30-500W
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System Testing
Systems tested -10 to 50C and 1000 hrs to date
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Industry First 30W System

FIRST integrated chemical hydride fuel cell
system TODAY 350-380 Whr/kg and TRL5 Q4 2005
425-500 Whr/kg and TRL6-7 72 hour mission _at_
30Watts continuous
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Protonex Value Proposition

• NEED 30 watts continuous for 72hr mission

BA5590 Batteries (today) Units required
13 Total weight 29.3 lbs Total volume 11.2
liters Cost/mission 1,040
Protonex Fuel Cell System Systems required
1 Cartridges required 6 Total weight 7.9
lbs Total volume 4.3 liters Cost/mission 433
Savings 60 on cost 62 on size 73 on
weight
Impact Significantly Decreased Logistics Burden
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Life Cycle Cost Details

• Lower life cycle cost vs. batteries
• Practical capital costs lt1500 _at_ 5K units
• Low cost COTS and FC components
• Design for manufacture focus
• Highly durable, low maintenance
• Tested 4,000 hrs (10,000 hrs possible)
• Low cost fuel cartridges
• Chemical hydride is safe, non-flammable
• Recycle cartridges for training
• Discard cartridges for battle

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Strategic Partners

• Parker Hannifin volume mfg of Protonex systems
  and key components (60 mfg. plants worldwide)
• Millennium Cell co-develop fuel cartridge
  w/Protonex
• Dow volume mfg of Protonex fuel cartridges

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Recent Milestones

• System prototypes built from 10 to 500W
• Over 600 stacks built
• Life testing over 4,000 hours
• Demonstrated integrated fueling system
• Multiple joint development projects
• Several high profile military program awards
• Military evaluations in progress
• New 12,000 sq.ft. facility
• 9 patents pending

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Summary - Our Strengths

• Best in Class fuel cell power systems for OEMs
• Leading product metrics
• Low system cost points enabling adoption
• Strong customer focus
• Product oriented, not just RD
• NGen patent pending technology
• Comprehensive suite of strategic partners
• Strong military activity support
• Strong private venture funding (matching )
• History of delivering to commitments

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Contact Information
Greg Cipriano VP Marketing Military
Development greg.cipriano_at_protonex.com 508.490.996
0 x208 Protonex Technology Corporation 153
Northboro Road Southborough, MA
01772 www.protonex.com