Development of Sensors for Automotive PEM-based Fuel Cells

DOE Agreement DE-FC04-02AL67616

Brian Knight – UTRCNancy Garland - DOE

DOE Hydrogen and Fuel Cells 2003 Annual Merit Review

May 22, 2003

UTC FC Series 200 - 50 kW PEM

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Development of Sensors for Automotive PEM-based Fuel Cells – Program Summary

• Project duration: 36 months (Apr 2002 – March 2005)

• Total cost: $3.7MM; • DOE cost: $3.0MM (80%) • UTC Cost Share: $0.7MM (20%)• Total expended to date: $0.51MM

• Project Team– UTC Fuel Cells– UTRC– ATMI– Illinois Institute of Technology (IIT)– NexTech Materials

• Project Director: Tom Clark UTC FC

Actuals Versus Spending Plan for Sensors for PEM Fuel Cells

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500

1000

1500

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2500

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A-02 J-02 O-02 F-03 M-03 A-03 D-03 M-04 J-04 S-04 J-05 A-05

Date

Thou

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Spending Planupdated 10/02Actual Expenditures

Sensors for Automotive PEM-based Fuel Cells Project

Contractor and subcontractor PIs:Name Affiliation Phone E-mailTom Clark UTCFC 860-727-2287 tom.clark@utcfuelcells.comBrian Knight UTRC 860-610-7293 knightba@utrc.utc.comFrank DiMeo ATMI 203-794-1100 x4279 fdimeo@atmi.comJoe Stetter IIT 312-567-3443 stetter@iit.eduScott Swartz NexTech 614-842-6606 x103 swartz@nextechmaterials.com

MATERIALS

NEXTECH

DOE program manager and technical advisor:Name Affiliation Phone E-mailNancy Garland DOE 202-586-5673 nancy.garland@ee.doe.govRobert Sutton ANL 630-252-4321 sutton@cmt.anl.gov

Team organization

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Sensors for Automotive PEM Fuel Cells - Motivation

Sensor Performance and Cost Improvements Needed

Gasoline TankFuel Reformer /

CO, NH3, H2S, flow sensors

Air ProcessingSystem / T, RH sensor

Thermal Management System

Cabin safety / H2 sensor

Fuel Cell Stack / CO, H2 , RH, O2 , pressure sensors

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Gasoline Fuel Reformer – Sensor Needs

Sulfur sensor

NH3, T, flow rate sensors

NH3, T, flow rate sensors

Sulfur sensor

NH3, T, flow rate sensors

NH3, T, flow rate sensors

•Chemical sensors–Process streams: before, in, and after reformer, before and in fuel cell stack: CO, H2, O2, H2S, NH3.–Safety [H2].–Response times compatible with function being monitored.

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Sensor Program Deliverables - Task 1 Milestone 22•Automotive PEM Fuel Cell Sensors Suite

–Develop suite of sensors for CO, H2, O2, H2S, NH3, flow, temperature, pressure, and relative humidity

–Meet performance requirements–Develop new measurement principles to meet sensitivity requirements–Improve reliability in harsh fuel cell system environments–Path to low cost (<$10 / sensor) at 500k qty–Develop test rig for sensor evaluation

• Program Reporting–Quarterly progress reviews–Annual and Final technical reports

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Sensor Program Team Responsibilities

Team Member

T ∆P RH flow O2 CO H2 SO2 H2S NH3 Technological Expertise / Responsibility

UTC FC X X X X X X X X X X Testing on S300 Breadboard

UTRC X X X X X X X X X X Testing in reformate simulator

ATMI X X X X Develop Using MEMS Silicon Microhotplate

IIT X X X X X X X X Testing in Benchmark Facility

NexTech X X X X Develop Using Solid State Electrochemical

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Sensor Suiteto DOE

Sensor Test inS300 PEM Plant

MEMS SensorDevelopment –ATMI

Solid State/Chem.Sensor Devel. –NexTech

Physical SensorEvaluation –UTRC

BenchmarkSensor Test –IIT

Sensor Test & Refinement –UTRC

Program LeadAnd EvaluationUTC FC/UTRC

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Sensors for Fuel Cells Program Plan

Calendar Year2002 2003 2004 2005

2.3 Benchmark Facility Testing

1.0 Physical Sensor Development & Test

2.1 Electrochemical Sensor Development

2.2 MEMS Sensor Development

2.5 S300 Gasoline PEM Fuel Cell Testing

NexTech

IIT

ATMI

UTRC / UTC FC

Legend

2.4 Simulated Reformer Stream Testing

3.0 Project Management and Reporting

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Milestones and Deliverables•Physical Sensors – UTRC Target Date

—Develop physical and chemical sensor test facility 04/15/03—Physical sensors survey and down-select 06/30/03—Physical sensor test in simulated reformate stream 11/14/03—Physical sensor performance review 11/24/03

•MEMS Sensor Development – ATMI—Deliver α prototype H2 sensor to IIT 04/14/03—Deliver β prototype H2 sensor to UTRC 12/10/03—Sensor performance review #1 02/04/04—Deliver α prototype Sulfur sensor to IIT 08/25/03—Deliver β prototype Sulfur sensor to UTRC 04/21/04—Sensor performance review #2 06/17/04—Deliver α prototype NH3 sensor to IIT 12/19/03—Deliver β prototype NH3 sensor to UTRC 08/18/04—Prototype delivery to UTC FC 10/21/04

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Milestones and Deliverables•Electrochemical Sensor Development – NexTech Target

