Title: Fuel%20Cell%20Electric%20Aircraft%20Energy%20Challenge%20New%20Era%20of%20Aviation
1Fuel Cell Electric Aircraft Energy
ChallengeNew Era of Aviation
- James Dunn
- Advanced Technology Products Worcester, MA
- Electric Aircraft Symposium
- San Fran May 2007
2Fuel cells in Aviation
- Electric UAVs Helios-NASA- Aerovironment
- Auxiliary Power Boeing APU Madrid
- Electric Airships HAA Lockheed Martin
- Electric Propulsion - Manned aircraft - E-Plane
3Aerovironment HELIOS UAVRegenerative fuel cell
system
4High Altitude AirshipSolar PV and Fuel Cells
5Electric Glider
Fuel Cell Powered Glider
6Piloted Fuel Cell Aircraft2-place Electric
DynAero
7Benefits of Electric Aircraft
- Increased Reliability 1 moving part!
- Improved Safety
- QUIET - only propeller noise
- Improved Comfort and Easy Maintenance
- No Vibration
- Reduced life-cycle costs
- NO EMISSIONS !
8Why Fuel Cells
- High Efficiency 2.5 X Gasoline Engines
- (60 vs. 23)
- Zero Emissions Only Water Vapor
- No odors or fumes
- Hydrogen Fuel Sustainable and Renewable
- High Energy Density 300 - 600 WH/kg
- 2-3 X battery density
9The Energy Challenge !
- Airplane needs 25kW Power _at_ 100 mph
- 300 Mi. flight requires 75 kWh of Energy
- Energy system Weight for 75kWh
- - Lead Acid Batteries 3000 kg
- - NiMH Batteries 1500 kg
- - LiIon Batteries 600 kg
- Fuel Cell system ( 3 kg H2) 165 kg
- (Gasoline Equivalent 100 kg !)
-
10The Challenge Matching the energy density of
Gasoline and IC Engines?
Gasoline 13,200 WH/kg _at_ 20 effic. Net 2600
WH/kg Best LiIon Batts 200 WH/kg Still a
131 advantage for Gas!! (H2 30,000
WH/kg) Issues Weight, Volume, HEAT, ()
11Hurdles Issues
- System Weight Power Density/Effic.
- Support Components Power Weight
- Hydrogen Storage/Generation System
- Heat Transfer methods HEX System
- Safety Issues FAA Ongoing
- Customer Acceptance
- Costly Technology
12Hydrogen Sources
- H2 Gas - High Pressure Tank 5000 psi
- Liquid Hydrogen Cryo issues
- Reformed Gasoline CO, CO2
- Methanol/Ethanol Direct or reformate
- Ammonia (dissociated) high yield
- Sodium borohydride safe, costly
- Magnesium Hydride
- Other ??
13NASA Fuel Cell Study Elements
14Selected Aircraft for Conversion
- AGA Lafayette III
- All Carbon Kit - 28 Wing
- We/Wo .31
- 80 hp. Rotax 912
- lt 12 kW to Cruise
- Vne of 180 kts
15Aircraft Modeling for Hydrogen PEM Fuel Cell
Motor ConversionNASA GRC
MCR01 ULM Kit Plane Airbreathing Systems Analysis
Office (NASA GRC) Systems Analysis Branch (NASA
LaRC)
16MCR01 ULM Fuel Cell Conversion Power Density
Technology Sensitivity PDPMAD 1.06 kW/kg
MCR01/Rotax 912 gt 800 nm Range
800
Advanced Technology Fuel Cell Stack Power
Density 2.50 kW/kg Electric Motor Power
Density 2.30 kW/kg PMAD Power Density 1.06
kW/kg Range 336 nm
2.3
Gross weight constantat 992 lb limit
2.5
2.0
2.3
1.8
2.1
1.7
1.9
PDMotor (kW/kg)
PDStack (kW/kg)
1.5
1.7
1.3
1.5
Applied State-of-the-Art Technology Fuel Cell
Stack Power Density 1.57 kW/kg Electric Motor
Power Density 1.35 kW/kg PMAD Power Density
1.06 kW/kg Range 58 nm
Further performance gains possible only if PMAD
weight is reduced!
