Evolution of Fuel Cells and Batteries for the Military: Trends and Markets

TABLE OF CONTENTS

INTRODUCTION

• STUDY GOALS AND OBJECTIVES
• REASONS FOR DOING THE STUDY
• CONTRIBUTIONS OF THE STUDY
• SCOPE AND FORMAT
• INFORMATION SOURCES
• AUTHORS' CREDENTIALS
• RELATED BCC, INC. CREDENTIALS
  • REPORTS
  • MONTHLY NEWSLETTERS
• ABOUT BCC
• DISCLAIMER
• BCC ONLINE SERVICES

SUMMARY

• Summary Table:
  ADVANCED POWER SOURCES FOR MILITARY APPLICATIONS BY TYPE, THROUGH 2008 ($ MILLION)
• Summary Figure:
  ADVANCED POWER SOURCES FOR MILITARY APPLICATIONS BY TYPE, 1980-2008 ($ MILLION)

OVERVIEW

• IMPACT OF ADVANCED TECHNOLOGY
  • IMPACT OF ADVANCED TECHNOLOGY (CONTINUED)
• BACKGROUND
• OBSERVATIONS
• DEPLOYED AND NON-DEPLOYED MILITARY APPLICATION REQUIREMENTS
• DOD ORGANIZATIONAL INVOLVEMENT IN FUEL CELL DEVELOPMENT
• FUEL CELL TEST AND EVALUATION CENTER (FCTEC)
• Table 1 DOD FUEL CELL TEST AND EVALUATION CENTER OBJECTIVES
  • CAPABILITIES
• Table 2 SUMMARY FCTEC CAPABILITIES
  • Concurrent Technologies Corporation (CTC)
  • DEFENSE ADVANCED RESEARCH PROJECTS AGENCY (DARPA)
    • TECHNICAL OFFICES
    • Support Offices
    • Palm Power Program
    • RESEARCH, DEVELOPMENT & ENGINEERING COMMAND (RDECOM)
• Figure 1: RDECOM ORGANIZATION (PROVISIONAL)
  • TACOM/National Automotive Center (NAC)
• Table 3 NATIONAL AUTOMOTIVE CENTER ORGANIZATIONAL STRUCTURE
  • Communications-Electronic Command (CECOM)/Communications-Electronic Research, Development and Engineering Command (CERDEC)
  • Communications-Electronic Command�c(Continued)
  • Army Research Lab (ARL)
  • TACTICAL TO PRACTICAL
    • DEPARTMENT OF HOMELAND SECURITY (DHS)
    • Directorates
• Table 4 DEPARTMENT OF HOMELAND SECURITY DIRECTORATES
  • FUNDING: ENABLING FACTOR OR PROBLEM FOR FUEL CELLS?
• Table 5 FUEL CELLS FOR MILITARY APPLICATIONS BY TYPE, THROUGH 2008 ($ MILLIONS)
• Figure 2 FUEL CELLS FOR MILITARY APPLICATIONS BY TYPE, 1980-2008 ($ MILLIONS)
  • FUNDING: ENABLING FACTOR OR�c(CONTINUED)

