DoD HYDROGEN INITIATIVES

POC: Franklin Holcomb
Phone: (217) 373-5864
Email: Franklin.H.Holcomb@usace.army.mil





Department of Energy Signs $2M Interagency Agreement with ERDC-CERL
The Office of Clean Energy Systems in the Department of Energy's (DOE's) Office of Fossil Energy recently signed an Interagency Agreement with ERDC-CERL valued at $2M over several years. The Agreement covers three areas of energy research to be performed by ERDC-CERL: energy conversion, energy storage, and power conditioning. These research areas are integral aspects of distributed generation technology, a mutual interest of DOE and ERDC-CERL for both traditional stateside and war fighter base camp facilities. The agreement enhances ERDC-CERL’s support of other installation energy efforts such as: the Army Energy Strategy Campaign Plan; a candidate FY07 Army Technology Objective new start with Research, Development, and Engineering Command (RDECOM) for a mobile advanced energy infrastructure; and an emerging hydrogen infrastructure project for the Department of Defense.

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Fort Stewart Waste to Energy ECIP Project
The U.S. Army is interested in using energy from a wastewater treatment plant to develop a hydrogen infrastructure for both stationary and mobile fuel cell applications. An important step toward implementing a hydrogen infrastructure is to design a system that provides both fuel flexibility and onsite storage. The concept is to use anaerobic digester gas in conjunction with a fuel processor to create hydrogen. The hydrogen can either be stored in tanks or it can be used in a fuel cell to produce electricity and heat. The project will utilize a commercially available steam reforming fuel cell power plant. The hydrogen storage capability will link a stationary fuel cell product to the emerging fuel cell transportation industry. This project has been submitted through Fort Stewart, GA for FY07 Energy Conservation Investment Program (ECIP) funding, with an estimated savings to investment ratio (SIR) of 1.74.
More Information
ERDC Tech Report

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Silent Camp™ for the 249th Engineer Battalion (Prime Power)
SilentCamp™ is a term coined by ERDC-CERL researchers to describe a system concept whereby a diesel generator is coupled with an electrolyzer, hydrogen storage system, and fuel cell to form an integrated package to silently power loads at forward base camps. Since the diesel generators deployed in the field are typically lightly loaded, the efficiency of the generators is very low. By feeding excess power from the generators to an electrolyzer, the generators run at higher efficiency with improved operation (less maintenance). The electrolyzer in turn splits water into hydrogen and oxygen, and the hydrogen can be stored and utilized in a fuel cell to power loads. SilentCamp™ has been endorsed by the 249th Engineer Battalion, who deploy 750 kW and larger generators in the field. Jason Whipple, a West Point graduate and then a Captain in the U.S. Army, obtained an M.S. in Mechanical Engineering at the University of Illinois with his thesis focused on an analysis of SilentCamp™. A report on modeling this technology has been published in the Journal of Fuel Cell Science and Technology.
More Information

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Fuel Cell and Hydrogen Curriculum Initiative with Champaign, IL Unit 4 Schools
ERDC-CERL was requested to submit a joint proposal with Champaign Unit 4 Schools for Illinois state grant funding to develop selected curricula and projects with the teachers. Fuel cells and hydrogen was one such curriculum that was submitted in the proposal. If funded, ERDC-CERL researchers will work with Unit 4 teachers to develop a hydrogen economy lecture along with a classroom fuel cell demonstration for the students. Unit 4 teachers will be invited to ERDC-CERL to learn about the DoD Stationary Fuel Cell Demonstration projects and associated activities with hydrogen infrastructure research. ERDC-CERL researchers will work with Unit 4 teachers to develop materials suitable for presentation and demonstration in their Science and/or Math classes.

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Tactical Mobile and Stationary Microgrid Development Initiatives
Research and Development Engineering Command (RDECOM) has an ongoing project at the Selfridge Air National Guard facility in Warren, MI, to develop what is being called a mobile microgrid, where various distributed generation and energy storage technologies, including fuel cells, are networked together with the loads that they serve in a “plug and play” configuration. This “intelligent” microgrid will serve airstrip lighting loads for the Selfridge project and will be designed so that it is readily deployable to forward combat airstrip facilities.

ERDC/CERL has become involved with the project because of its relevance to the mission of the Corps of Engineers 249th Engineer Battalion, or Prime Power, who similarly provide large power systems to forward base camps and to Federal Emergency Management Agency (FEMA) disaster relief efforts. ERDC-CERL is also working with RDECOM to propose an Army Technology Objective, which will investigate the feasibility of scaling up the microgrid concept as a better means of providing secure, reliable, high quality, sustainable and affordable power to mission critical activities at Army installations.

