Manhattan Project in Fuel Cell Manufacturing

Presented by Carmine Meola Rebecca Morris Randy Hiebert

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Manhattan Project in Fuel Cell Manufacturing

Table of Contents
Introduction to the B2P
Mission Vision Role

Manufacturing Fuel Cell Manhattan Project

Goals and Benefits MFCMP Structure

Montana Tech Overview

Manhattan Project in Fuel Cell Manufacturing

INTRODUCTION

Manhattan Project in Fuel Cell Manufacturing

MISSION The B2PCOE mission is to identify, validate, and disseminate best in-class practices, processes, methodologies, systems, and technologies with the end objective of improving the level of competitiveness, affordability and performance of the defense industrial base, defense platforms and weapons systems. VISION The B2PCOE vision will to be a DoD resource for developing and sharing best practice standards for mature manufacturing technologies, stable and producible designs, and mature production processes. ROLE The B2PCOE is to collect data to identify and validate best practice standards.

Manhattan Project in Fuel Cell Manufacturing

Manhattan Project in Fuel Cell Manufacturing

Example Special Projects within the B2PCOE
Energy Usage Ship Yard Cost Reduction Lead Free Manhattan Project (DoD Leverage) Best Practices for Assurance of Skilled Workers Best Practices in Ship System Integration Advanced Shipbuilding Affordability Technologies Manufacturing Fuel Cell Manhattan Project

Manhattan Project in Fuel Cell Manufacturing

MANUFACTURING FUEL CELL MANHATTAN PROJECT

Manhattan Project in Fuel Cell Manufacturing

Difference between Generators, Batteries and Fuel Cells Generators: mechanical production of electricity Batteries: chemical production of electricity
Internal storage of chemical reactants Replace primary batteries Recharge secondary batteries (rechargeable batteries)

Fuel Cells: chemical production of electricity

External storage of chemical reactants (hydrogen / oxygen) Refuel

Manhattan Project in Fuel Cell Manufacturing

Reason for Navy use of Fuel Cells instead of Diesel and Gas Turbines for 5kW to 50kW range Increase fuel efficiencies Modularity for distributed power systems Reduce ship signatures
Lower thermal signatures Lower audible noise

Lower hydrocarbon emissions Lower SOx and NOx emissions

Manhattan Project in Fuel Cell Manufacturing

Goals of Manhattan Fuel Cell Project
Identification of existing best manufacturing practices Adaption of fuel cell technology roadmap to address manufacturing technology gaps Dissemination of data through the B2PCOE Provide fuel cell manufacturers with technical and economical requirements for Navy fuel cell technology Provide guidance for Navy investments
Who is Participating in the Project to achieve these goals ? This is a collaborative effort sponsored by the ONR through the B2PCOE Industry - B2PCOE Academia Input Needed for the Selection of - Montana Tech Government Subject Matter Experts - SMEs FC Consortiums

Manhattan Project in Fuel Cell Manufacturing

Technical Leads
Donald Hoffman : NAVSEA Marc Gietter : CERDEC Jerry Aschoff: Boeing Jay McCloskey: Montana Tech Randy Hiebert: Montana Tech

Consultants
Jim Gucinski:

Manhattan Project in Fuel Cell Manufacturing

Navy Benefits
Integrated Power Systems (IPS)
Total ship electric power Electric propulsion, Power conversion and distribution, Combat system support Mission load interfaces to the electric power system

Roadmap Objectives
Increased power efficiency Reduced greenhouse emissions Reduced cost of reforming Reduced the frequency of vessel refueling Better fuel cell integration into power generation systems

DDG-1000, DDG-1000 spiral development, and CG(X) Undersea Unmanned Vehicles (UUV) SEAL teams -reduce number and weight of batteries

Project Deliverable
Low Temp Fuel Cell BP and Roadmap High Temp Fuel Cell BP and Roadmap PMI Roadmap

Manhattan Project in Fuel Cell Manufacturing

Power Range of Most Interest for Navy Mobile Power (5kW-50 kW) Fuel Available: Logistics Fuel (JP-5 / JP-8)
Already in DoD supply Chain Avoid introducing new fuel to supply chain

Down Select Fuel Cell Technology Areas For Manhattan Manufacturing Project Low Temperature Fuel Cells
Example: high temp Polymer Electrolyte Membrane (PEM) Fuel Cell

High Temperature Fuel Cells

Example: Solid Oxide Fuel Cells (SOFC)

Manhattan Project in Fuel Cell Manufacturing

Three proposed Fuel Cell Projects
Low Temp Fuel Cells (PEM / SOFC, etc.)
Reformer Manufacturing Hydrogen Purifier Manufacturing 1 Provide Current Manufacturing BP Improved Internal PEM Catalysts 2 Produce Roadmap to Fill Current Gaps Manufacturing Cell Stack Subsystems manufacturing 3 Recommended PMI Plan for Naval Vessels The Focus of These Projects

High Temp Fuel Cells (PEM / SOFC)

Reformer Manufacturing Cell Stack Subsystems Manufacturing Thermal Management Power Range Target

PMI
Power Management Integration of the Two Technologies in Navy Vessels 5-50 Kw Output

Manhattan Project in Fuel Cell Manufacturing

MFCMP Overview Focus on Project Scope and Objectives
Best Practices not Bleeding edge Meet the Navy and DoD objectives
Affordable Clean Efficient

Pre-Project Planning
Project Management Technical Leaders Moderator
Logistics Planning Agenda Development Agenda Facilitation