DEPARTMENT OF DEFENSE FUEL CELL APPLICATIONS

• STATIONARY POWER
  • KEY CONSTRUCTION ENGINEERING RESEARCH LABORATORY (CERL) FUEL CELL PROGRAMS
• Table 6 ADVANCED POWER AND ENERGY PROGRAM GOALS
• Table 7 ADVANCED POWER AND ENERGY PROGRAM OBJECTIVES
• Table 7 (CONTINUED)
  • Activities Supporting Fuel Cell Deployment
• Table 8 ADVANCED POWER AND ENERGY PROGRAM TASKS
  • FIRST GENERATION FUEL CELL PROGRAM
  • Monies Appropriated
  • Phosphoric Acid Sites and Performance
  • CERL RESIDENTIAL FUEL CELL PROGRAM
• Table 9 CERL SITE PERFORMANCE, FY 2001-2002
  • INSTALLATION CASE STUDIES
  • Watervliet Arsenal
  • McChord AFB
  • Preliminary Project Description
  • Hydrogen Storage and Supply
  • Data Acquisition
  • Economic Analysis
  • Geiger Field Air National Guard Facility
  • Hydrogen Supply
  • Economic Analysis
  • VALUE OF FUEL CELLS FOR STATIONARY MILITARY APPLICATIONS
• Table 10 VALUE OF FUEL CELLS BY TYPE FOR STATIONARY MILITARY APPLICATIONS, THROUGH 2008 ($ MILLIONS)
  • TRANSPORTATION
    • STRYKER 8-WHEEL DRIVE ARMORED VEHICLE
    • EVOLUTIONARY VARIANTS
    • Overseas Delivery Requirements
    • COMBATT Program
    • Dodge Ram 2500 COMBATT C-11 Hybrid
    • GM COMBATT Initiatives
    • Reality Check
    • FUEL SUPPLY
• Table 11 ENERGY DENSITY FOR DOD MAIN FUEL TYPES
  • Desulfurizing Gasoline or Diesel Fuel
  • Surrogate JP-8 into Hydrogen
  • VALUE OF FUEL CELLS IN MILITARY TRANSPORTATON
• Table 12 VALUE OF FUEL CELLS FOR MILITARY TRANSPORTATION, BY TYPE, THROUGH 2008 ($ MILLIONS)
  • MOBILE ELECTRIC POWER (MEP)
    • TACTICAL ELECTRIC POWER
    • EVOLVING FUEL CELL PROJECTS
    • Logistic Fuel Processor
    • VALUE OF MOBILE ELECTRIC POWER FUEL CELLS BY TYPE
• Table 13 VALUE OF FUEL CELLS BY TYPE FOR MOBILE ELECTRIC POWER, THROUGH 2008 ($ MILLIONS)
  • PORTABLE POWER
    • INFLUENCE OF DEVICES
    • Fuel Cell or Advanced Battery
• Table 14 ZINC-AIR BA/8180/U SPECIFICATIONS
  • VALUE OF FUEL CELLS IN MILITARY PORTABLE APPLICATIONS
• Table 15 VALUE OF FUEL CELLS BY TYPE FOR MILITARY PORTABLE APPLICATIONS, THROUGH 2008 ($ MILLIONS)
  • ADDITIONAL INITIATIVES
    • DRONES FOR THE MARINES
    • SHIP POWER
    • AIRPLANES AND OTHER EQUIPMENT
    • COUNTERTERRORISM
    • SmarTruck II
    • Smartruck II (Continued)
    • NON-U.S. INITIATIVES
    • U-31/U-32 Submarines (Germany)
    • VALUE OF ADDITIONAL INITIATIVES FOR FUEL CELLS
• Table 16 VALUE OF ADDITIONAL INITIATIVES FOR FUEL CELLS BY TYPE, THROUGH 2008 ($ MILLIONS)