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Ethanol Reformation for Military Applications SBIR

ERDC-CERL submitted a Small Business Innovative Research (SBIR) topic to design and build a prototype reformer to demonstrate efficient hydrogen production from renewable ethanol fuel which can be used for fuel cells and other military applications.

Using ethanol for hydrogen production allows the Department of Defense to meet one of the many objectives of the recently passed energy bill (The Domenici-Barton Energy Policy Act of 2005), which requires all components of the Federal Government to increase the use of energy from renewable sources. The 2005 Army Energy Campaign Plan also cites the goal of increased use of renewable energy and expansion of use of alternative fuels at Army installations. Ethanol-powered fuel cells and the associated hydrogen platforms will assist in meeting both of these goals.

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MCAGCC Twentynine Palms Fuel Cell Project

As part of an FY05 Congressionally funded effort with ERDC-CERL, LoganEnergy Corporation will install a 250 kW Fuel Cell Energy (FCE) Molten Carbonate Fuel Cell at the Marine Corps Air Ground Combat Center in Twentynine Palms, CA. The fuel cell will supplement the other alternative energy projects on the base, including a 1.1 MW photovoltaic array, and a 7 MW cogeneration plant. Under the terms of the contract, the fuel cell will operate for a minimum of three years and a detailed analysis of the fuel cell’s operation will be provided via monthly reports.

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TARDEC Hydrogen Initiatives
The U.S. Army Tank Automotive Research, Development and Engineering Center (TARDEC) is the nation’s laboratory for advanced military automotive technology. TARDEC is headquartered at the Detroit Arsenal, in Warren, MI. TARDEC is working on numerous hydrogen initiatives. Two examples are provided below:

One initiative uses a Multi-Service-Regenerative Fuel Cell Auxiliary Power Unit (MREF-APU) concept to meet low emissions (acoustic, thermal, pollutants, etc.) requirements termed “Silent Watch” on the Stryker Light-Armored-Vehicle. This “Silent Watch” occurs when the vehicle engine is shut off and reconnaissance equipment is activated.

With the MREF-APU, whenever the vehicle engine is running the alternator feeds an electrolyzer to continuously create hydrogen fuel. The system stores this low pressure hydrogen fuel in metal hydride form, so there is no need for a compressor. When auxiliary power is needed for “Silent Watch” capability the system is switched from the “Electrolyzer Mode” to the “Fuel Cell Mode,” and provides power to the reconnaissance equipment.

A second initiative involves a partnership General Motors Corp. in supplying the U.S. Army Research, Development and Engineering Command (RDECOM) with a fuel cell powered Chevrolet Silverado. The vehicle is equipped with two 94-kilowatt fuel cell stacks and fueled by compressed hydrogen gas. The truck was delivered to Fort Belvoir, VA in April 2005 and will be evaluated until July 2006. This Chevrolet Silverado represents the first fuel-cell-powered military truck.

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Robins AFB Common Core Power Production (C2P2)

ERDC-CERL is in the second year of partnering with Robins AFB as part of the Air Force’s Common Core Power Production (C2P2) effort. The C2P2 initiatives consist of fielding affordable, integrated, reliable, zero-emissions, zero-grid military and civil aircraft service event capability, and Basic Expeditionary Airfield Resources (BEAR) Base and civilian relief installations. Under the current year’s effort, ten second-generation 5 kW Gensys Proton Exchange Membrane (PEM) Fuel Cells from Plug Power have been installed at Robins Air Force Base for a one-year demonstration project. These fuel cells are fueled by Liquified Petroleum Gas (Propane) and provide AC power to the base electrical grid near the Groundwater Treatment Plant. The units will operate at various load conditions and load profiles to simulate off-grid electric load-following operation. Of particular interest is the units’ capability to maintain high availability with few unplanned service calls, and to track the degradation rate of the fuel cell stack during operation.

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Demonstration of JP-8-Based Hydrogen Production and Use in Military Fuel Cell Electric Hybrid Vehicles
As part of an FY05 Congressionally funded effort with ERDC-CERL, the University of North Dakota Energy & Environmental Research Center (EERC) and ePower Synergies, Inc. (ePower), initiated work on an anticipated 3-year program to demonstrate the military viability of a hydrogen supply–fuel cell vehicle combination as a key step toward meeting the U.S. Army After Next (AAN) objective of a 75% reduction in battlefield petroleum use. Objectives of the anticipated 3-year program are to:
  • Develop and optimize a JP-8-based field-portable system capable of on-demand production and dispensing of high-pressure proton exchange membrane (PEM) fuel cell-quality hydrogen.
  • Design and manufacture PEM fuel cell electric hybrid (FCEH)-powered aircraft ground support vehicles.
  • Demonstrate and perform an operational comparison of the military viability of the hydrogen supply–vehicle supply combination in wide-ranging climate conditions—at Grand Forks Air Force Base (GFAFB) in North Dakota and at Hickam Air Force Base (HAFB) in Hawaii.
  • Design and evaluate a mobile JP-8-based on-demand hydrogen production and dispensing system for frontline supply of high-pressure hydrogen to fuel cell-powered equipment.
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Hydrogen Fueling Station Project at Camp Pendleton
Ztek Corporation has reached agreement with U.S. Department of Navy (DoN) to collaborate on a hydrogen fueling station project at the U.S. Marine Corps Base Camp Pendleton in California. Ztek will supply a High Performance Steam Reformer (HPSR) with a capacity sufficient to service the military needs on the base and civilian hydrogen vehicles from the area. Funding for the project will be provided jointly by Ztek and the DoN, with the potential participation of the State of California through its “Hydrogen Highways” initiative. Press Release

