Fuels and Power at US Army TARDECPaul F. SkalnyDirector, U.S. Army TARDEC – National Automotive Center

North Carolina Military Foundation - Fuels and Power Event

28 Jan 2010 DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

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Agenda

• Introduction

• Ground Vehicle Power and Energy

• End-to-End Energy

• Fuels Qualification / Certification

• Closing

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– Provides full life-cycle engineering support and is provider-of-first-choice for all DODground combat and combat support weapons and vehicle systems.

– Develops and integrates the right technology solutions to improve Current Force effectiveness and provide superior capabilities for the Future Force.

Responsible for Research, Development and Engineering Support to 2,800 Army systems and many of the Army’s and DOD’s Top Joint Warfighter Development Programs

Tank Automotive Research, Development & Engineering Center (TARDEC)

Ground Systems Integrator for the Department of Defense

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Portfolio

Combat Vehicles • Heavy Brigade Combat Teams• Strykers• MRAPs• Ground Combat Vehicles (Future)

Tactical Vehicles• HMMWVs • Trailers• Heavy, Medium and Light

Tactical Vehicles

Force Projection• Fuel & Water Distribution • Force Sustainment • Construction Equipment • Bridging • Assured Mobility Systems

Robotics• Technology Components• Demonstrators• Military Relevant Test & Experimentation• Transition and Requirements Development

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Technology Thrust Areas

Ground Vehicle Power & Mobility• Prime Power (Powertrain)• Non Primary Power• Power & Thermal Management• Energy Storage• Track & Suspension• Alternative Energy

Ground Systems Survivability• Integrated Vehicle Protection Systems• Active Defense• Signature Management• Laser Vision Protection• Ballistic Protection• Crew Survivability

Force Projection Technology • Water Generation, Purification, Storage, Distribution & Quality Surveillance (QS)

• Petroleum Storage, Distribution & QS• Material Handling Equipment• Petroleum, Oils & Lubricants Technology• Mechanical Countermine Equipment• Tactical Bridging•Alternative Fuels

Intelligent Ground Systems • Autonomous Robotics Systems•Safe Operations Technologies • Indirect Vision Technologies • Unmanned Systems Technology Development

• 360°Situational Awareness Technologies • Soldier Machine Interfaces• Connected Vehicles

Vehicle Electronics & Architecture

• Electronics Integration• Data Architecture• Condition-Based Maintenance (CBM+)• Power Architecture/Management

Systems Engineering

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Mission: “The Center will serve as the Army focal point for the

development of dual-use automotive technologies and their application to

military ground vehicles. It will focus on facilitating joint efforts between

industry, government and academia in basic research, collaboration,

technology, industrial base development and professional development.”

U.S. Army National Automotive Center (NAC)

Chartered by Secretary of the Army 21 June 1993

“Leveraging Opportunities to Fill Technology Gaps.”

“Accelerating the infusion of commercially viable technology into military land warfare systems”

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Increases Heat Rejection LoadsLow-grade Heat, Heat Sensitive Electronics

Army Ground Vehicle Power and Energy Drivers

NET-CENTRIC WARFAREWFO#1: Battle Command NetworkNet-Centric KPP

SURVIVABILITYWFO #2: Counter IED and MineSystem Survivability KPP

ENVIRONMENTAL CONTROLWFO #4: Human Dimension

INCREASING POWER DEMANDWFO #3: Power and EnergyEnergy Efficiency KPP

Air Conditioning Thermal Condenser Heat Load

Power for Air ConditioningCompressor, Fan

Vehicle Weight Growth

Additional Armor, Mine Kits

Low-Grade HeatSilicon based Power Electronics

Continuous Power for C4ISRNode on Network, High Bandwidth

Power for APS, IED DefeatElectric Armor, Electric Warfare

REQUIREMENTS DRIVERS FOR POWER AND ENERGY GROWTH ON MILITARY GROUND VEHICLES:

Power for Mobility

Hybrid Electric Drivetrain, Increase Dash/ Top Speed

Future ground vehicle will demand more electric powerThermal loads and rising vehicleweights compound power issuesEfficiency critical to reducing system power demands

Electrical BurdenThermal BurdenWeight Burden

LEGEND:

Increasing power demand, heat rejection difficulties, and vehicle weight gain are all interrelated problems that require a coordinated response across RDECOM.

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Ground Vehicle Power and Energy Technology Taxonomy

Gro

und

Vehi

cle

Pow

er a

nd E

nerg

y Te

chno

logy

Pow

er

Gen

erat

ion

Ener

gy S

tora

geTh

erm

al

Tran

spor

t &

Dis

trib

utio

n

Pow

er C

ontr

ol &

D

istr

ibut

ion

Trac

k &

Su

spen

sion

JP-8 Fuel Cells

Rotary Engines Alternators

Integrated Starter Generator

Turbine Engines

Diesel Engines

Transmissions Traction Motors

Drivelines

Li-Ion / Ultracap Hybrid Energy Storage Capacitors Advanced Batteries

Fuels

RadiatorsHeat Recovery

Thermal Interface Materials Phase Change CoolingAdvanced Electronics

CoolingThermal

Architectures

High Temp Inductors

High Temperature Capacitors

Power Controllers for Power Management Power Converters/Inverters

Wide Band Gap Materials (SiC)

High Temperature SiC Modules Pulse Power

Switching

Track Systems

SuspensionSystems

Elastomer Research

Electronic Stability Control

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TARDEC’s End-to-End Energy Business:From Generation to Application

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End-to-End Energy Initiatives