HYDROGEN FUEL CELLS FOR MILITARY DEVICES AND SYSTEMS

• TECHNICAL SETTING
  • CONSIDERATIONS FOR CURRENT MILITARY FUEL CELL RESEARCH
• Table 17 RESEARCH MOST RELEVANT FOR MILITARY FUEL CELL APPLICATIONS
  • EVOLUTION OF FUEL CELLS AND THERMODYNAMICS
  • PROTON EXCHANGE MEMBRANE (PEM) FUEL CELL
    • OPERATION COMPLEXITIES
• Figure 3 WATER TRANSPORT IN A PEM FUEL CELL
  • Needed Components
  • R&D HIGHLIGHTS
  • Development at Gas Technology Institute
  • Development at Plug Power
  • Patent Developments of the United States Army
  • Development at Lynntech
  • Developments at Altergy Systems
  • Synopsis of Polymers for Ion Selective Membranes for Pems
• Table 18 SYNOPSIS OF POLYMERS FOR ION SELECTIVE MEMBRANES FOR PEM FUEL CELLS
  • DIRECT METHANOL FUEL CELL (DMFC)
  • Operation
  • Los Alamos National Laboratory
  • R&D Highlights
  • Developments at Ball Aerospace
  • Developments at Energy Visions
  • Developments at Genesis Fueltech, Inc.
  • Developments at Giner Electrochemical Systems
  • Developments at Hewlett Packard
  • Developments at Manhattan Scientifics, Inc.
  • Developments at MTI Micro
  • Developments at Medis Technologies
  • Progress at Other Organizations
  • VALUE OF PEM FUEL CELLS FOR THE MILITARY
• Table 19 VALUE OF PEM FUEL CELLS FOR THE MILITARY, THROUGH 2008 ($ MILLIONS)
  • INDUSTRY STRUCTURE AND INFORMATION BANK FOR MILITARY PEM/DM FUEL CELLS
  • Industry Structure and Information Bank�c(Continued)
  • Industry Structure and Information Bank�c(Continued)
  • SOLID OXIDE FUEL CELLS (SOFC)
  • OPERATION
  • Components and Construction
  • Electrolyte
  • Electrodes
  • Tubular Configuration
  • Tubular Configuration (Continued)
  • Closed-End Ceramic Tubes
  • Planar Configuration
  • Flat Plate Design
  • Monolithic
  • R&D Highlights
  • Development at Acumentrics
  • Developments at Adaptive Materials, Inc.
  • Developments at Gas Technology Institute
  • Developments at Siemens Westinghouse
  • VALUE OF SOLID OXIDE FUEL CELLS FOR THE MILITARY
• Table 20 VALUE OF SOLID OXIDE FUEL CELLS FOR THE MILITARY, THROUGH 2008 ($ MILLIONS)
  • INDUSTRY STRUCTURE AND INFORMATION BANK FOR MILITARY SOFC
  • MISCELLANEOUS TYPES OF FUEL CELLS
    • MOLTEN CARBONATE FUEL CELLS (MCFC)
    • Operation
    • Manifolds
    • Electrodes
    • Process at the Electrodes
    • R&D HIGHLIGHTS
    • Improved Lifetimes
    • Improved Lifetimes Continued)
    • INFORMATION BANK FOR MCFC MANUFACTURERS AND SUPPLIERS
    • PHOSPHORIC ACID
    • PROTONIC CERAMIC FUEL CELL
    • REGENERATIVE
  • HYBRIDS
• Figure 4 REALATED ADVANCED TECHNOLOGIES
  • ULTRACAPACITOR
  • SUMMARY VALUE OF HYDROGEN FUEL CELLS FOR MILITARY APPLICATIONS
• Table 21 VALUE OF HYDROGEN FUEL CELLS FOR MILITARY APPLICATIONS, BY TYPE, THROUGH 2008 ($ MILLION)
• Figure 5 VALUE OF HYDROGEN FUEL CELLS FOR MILITARY APPLICATIONS, BY TYPE, 1980-2008 ($ MILLION)
  • SUMMARY VALUE �c APPLICATIONS (CONTINUED)

METAL-AIR FUEL CELLS

• INTRODUCTION
• BACKGROUND
  • ELECTRONEGATIVITY
  • OPERATION
  • Operation (Continued)
  • ELECTROCHEMICAL PACK
• HYBRIDS
• DEVELOPMENTS IN THE ZINC-AIR FUEL CELL INDUSTRY
  • PROGRESS AT AROTECH/ELECTRIC FUEL CORP
  • Progress at Arotech/Electric Fuel Corp (Continued)
  • PROGRESS AT EVIONYX, INC.
  • PROGRESS AT GILLETTE/DURACELL
  • PROGRESS AT POWERZINC ELECTRIC, INC.
  • ADVANCES AT METALLIC POWER
  • STATUS OF RAYOVAC
• VALUE OF ZINC-AIR BATTERIES IN MILITARY SYSTEMS/DEVICES
• Table 22 VALUE OF ZINC-AIR BATTERIES IN MILITARY SYSTEMS/DEVICES, THROUGH 2008 ($ MILLIONS)
• Figure 6 VALUE OF ZINC-AIR BATTERIES IN MILITARY SYSTEMS/DEVICES, 1980-2008 ($ MILLIONS)
  • INFORMATION BANK FOR ZINC-AIR MANUFACTURERS AND SUPPLIERS