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Distributed Hydrogen Production Utilizing Molten Carbonate Fuel Cells
FuelCell Energy has demonstrated the operation of its Molten Carbonate "Direct FuelCell (DFC®) Power Plants on a variety of hydrocarbon fuels, such as natural gas, methane, propane, and diesel. FCE has over 50 units (250 kW or larger size power plants) across the world that have generated over 94 million kWh. The baseline DFC® units have an electrical efficiency of 45-50%. The baseline fuel cell system (see link below) is simple and includes minimum Balance of Plant (BOP) equipment. It produces its own hydrogen internally from the hydrocarbon fuel while simultaneously providing cooling for the fuel cell stack. Typically, 75% of this hydrogen is used in the fuel cell and the remaining 25% is used to preheat the incoming air. The unutilized excess hydrogen (~25% of the feed) from the anode exhaust is available at no additional cost. Development of a low-cost, low-energy hydrogen separator is proposed to separate the hydrogen from the anode exhaust. The hydrogen from the anode exhaust is separated and is sold as a product. Overall system efficeincy of co-production of electricity, hydrogen and heat is expected to be in the 75-85% range, depending on the site and system operating conditions.

Schematic of Advanced DFC Stationary Power Plant

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Defense Logistics Agency Fuel Cell Powered Forklift Pilot Projects

The Defense Logistics Agency (DLA) is implementing pilot projects at three defense distribution depots to support the development and commercialization of hydrogen fuel cell technologies to support DoD operations. Forklift operations provide a niche application where fuel cells can offer real financial benefits to the DoD while helping to improve the state of the technology for future applications.

The two-year pilot projects have been designed to explore a range of technological capabilities and operational characteristics. The Defense Distribution Depot Susquehanna Pennsylvania (DDSP) will deploy 40 retrofitted forklifts powered by hydrogen that is delivered to the site through contracts with two providers. DDNV (Norfolk, VA) will deploy 20 retrofitted forklifts using hydrogen generated on site via natural gas reformation and dispensed with a mobile refueler. DDNV will also receive a 25 passenger fuel cell shuttle bus for base transportation routes. Finally, DDJC (San Joaquin, CA) will deploy 10 new forklifts using hydrogen generated on site via electrolysis, potentially using solar power.

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Links to Hydrogen-related Websites

  • 4hydrogen.com is maintained by Environmental Media Northwest, a “Bellingham Washington based, non-profit organization that produces PSAs (public service announcements) for radio, television, and movie theatres”. The website contains PSAs, an “about Hydrogen” page and links to other hydrogen-related websites.

  • Hydrogen Cars Business Online (H2CARSBIZ) (www.h2cars.biz) is a hydrogen news site with a focus on hydrogen-powered vehicles.

  • DOE Hydrogen Program Website (www.hydrogen.energy.gov) contains extensive information on hydrogen and related technologies as well as codes and standards. Other DOE related sites are:
    • The DOE National Energy Technology Laboratory (NETL) Website (www.netl.doe.gov)
    • The DOE Solid State Energy Conversion Alliance (SECA) Website (www.seca.doe.gov)

  • HydrogenHighway.com is essentially a ‘meta-news’ site which links to information on hydrogen and hydrogen technology at other public sources. The site also includes opinion pieces.

  • The National Hydrogen Association (NHA) (www.hydrogenus.org) is an industry organization with the mission to “foster the development of hydrogen technologies and their utilization in industrial, commercial, and consumer applications and promote the role of hydrogen in the energy field.” The NHA website contains general hydrogen information as well as media/press and policy/safety information.

  • Fuel Cells 2000 (www.fuelcells.org) focuses on fuel cells but discusses hydrogen basics and the relationship between hydrogen and fuel cells.

  • Other Government Fuel Cell Project Links (http://dodfuelcell.cecer.army.mil/links.php)


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