Transcript 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 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 +
 Electric Airships – HAA – Lockheed Martin
 Electric Propulsion - Manned aircraft - E-Plane
Aerovironment “HELIOS” UAV
Regenerative fuel cell system
High Altitude Airship
Solar PV and Fuel Cells
Fuel Cell Powered Glider
Electric Glider
Piloted Fuel Cell Aircraft
2-place Electric DynAero
Benefits of Electric Aircraft
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Increased Reliability – 1 moving part!
Improved Safety
QUIET - only propeller noise
Improved Comfort and Easy Maintenance
No Vibration
Reduced life-cycle costs
 NO EMISSIONS !
Why 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
The Energy Challenge !
 Airplane needs 25kW Power @ 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 !)
The Challenge – Matching the energy
density of Gasoline and IC Engines?
Gasoline =13,200 WH/kg
@ 20% effic. Net = 2600 WH/kg
Best LiIon Batts = 200 WH/kg
Still a 13:1 advantage for Gas!!
(H2 = 30,000 WH/kg)
Issues – Weight, Volume, HEAT, (+$$)
Hurdles & Issues
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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
Hydrogen Sources
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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 ??
NASA Fuel Cell Study
Elements:
Selected Aircraft for Conversion
 AGA Lafayette III
 All Carbon Kit - 28’ Wing
 We/Wo = .31
80 hp. Rotax 912
< 12 kW to Cruise
Vne of 180+ kts
Aircraft Modeling for Hydrogen PEM
Fuel Cell Motor Conversion
NASA GRC
MCR01 ULM Kit Plane
Airbreathing Systems Analysis Office (NASA GRC)
Systems Analysis Branch (NASA LaRC)
MCR01 ULM Fuel Cell Conversion
Power Density Technology Sensitivity: PDPMAD = 1.06 kW/kg
H2 Fuel
MCR01/Rotax 912
800
Advanced Technology
> 800 nm Range
Aircraft
Structures
Fuel Delivery
Fuel Cell Stack Power Density: 2.50 kW/kg
Electric Motor Power Density: 2.30 kW/kg
PMAD
PMAD Power Density: 1.06 kW/kg
Range = 336 nm
350
Still Air Range (nm)
H2 Tank
Aircraft
Systems &
Equipment
FAR 23.25
Pilot
300
Fuel Cell
System
250
Supercharger
Electric Motor
200
2.5
150
2.3
Propeller
Electric Motor
2.0
2.3
100
50
1.5
1.7
Gross weight constant
at 992 lb limit
H2 Tank
1.7
1.9
PDStack (kW/kg)
H2 Fuel
1.8
2.1
Propeller,
Cowl &
Mounts
PDMotor (kW/kg)
Fuel Delivery
Aircraft
Structures
PMAD
1.5 1.3
0
0
5
Further performance gains
possible only if PMAD weight
reduced!
Aircraft
Systems &
Equipment
Applied State-of-the-Art Technology
10
15
20
25
Fuel Cell Stack Power Density: 1.57 kW/kg
Fuel Cell
Electric Motor Power Density: 1.35 kW/kg
System
PMAD Power Density: 1.06 kW/kg
is
Range = 58 nm
Supercharger
Electric Motor
Propeller
Electric Motor
FAR 23.25
Pilot
Propeller,
Cowl &
Mounts
MCR01 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
800
700
H2 Tank
600
Still Air Range (nm)
H2 Fuel
500
2.5
400
2.3
2.3
2.1
1.7
1.9
1.7
300
PDStack (kW/kg)
1.8
2.0
1.5
1.5 1.3
PDMotor (kW/kg)
PMAD
Fuel Cell
System
100
Propeller
Electric Motor
0
0
5
10
15
20
Aircraft
Systems &
Equipment
Fuel Delivery
Supercharger
Electric Motor
200
Aircraft
Structures
25
Diminishing returns on range – The heavy
compressed hydrogen tank limits further gains.