UPDATED LOOK AT ADVANCED BATTERIES FOR MILITARY SYSTEMS/DEVICES

• LEGACY TECHNOLOGY
  • TYPICAL MILITARY BATTERY USES
• LITHIUM BATTERIES
  • LITHIUM-SULFUR DIOXIDE BATTERIES
  • Developments at Saft
  • VALUE OF LITHIUM SULFUR DIOXIDE BATTERIES IN MILITARY SYSTEMS/DEVICES
• Table 23 VALUE OF LITHIUM SULFUR DIOXIDE BATTERIES IN MILITARY SYSTEMS/DEVICES, THROUGH 2008 ($ MILLIONS)
  • LITHIUM-MANGANESE DIOXIDE BATTRIES
  • Secondary Li-MnO₂
  • Primary Li-MnO₂
  • Pouch Design
  • Developments at Ultralife
  • Technology at Duracell, Inc.
  • VALUE OF LITHIUM-MANGANESE DIOXIDE BATTERIES IN MILITARY SYSTEMS/DEVICES
• Table 24 VALUE OF LITHIUM-MANGANESE DIOXIDE BATTERIES IN MILITARY SYSTEMS/DEVICES, THROUGH 2008 ($ MILLIONS)
  • LITHIUM-ION/POLYMER
  • Temperature Performance
  • CECOM Electrolytes
  • Battery Engineering and Hitachi Maxell Electrolytes
  • Design of "Smart" Cells
  • Army Research Laboratory (ARL) Anode Research
  • Development at Litech
  • Developments at Oak Ridge Micro-Energy
  • Developments at Saft Lithium-Ion/Polymer Technology
  • Developments at Alliant Techsystems
  • VALUE OF LITHIUM-ION/POLYMER BATTERIES IN MILITARY SYSTEMS/DEVICES
• Table 25 VALUE OF LITHIUM-ION/POLYMER BATTERIES IN MILITARY SYSTEMS/DEVICES, THROUGH 2008 ($ MILLIONS)
  • NICKEL METAL HYDRIDE
    • INDUSTRY CHANGES
    • OPERATION IN MILITARY COMMUNICATIONS
    • VALUE OF NIMH BATTERIES IN MILITARY SYSTEMS/DEVICES
• Table 26 VALUE OF NICKEL METAL HYDRIDE BATTERIES IN MILITARY SYSTEMS/DEVICES, THROUGH 2008 ($ MILLIONS)
  • OTHER
  • SUMMARY VALUE OF ADVANCED MILITARY BATTERIES BY CHEMICAL TYPE
• Table 27 ADVANCED MILITARY BATTERIES, BY TYPE, THROUGH 2008 ($ MILLIONS)
• Figure 7 ADVANCED MILITARY BATTERIES, BY TYPE, 1980-2008 ($ MILLIONS)
  • INFORMATION BANK FOR MILITARY LITHIUM BATTERY MANUFACTURERS AND SUPPLIERS
  • Information Bank for Military Lithium�c(Continued)
  • Information Bank for Military Lithium�c(Continued)
  • Information Bank for Military Lithium�c(Continued)
  • Information Bank for Military Lithium�c(Continued)

LIST OF TABLES

Summary Table:
ADVANCED POWER SOURCES FOR MILITARY APPLICATIONS BY TYPE, THROUGH 2008 ($ MILLION)

Table 1 DOD FUEL CELL TEST AND EVALUATION CENTER OBJECTIVES

Table 2 SUMMARY FCTEC CAPABILITIES

Table 3 NATIONAL AUTOMOTIVE CENTER ORGANIZATIONAL STRUCTURE

Table 4 DEPARTMENT OF HOMELAND SECURITY DIRECTORATES

Table 5 FUEL CELLS FOR MILITARY APPLICATIONS BY TYPE, THROUGH 2008 ($ MILLIONS)