17MCR01 ULM Fuel Cell Conversion Power Density
Technology Sensitivity PDPMAD 2.60 kW/kg
Advanced Technology Fuel Cell Stack Power
Density 2.50 kW/kg Electric Motor Power
Density 2.30 kW/kg PMAD Power Density 2.60
kW/kg Range 644 nm
2.3
2.5
2.0
2.3
1.8
2.1
1.7
1.9
1.5
1.7
1.3
1.5
PDStack (kW/kg)
PDMotor (kW/kg)
Gross weight constantat 992 lb limit
Diminishing returns on range The heavy
compressed hydrogen tank limits further gains.
18Program Objectives
- Demonstrate viability of Fuel Cell powered
electric propelled aircraft - Determine the optimum energy source
- Analyze performance parameters range
- Design/develop High efficiency H2 PEM fuel cell
- Integrate all components into Airframe and Test
- Provide educational vehicle for students
19Basic Schematic of Components
20Students at Oshkosh
21Energy Distribution
22Battery Fuel Cell System Rqmts.
- Max Power - Batteries Fuel Cell 75 kw
- Bus voltage 270 DC
- Net Stack power - cont. 17 kw
- No. of Cells 180
- Efficiency 60
- Fuel Cell sys. Wt. (w/sgl.H2 tank) 80 kg
- Battery Master Power Xtrol Wt. 50 kg
- Total Energy System Weight 130 kg
23Fuel Cell System target weight
- Stack (10-18kW) 25 kg
- Blower (Compressor) duct 5 kg
- Misc. BOP, plumbing, sensors 4 kg
- HEX System w/Radiators 9 kg
- DC-DC Up-convertor 7 kg
- Fuel Cell Controller/mon. 5 kg
- Dynatech Tank/Reg. 18 kg
- Mounting Misc. 5 kg
- TOTAL fuel Cell System Weight 78 kg
24New Lynntech Stack Design
- Ultrahigh Efficiency
- (60)
- LightWeight Metal (No
- Graphite) Bipolar Plates
- Ambient Air Ops
- No Compressor
- No Hydrators
25 10 kW Fuel Cell Stack
- DESIGN SPECIFICATIONS
- 180 cells
- 300 cm2 active area
- Generation 3 endplates
- 10.25 kW _at_ 16 psia
- 137 V
- 75 A
- 50 C
- 25 kg (hydrated)
- 400 W/kg (_at_ 250 mA/cm2)
- 720 W/kg (_at_500 mA/cm2) 18KW
26Specific Energy Equivalent Total Fuel Cell System
- Sgl. Tank - 78 kg System - 1 kg H2 24 kWH
-
- Net Energy Density 24/78 307 WH/kg
- Dbl. Tank 96 kg system 2 kg H2 48 kWH
-
- Net Energy Density 48/96 500 WH/kg
-
27Boeing 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
28Boeing Activities Electrical Subsystem
- Electrical Subsystem Configuration
- Power Balance
- Power Demand
- Motor Drive
- Controllers
- Converters
- Power Generation
- Fuel Cells
- Battery
- Ground Auxiliary Power
29Safety and Flight Testing
- Major concern on all new Aircraft
- Pilot and Airframe issues
30Safety and Flight Testing(Whoops wrong button
!)
31Energy System Challenges
- Energy Density
- Thermal Management
- Recharge or Refuel
- Integration of Solar PV
- Cost
- Life
- Reliability
32Technology Evolution
- Area Today Future (2020)
- Motor/Xtrol 2kw/kg 8-10 kw/kg
- Fuel Cell Sys. 2kw/kg 5-6 kw/kg
- Fuel/H2 Storage 7 H2 Wt. 12-15
- Energy Storage 200 WH/kg 5-800 WH/kg
- Energy Produced 150 kWH 1000 kWH
- Range 100 Mi 1000 mi.
33Emerging Energy Solutions
- Advanced Batteries Lithium Ion
- High Density UltraCaps EEStor Other
- NanoStructured Electrodes 500-2000 WH/kg
- High Temp Fuel Cells Higher power density
- Advanced H2 Storage New matls tanks
- New Energy Gen. Sources - Many
34Future Technology Options
- Airframe Weight reduction
- Improved Airframe/Propulsion Efficiency
- Energy/Fuel Storage options
- Higher Energy Density Storage Techs
- New Designs with integrated storage
- Improved Solar PV Design - Integration
35Future Electric PAV ?
36CarterCopter Hi-Speed Electric GyroCopter
37