Department of Defense Fuel Cell Test and Evaluation Center Successes

24 May 2007JSEM Energy Technical Session

Columbus, Ohio

Heather Moyer, CTC

Department of Defense Fuel Cell Test and Evaluation Center Successes

24 May 2007JSEM Energy Technical Session

Columbus, Ohio

Heather Moyer, CTC

• Established in 1998– ERDC-CERL, UTCFC & CTC

• Located in Johnstown, PA (CTC’s ETF Facility)• >35,000 sq. ft. (test equipment, test stations)• Technology and Vendor Neutral• Recognized as a National Resource for 3rd Party RDT&E• Original Mission: to advance fuel cell systems from 3 KW to

300 KW• Wide Variety of Engineering Expertise for Design, Engineering,

Integration, Demonstration, and Implementation • System Integrators• One Stop Shop / Turn-key Programs• Utilized by Government, Developers, and End Users

Background

The Test Center Provides Unique Services & Capabilities

The Bottom LineThe Bottom Line

• 108 Fuel Cell Systems in Field Demonstrations• 99 Written Deliverables• 45 Alternative Energy Technologies Evaluated• 14 Test Systems Integrated into FCTec

Infrastructure• 6 Hybrid Fuel Cell Vehicles

– 3 in use– 3 in integration phase

• Expanding Portfolio across broad spectrum of Advanced Energy Technologies

• Altitude Chamber• Environmental Chamber• EMC Chamber• Emissions Monitoring Trailer• Shock & Vibration Table• AC/DC Load Simulators• Logistic Fuels Supply

• Resistive/Inductive Load Banks• Thermal Load Banks• Home Simulator• Grid Simulator• Gas & Fluid Analysis Systems• SOFC Stack Tester• Reformer Test Station

FCTec’s Test Center EquipmentProvides Versatile Test Environments

Test Center Designed to SupportMultiple Test Programs

Transportation Test Station

Home Simulator

Stationary Test Station

Multiple Fuels Distribution System

• ERDC-CERL• AEFB• APTO Robins AFB• AFRL• FAA• National Forest

Service• HCATT• IdaTech• Ballard• Acumentrics• Millennium Cell

• RDECOM

• DOE / NETL

• Plug Power

• UTCFC

• Fuel Cell Energy

• Hydrogenics

• Intelligent Energy

• Siemens Power

• ReliOn

• Protonex

Military and Industry Leaders Are Some KEY Clients for the Test Center

• UTCFC T&E– Clients

ERDC-CERL & UTCFC

– ObjectiveTest and validate the PC25-C 200 kW PAFC

– Accomplishments1. Validated heat recovery system2. Validated electrical performance capabilities3. Validated emission, gas and water streams4. Validated system performance with different

fuels5. Identified improved BoP modifications Status

– Completed

CTC Validates and Enhances Fuel Cell Power Plant Performance for UTCFC

• FCE Dual Fuel Program– Clients

ERDC-CERL & FCE– Objective

Demonstrate that HD-5 propane is a viable fuel for the FCE DFC-300A 250 kW MCFC

– Accomplishments1. Designed and constructed the propane storage, supply

system and fuel train2. Designed and implemented control logic and software

upgrades and prepared data acquisition system3. Developed master test plan and procedure for

determining system efficiency4. Completed power plant start-up and basic operation5. Completed reliability testing and fuel swapping

– Completed

CTC Validates and Enhances Fuel Cell Power Plant Performance for FCE

• Common Core Power Production (C2P2) – Clients

Phase I - AEF Battlelab

− ObjectivesOne common engine for deployable assets

− Accomplishments1. Business Case Analysis - ECAMSM

• Diesel, turbine, FC, etc.• PEM fuel cell selected

2. Demonstrations• Office equipment (4.0 kW-120VAC-60Hz)• Aircraft power (8.0 kW-208/120VAC-400Hz)• Industrial/aircraft equipment (12.0 kW-480/277VAC-60Hz)

3. Application• 1st Fuel cell powered aircraft tow vehicle (12 kW PEM FCS)

CTC Validates Fuel Cell Power Plants for Tent City and Aircraft GSE Applications

• C2P2– Clients

Phase II – APTO / ERDC-CERL

– Accomplishments1. MB-4 Tow Vehicle Integration

• Electric drive conversion• 65 kW PEM FC

2. 5 kW Hydrogen On-Demand• Design and construct• Test and evaluate

3. 5 kW PEM Test and Evaluation• Reliability and transient reliability• Parallel operations

4. JP-8 Plasma Arc Reformer Testing • Emissions testing• Energy balance

CTC Validates Fuel Cell Power Plants for Tent City and Aircraft GSE Applications

• Fuel Cell Demonstrations– Clients

ERDC-CERL, FAA, NFS, CVNP, various Army installations

– ObjectiveDemonstrate residential sized fuel cell power

plants utilizingdifferent fuels (Hydrogen, natural gas, propane)

– Accomplishments1. Procured fuel cell power plants from IdaTech,

Acumentrics, ReliOn, and SW/FCT (SOFC & PEMFC)

2. Completed site design for FAA, NFS & CVNP demos

3. Installed fuel cell power plants at 4 FAA sites, NFS & CVNP

– Completed

CTC Contributes to Fuel Cell Field Demonstrations

• Capstone Microturbine– Clients

ERDC-CERL & Capstone

– ObjectiveDemonstrate that Biodiesel is a viable fuel for the

Capstone C60 Liquid Fuel Microturbine

– Accomplishments1. Acquired all local permitting 2. Installed the microturbine at the test center3. Identified a local biodiesel supplier4. Completed efficiency testing on 100% diesel5. Initiated biodiesel testing – B5, B20, B50,

B75, B100

– StatusTo be completed 3nd Quarter 2007

CTC Validates Microturbine Performance on Biodiesel for Capstone

• Man-Portable Fuel Cell System for Military Applications

– ClientsAFRL

– ObjectiveSubject a man-portable fuel cell system to environmentaltesting in accordance with MIL-STD-801F and MIL-STD 1472F

– Accomplishments1. Completed high/low and surface temperature testing2. Initiated vibration testing3. Prepared for altitude and drop testing

– StatusTo be completed 3rd Quarter 2007

CTC Validates Portable Power Systems for Environmental Ruggedness

• Advanced Energy Center of Excellence – providing Energy Security and Sustainability through Advanced Energy Solutions

• Turn-key Programs to transition Alternative P&E Technologies for practical use in military applications through TRLs

• Centralized, Independent RDT&E, Integration, Optimization Service of Alternative Energy Technologies for Government Agencies and Private Industry

FCTec Long Term Vision - Future

• Fuel Cell Augmented Flightline Maintenance Vehicle

• Fuel Cell Powered Aircraft Tow Vehicles

• Camp Perry-Renewable Energy Demonstration Program

• Toledo ANG-Renewable Energy Demonstration Program

• DLA-Material Handling Equipment and Infrastructure Program

• Portable Power Testing

FCTec Future Projects

Susan Van ScoyocCTC, Manager, Army Power & Energy Programs

vanscoy@ctc.com814.269.2826

Robert WertzCTC, Manager, Advanced Power and Energy Program Development

wertzr@ctc.com814.269.6848

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Department of Defense Fuel Cell Test and Evaluation Center Successes ��24 May 2007�JSEM Energy Technical Session�Columbus, OhiThe Bottom Line