Alternative Fuel Vehicles & Infrastructure

Domestic Manufacturing Capability

CellsModules Packs

Dual-Use Applications

Advanced Automotive Batteries Enabler of Alternative Energy

Alternative Fuels Program

Fuel EvaluationsChemical CompositionPhysical propertiesFuel system impacts

Engine EvaluationsFuel ignitabilityFuel combustionPerformance / durability

System EvaluationsFuel-system interactionsSystem performance and durabilityFuel specification inputsSuitability of fuel for use in Army

equipment

SANGB HydrogenFilling Station

Advanced Mobile

Microgrid

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Electronic Power Conditioning & Control – Distributed Generation

Mobile Encampment Waste to Electrical Power (MEWEPS)

Plug-in Hybrid Electric Vehicles (PHEV)

Vehicle Inputs

Renewable Inputs

Generator Inputs

Tactical Quiet Generator (TQG)

Electric Power Control and Conditioning (EPCC)

Solar

Supply – Infrastructure - Demand

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Alternative Source Liquid Hydrocarbons for DoD Ground Systems (Tactical/Combat)

Fossil Energy Feedstock(large U.S. resource)

coal

petcokeoil shale

• Various conversion processes dependent on feedstock• Product meeting military or commercial fuel specifications

tallow, fats, lard

wood waste &by-products

agri-wastenon-foodcrops

algae

Biomass Feedstock(renewables)

Petroleum Crude Oil

(declining discovery and production)

Jet Fuels / JP-8

• Blending Stock (FT SPK, HRJ)• “Drop in”• Single Fuel in the Battlefield*

Diesel Fuel / Commercial

• Blending Stock (B100)• “Drop-in” (HRD?, FTD?)• Fuel most Army ground engines designed to operate on *Diesel fuel in ground equip. allowed when supplying

jet fuel not practicable or cost effective

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Qualification / Certification Pipeline

Systems Engineering

RDT&E / Qualification

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TRL 1 TRL 5-6

CertificationTRL 9

100% FT

100% bio

Fuels may travel along conveyor at different rates!

HRJ moving fast, “drafting” FT SPK

DARPA

**Approved Fuels, ASTM D7566Specification for Aviation Turbine Fuels Containing Synthesized Hydrocarbons

non-HRJ bio

Courtesy Dr. Tim Edwards, AFRL (modified)

• Issued September 2009• Criteria for production, distribution, and use of FT jet fuels made from coal, natural gas, or biomass. • Future versions may allow synthetic jet fuels produced using other processes once they are qualified.

Jet A/A-1

JP-8/5

Fischer-Tropsch Synthetic Paraffinic Kerosene (FT SPK)Hydroprocessed Renewable Jet (HRJ)Semi-Synthetic Jet Fuel (SSJF)Fully Synthetic Jet Fuel (FSJF)

HRJ“50/50” blends

Civil Aviation HRJ“50/50” blends

USAF

Potential Alternative

Fuels

Incubator

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RDT&E of Alternative Ground Fuels

Systems Engineering

Market ConnectionManufacturing technologyFuel data, samplesMarket drivers

EMERGINGALTERNATIVE FUELS MARKET

DODDOEIndustryAcademiaFuel ProducersEquipment OEMsOther Government AgenciesStandards Development Organizations

Fuel / Component EvaluationsChemical compositionPhysical propertiesComponent performance / durability

Engine EvaluationsFuel ignitabilityFuel combustionPerformance / durability

System EvaluationsOperabilityPerformanceDemonstrations

Approval and acceptability of alternative fuels for use in

DOD ground equipment.

Poor lubricity fuel may cause increased wear rates in fuel injectors and injection pumps.

Fuel with low cetane ratings may cause cold-starting problems, and misfire and combustion instability, esp. for lt-med load operation.

Low fuel viscosity may result in fuel pump internal leakage and associated loss of power.

Fuel Qualification

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Alternative Fuels Qualification

Systems Engineering

Laboratory Evaluations

Component Evaluations

System Evaluations Demonstrations

Build user knowledge of and confidence in use of fuel.

• Completed– Fuel chemical composition and properties– Materials compatibility evaluations– Fuel blends studies– Limited component/engine/system testing (ground equipment)– Test track evaluation (HMMWV)– Tactical Wheeled Vehicle pilot field demo

• In Progress – Some engine testing (NATO test cycle)– Fuel injection test rig testing (rotary pump, high pressure common rail) – Cetane - Volatility window studies

• Planning– Tactical generator sets testing– Additional component/engine/system testing and demos (including Army Aviation)

Develop data needed to assess fuel’s suitability for use.

Blends of FT SPK and JP-8 undergoing qualification; based on similarity of HRJ with FT SPK, blends of HRJ and JP-8 will be integrated to conduct a concurrent qualification.

Timelines for evaluations and demos dependant on the availability of test fuel volumes required.

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Beyond Traditional BoundariesNew Partnership Strategies…

Memorandum of Agreement with DOE, Energy Efficiencyand Renewable Energy, Office of Vehicle Technologies

Department of Energy (DOE) $25B Loan GuaranteeTARDEC supported review of proposals that leveraged expertise in Ground Vehicle Power & Mobility and Lightweight Materials

Alliance(s) with MEDC, DOE, Oakridge National LaboratoryAdvanced BatteriesAdvanced Lightweight MaterialsAlternative Fuels

Advanced Automotive Battery InitiativeIndustry, Government and Academia vetted White Paper

Advanced Vehicle & Power InitiativeIndustry, Government and Academia vetted White Paper

Michigan Economic Development Corporation (MEDC)Cooperative Research and Development Agreement (Centers of Energy Excellence)Michigan Automotive Robotics Cluster (MARC)

User Forums: Hybrid Truck Users Forum (HTUF); Commercial Construction Equipment Users Forum (CCEUF); Class 8 Truck Users Forum (Class8TUF)

Fuel Efficiency ground vehicle Demonstrator (FED)