Table 6 ADVANCED POWER AND ENERGY PROGRAM GOALS

Table 7 ADVANCED POWER AND ENERGY PROGRAM OBJECTIVES

Table 8 ADVANCED POWER AND ENERGY PROGRAM TASKS

Table 9 CERL SITE PERFORMANCE, FY 2001-2002

Table 10 VALUE OF FUEL CELLS BY TYPE FOR STATIONARY MILITARY APPLICATIONS, THROUGH 2008 ($ MILLIONS)

Table 11 ENERGY DENSITY FOR DOD MAIN FUEL TYPES

Table 12 VALUE OF FUEL CELLS FOR MILITARY TRANSPORTATION, BY TYPE, THROUGH 2008 ($ MILLIONS)

Table 13 VALUE OF FUEL CELLS BY TYPE FOR MOBILE ELECTRIC POWER, THROUGH 2008 ($ MILLIONS)

Table 14 ZINC-AIR BA/8180/U SPECIFICATIONS

Table 15 VALUE OF FUEL CELLS BY TYPE FOR MILITARY PORTABLE APPLICATIONS, THROUGH 2008 ($ MILLIONS)

Table 16 VALUE OF ADDITIONAL INITIATIVES FOR FUEL CELLS BY TYPE, THROUGH 2008 ($ MILLIONS)

Table 17 RESEARCH MOST RELEVANT FOR MILITARY FUEL CELL APPLICATIONS

Table 18 SYNOPSIS OF POLYMERS FOR ION SELECTIVE MEMBRANES FOR PEM FUEL CELLS

Table 19 VALUE OF PEM FUEL CELLS FOR THE MILITARY, THROUGH 2008 ($ MILLIONS)

Table 20 VALUE OF SOLID OXIDE FUEL CELLS FOR THE MILITARY, THROUGH 2008 ($ MILLIONS)

Table 21 VALUE OF HYDROGEN FUEL CELLS FOR MILITARY APPLICATIONS, BY TYPE, THROUGH 2008 ($ MILLION)

Table 22 VALUE OF ZINC-AIR BATTERIES IN MILITARY SYSTEMS/DEVICES, THROUGH 2008 ($ MILLIONS)

Table 23 VALUE OF LITHIUM SULFUR DIOXIDE BATTERIES IN MILITARY SYSTEMS/DEVICES, THROUGH 2008 ($ MILLIONS)

Table 24 VALUE OF LITHIUM-MANGANESE DIOXIDE BATTERIES IN MILITARY SYSTEMS/DEVICES, THROUGH 2008 ($ MILLIONS)

Table 25 VALUE OF LITHIUM-ION/POLYMER BATTERIES IN MILITARY SYSTEMS/DEVICES, THROUGH 2008 ($ MILLIONS)

Table 26 VALUE OF NICKEL METAL HYDRIDE BATTERIES IN MILITARY SYSTEMS/DEVICES, THROUGH 2008 ($ MILLIONS)

Table 27 ADVANCED MILITARY BATTERIES, BY TYPE, THROUGH 2008 ($ MILLIONS)  

LIST OF FIGURES

Summary Figure:
ADVANCED POWER SOURCES FOR MILITARY APPLICATIONS BY TYPE, 1980-2008 ($ MILLION)

Figure 1: RDECOM ORGANIZATION (PROVISIONAL)

Figure 2 FUEL CELLS FOR MILITARY APPLICATIONS BY TYPE, 1980-2008 ($ MILLIONS)

Figure 3 WATER TRANSPORT IN A PEM FUEL CELL

Figure 4 REALATED ADVANCED TECHNOLOGIES

Figure 5 VALUE OF HYDROGEN FUEL CELLS FOR MILITARY APPLICATIONS, BY TYPE, 1980-2008 ($ MILLION)

Figure 6 VALUE OF ZINC-AIR BATTERIES IN MILITARY SYSTEMS/DEVICES, 1980-2008 ($ MILLIONS)

Figure 7 ADVANCED MILITARY BATTERIES, BY TYPE, 1980-2008 ($ MILLIONS)