FAR 23.25
Pilot
Propeller,
Cowl &
Mounts
Gross weight constant
at 992 lb limit
Program 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
Basic Schematic of
Components
MOTOR
AVIONICS,
BATTERY
MONITORING
AND
TELEMETRY
THROTTLE
MOTOR CONTROLLER
FUEL
CELL
SURGE ENERGY,
ULTRA-CAPS,
FLYWHEEL,
OR THIN METAL
FILM BATTERIES
MAIN
BATTERY
STORAGE
POWER GENERATION
FOR RANGE EXTENSION
AIR/O2
H2
Students at Oshkosh
Energy Distribution
Power Consumption
Propulsive Pow er
67%
Losses
19%
Up Converter Loss
4%
MotorController Loss
9%
Prop Loss
8%
FC Coolant Pump
2%
Main Coolant Pump
4%
Compressor
6%
Battery + 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
Fuel Cell System target weight
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Stack (10-18kW)
Blower (Compressor)+ duct
Misc. BOP, plumbing, sensors
HEX System w/Radiators
DC-DC Up-convertor
Fuel Cell Controller/mon.
Dynatech Tank/Reg.
Mounting + Misc.
TOTAL fuel Cell System Weight
25 kg
5 kg
4 kg
9 kg
7 kg
5 kg
18 kg
5 kg
78 kg
New Lynntech Stack Design
 Ultrahigh Efficiency
(60%)
 LightWeight – Metal (No
Graphite) Bipolar Plates
 Ambient Air Ops
No Compressor
No Hydrators
10 kW Fuel Cell Stack
DESIGN SPECIFICATIONS
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180 cells
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300 cm2 active area
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Generation 3 endplates
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10.25 kW @ 16 psia
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137 V
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75 A
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50 ˚C
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25 kg (hydrated)
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400 W/kg (@ 250 mA/cm2)
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720 W/kg (@500 mA/cm2) 18KW
Specific 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
Boeing Fuel Cell Glider Activities
System Integration
System Lay – out Design
•Motor and Drive
•Battery
Motor
Controller
Motor
Fuel Cell
Controller
Electricity
Liquid
Coolant
Control
Hydrogen
delivery/regulat
ion
“Throttle”
Electric
controlled
propeller
•Controllers and Converters
•H2 System
Fuel
Power Conditioner,
Regulation, Battery
charger
Batteries
•Fuel Cell Systems
•Compressor
•Heat exchanger
•Pumps
•Controller
Legend
Prop Control
Liquid to air heat
exchanger
Outside Air
Fuel Cell
Stack
Hydrogen
storage
Boeing Activities
Electrical Subsystem
Electrical Subsystem Configuration
Power Balance
•Power Demand
•Motor & Drive
•Controllers
•Converters
60
50
40
Pow er
Generation 30
[kW]
20
Bat
Fuel Cell
10
0
Time
Ext
6
13
20
27
34
41
48
Mission Tim e [m in]
60
50
Power Demand [kW]
•Power Generation
•Fuel Cells
•Battery
•Ground Auxiliary Power
40
30
20
Motor
10
Aux
0
0
10
20
30
Mission Time [min]
40
50
Safety and Flight Testing
 Major concern on all new Aircraft
 Pilot and Airframe issues
Safety and Flight Testing
(Whoops – wrong button !)
Energy System Challenges
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Energy Density
Thermal Management
Recharge or Refuel
Integration of Solar PV
Cost
Life
Reliability
Technology Evolution
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Area
Motor/Xtrol
Fuel Cell Sys.
Fuel/H2 Storage
Energy Storage
Energy Produced
Range
Today
2kw/kg
2kw/kg
7% H2 – Wt.
200 WH/kg
150 kWH
100 Mi
Future (2020)
8-10 kw/kg
5-6 kw/kg
12-15 %
5-800 WH/kg
1000 kWH
1000 mi.
Emerging 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 mat’ls + tanks
 New Energy Gen. Sources - Many
Future Technology Options
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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
Future Electric PAV ?
CarterCopter Hi-Speed Electric
GyroCopter