Date

—Deliver α prototype CO, NH3, S-compound sensors to IIT 07/07/03*

—Sensor response optimization 09/30/03

—Sensor performance review #1 10/03/03

—Deliver β prototype CO, NH3, S-compound sensors to IIT 04/30/04

—Sensor performance review #2 06/25/04

—Deliver final prototypes to UTC FC 12/15/04* Dependent upon budget release from DOE

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Milestones and Deliverables•Benchmark Facility Testing – IIT Target Date

—Overall sensor performance review 01/02/04

—Performance analysis and interface design 02/11/05

•S300 Gasoline PEM fuel cell testing – UTC FC

—Physical sensor testing 06/15/04

—Chemical sensor testing 02/28/05

—Deliver sensor suite to DOE for go/no go decision 03/15/05

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Technical Progress

• ATMI– Alpha prototype H2 sensor delivered to IIT

•IIT– Modifying facility for new sensors; starting H2 sensor tests

• NexTech– Modifying CO sensor for integration with IIT/UTRC test facilities

• UTRC– Sensor Test Rig and Software Development complete

– Preliminary Physical Sensor survey completed• Most promising technologies and corresponding vendors are identified; presently interacting with vendors and obtaining samples.

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PEM Fuel Cell Gas Stream Simulator and Sensor Testing Rig

House N2

Sensor chamber

D/A , GPIB, data acquisition

Condenser

GC

NDIR

NH3 analyzer

Computer 2 (Analysis)

Computer 1

(Control and data acquisition)

Steam generator1

Back pressure regulator

Heated tubing

Cable

Solenoid valve

Manual valve

Temp. & Pres.

Signal &Control

Check valve

Ar House H2

Excess valves

To vent

To vent

To ventDummy chamber

Chamber temperature: 0~250ºC.

Chamber pressure: 1~3atm

Blower/ circulate Switch valve

N2+H2SMFC1

MFC3CO

CO2

MFC4

MethaneMFC0 100 psi relief valve

House H2

MFC5

D.I. Water LFC

To vent

House N2

MFC6

100 psi relief valve

To vent

Flow meter

In vented cabinet

To vent

Syn gas bottle ( H2, CO, CO2..)

Manual 3-w valve

In vented cabinet

Steam generator2House N2

Sensor chamber

D/A , GPIB, data acquisition

Condenser

GCGC

NDIRNDIR

NH3 analyzerNH3 analyzer

Computer 2 (Analysis)

Computer 1

(Control and data acquisition)

Steam generator1

Back pressure regulator

Heated tubing

Cable

Solenoid valve

Manual valve

Temp. & Pres.

Signal &Control

Check valve

Heated tubing

Cable

Solenoid valve

Manual valve

Temp. & Pres.

Signal &Control

Check valve

Ar House H2

Excess valves

To ventTo vent

To vent

To ventTo ventDummy chamber

Chamber temperature: 0~250ºC.

Chamber pressure: 1~3atm

Blower/ circulate Switch valve

N2+H2SN2+H2SMFC1MFC1

MFC3MFC3COCO

CO2CO2

MFC4MFC4

MethaneMethaneMFC0MFC0 100 psi relief valve

House H2

MFC5MFC5

D.I. Water LFCLFC

To vent

House N2

MFC6MFC6

100 psi relief valve

To vent

Flow meter

In vented cabinet

To vent

Syn gas bottle ( H2, CO, CO2..)

Manual 3-w valve

In vented cabinet

Steam generator2

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Sensor Test Facility at UTRC

Gas Flow Control and Test ChamberOverall System and Controls

Data AcquisitionAnd Control Computer

Mass Flow Controllers Steam Condenser

Facility Interface andSafety System Control

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Physical Sensor Survey•Humidity Sensors

—Polymer Capacitive and MEMS Strain Gauge investigated

•Flow Rate Sensors

—Ultrasonic vortex shedding

—Turbine meter

—Thermal Dissipation

—Differential pressure flow sensing

•Differential Pressure Sensors

—Strain gauge

•Temperature Sensors

—Thermocouples, thermistors and RTD’s

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Selection of Physical Sensors for PEM Fuel Cell Power PlantTechnical and Cost Gap Findings

MediumCollaborate with vendor for miniaturization and significant cost reduction. Needs major development and modifications.

MostDifferential pressure

Most

Most

Most

Meet DOE/FC

tech. specs

HighCollaborate with vendors to improve stability. Identify new technologies.

Flow rate

LowIdentify inexpensive thermistor for high temp. Improve response time.

Temperature

MediumValidate new technologies (MEMS sensors) to improve the condensation recovery time.

Humidity

Technical / Cost gap

Further effortSensor

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•ATMI–H2, SO2, H2S, NH3 Sensor Development–Patented micro hotplate for H2 detection–New sensing technologies being explored for fast response, sensitivity, and cost reduction

100

80

60

40

20

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ista

nce

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s)

76543210

Time (min)

20 seconds on20 seconds off0.25% H 2 in dry air

On

Off

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•NexTech Materials–CO, SO2, H2S, and NH3 Sensor Development–Demonstrated sensitivity for ppm level CO in 75% H2

–New sensing materials and technologies being explored for PEM systems to meet sensitivity, robustness, and cost requirements

Effect of carbon monoxide (1000 ppm) on resistance of NexTech sensorin a baseline gas composition of 50% hydrogen and 50% nitrogen.

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Program Status Summary

• Physical and chemical sensor facility at UTRC built and physical sensor testing begun

• ATMI, IIT, and NexTech fully engaged in program as budget allows • Monthly telecons between UTRC and other subcontractors to

focus closely on coordination issues started in March 2003• UTRC to visit all subcontractor sites within the next two months

to increase direct communication and knowledge transfer

• Physical sensor evaluation underway• H2 sensor testing underway at IIT and UTRC