Manhattan Project in Fuel Cell Manufacturing

Team Selection
Advisory panel selected on the basis of requisite qualifications With the SMEs objectively rated on specific expertise Process ! The Top 15 are chosen based on the selection metric
Stick

Organizing Schedule Development of Project Culture Artifacts

Brochures, Storyboards, Outlines, etc

Communication Conflict Management Self Management Process Review

B2P review

Define a BP Agree to Terminology Gather a Consensus

Manhattan Project in Fuel Cell Manufacturing

The Keys to Success
Clarity of Vision Leadership Team Selection Knowledge Management Code of Conduct Constructive Conflict Ground Rules After Hour Activities All intended to meet the Deliverable Outside Presentations and Reviews Tag-up Sessions Tacit Knowledge Exchange Storyboarding and Posting Co-Leader review and Feedback

Effective Collaboration

Structured Development Process

Templates, Deadlines, Feedback, Milestones

Manhattan Project in Fuel Cell Manufacturing

Supporting Technology
Web enabled Teleconferencing Breakout Rooms FTP upload and download capability Dedicated Server Outcome in short time frame Can be replicated for many technical areas Clarity of Focus Model for the advancement of future endeavors

Findings

Manhattan Project in Fuel Cell Manufacturing

MONTANA TECH OVERVIEW

Manhattan Project in Fuel Cell Manufacturing

Center for Advanced Mineral and Metallurgical Processing

Manhattan Project in Fuel Cell Manufacturing

Montana Tech Overview

Founded in 1896 2,300 Students 140 Faculty Mines & Engineering Mathematics & Sciences Professional Studies College of Technology

Manhattan Project in Fuel Cell Manufacturing

Center for Advanced Mineral and Metallurgical Processing
CAMPs mission is to support, develop and add value to the global mineral, metallurgical and materials industry. Economic enhancement is encouraged through added-value processing of minerals, materials & metallurgical wastes and minimizing waste generation. Research, testing, design, consulting and feasibility studies:
Mineral processing & hydro- & pyrometallurgical applications Precious metal recovery & refining technologies Process simulation and modeling X-Ray diffraction/scanning electron microscopy Alternative energy/hydrogen catalyst development Wastewater remediation and resource recovery Materials innovation

Manhattan Project in Fuel Cell Manufacturing

CAMP EMPLOYEES
6 12 1 7 20 Engineers Faculty (part-time) Program Coordinator Graduate Students Undergraduate Students Several Consultants

Manhattan Project in Fuel Cell Manufacturing

Polymer Electrolyte Membrane (PEM) Manhattan Project scheduled for October 2010. Solid Oxide Fuel Cell (SOFC) Manhattan Project planned for mid-2011. Working with B2P and ONR to select 15 Subject Matter Experts (SMEs) and 10 Graduate Students for participation.

Manhattan Project in Fuel Cell Manufacturing

Fuel Cell Project
Multi-Year Funding from U.S. Navy Office of Naval Research (ONR). Original Scope: Develop a catalytic filter to purify hydrogen reformed from JP-8. Investigate plating a palladium membrane onto a porous stainless steel substrate, manufactured with S/S powders using ProMetal R2 3-D printer. Current Scope: Tasked by ONR to host two Fuel Cell Manhattan Projects. Working with B2P and ACI to coordinate conference. Identify problem areas and issues from Manhattan Projects and work with industry and government to find solutions.

Manhattan Project in Fuel Cell Manufacturing

Advanced Free Form Fabrication

ProMetal R2 3D Printing Machine

Manhattan Project in Fuel Cell Manufacturing

Technical Progress
Actual bulb Part Prior to Sintering

Innovative Design for Hydrogen Gas Separation Developed at CAMP

Manhattan Project in Fuel Cell Manufacturing

Technical Progress
Innovative Design for Hydrogen Gas Separation Developed at CAMP Sintering Conditions Have Been Determined to Produce Desirable Substrate
Formed and Cured Sintered

Sintered product structure

Particle Fusion Accomplished

Manhattan Project in Fuel Cell Manufacturing

Conceptual Figure
Substrate and Permeation Measurement System

Manhattan Project in Fuel Cell Manufacturing

Sensitization/ActivationNo Oxide Infiltration Oxide InfiltrationSensitization/Activation

Pd Cr

Fe

Pd Cr Fe Ni

Ni

Manhattan Project in Fuel Cell Manufacturing

Initial control experiments show the Pd coating thickness can be manipulated
Variable layer thicknesses

Secondary Electron Image of Pd-coated bulb

X-ray digital map for iron of Pd-coated bulb

X-ray digital map for palladium of Pd-coated bulb

Manhattan Project in Fuel Cell Manufacturing

Hydrogen Filter Specifications
Technical Targets: Dense Metallic Membranes for Hydrogen Separation and Purification Performance Criteria Flux Rate Module Cost (including membrane material) Durability Operating Capability Hydrogen Recovery Hydrogen Quality Units scfh/ft2 $/ft2 of membrane hr psi % % of total (dry) gas Current Status >200 1,500 <8,760 200 60 99.98 2010 Target 250 1,000 26,280 400 >80 99.99 2015 Target 300 <500 >43,800 400-600 >90 >99.99

Manhattan Project in Fuel Cell Manufacturing

Montana Tech Resources

Analytical Lab Analytical Imaging Lab Optical Imaging Lab Advanced Materials Thermal Characterization Mechanical Characterization Lab Mineral Processing Material Development for Space and Defense Hydro- and Pyro-Metallurgy

Manhattan Project in Fuel Cell Manufacturing

Questions?