Open Competition 1 - Electronics and Photonics

Direct Fuel Power Module

Sponsor: NexTech Materials

• Project Performance Period: 11/1/2002 - 6/30/2005
• Total project (est.): $2,245,519.00
• Requested ATP funds: $2,000,000.00

Fuel cells -- devices that efficiently convert chemical energy to electrical energy without combustion or moving parts -- are promising technologies for the supply of clean and affordable electric power, but significant technical hurdles must still be overcome. Proton exchange membrane fuel cells are costly because fabrication requires expensive membranes and precious metals. Direct methanol fuel cells have potential, but currently fail to provide useful power density levels for portable appliances. Current solid oxide fuel cells (SOFC) are suitable for stationary power plants, but disadvantages include high cost, uncertain long-term reliability, and high operating temperature. NexTech proposes to develop the Direct Fuel Power Module (DFPM), a revolutionary SOFC for appliances requiring 5 watts to 5 kilowatts of power. The novel design integrates multiple series-connected thin film cells on porous flattened tube substrates that combine the best features of tubular and planar SOFCs by eliminating sealing problems and providing high volumetric efficiency. Advanced materials for electrolytes, anodes, and cathodes reduce operating temperature to 550 to 750 degrees Celsius, which allows using low-cost interconnect materials. The DFPM will operate directly on hydrocarbon fuels without reforming (adding steam to the fuel), greatly simplifying system design. Being able to run on either gaseous (methane) or liquid (propane or butane) fuels provides fuel flexibility. Prototype module platforms with 20- and 150-watt power outputs will be produced and tested to demonstrate feasibility. NexTech, a small business, is unable to fund this high-risk project internally. The risks are too high for other companies, and venture capital is deterred by the long payback period. If successful, this technology has the potential to help U.S. manufacturers win a larger share of the portable power and rechargeable battery markets, which foreign companies now dominate. Consumers will benefit from applications that include propane-fueled 5-50 Watt power supplies for portable electronic appliances, 1-3 kilowatt automotive auxiliary power units, and 3-5 kilowatt systems for residential power and heat. Additionally, DFPM technology could meet the military's urgent need for compact, lightweight, highly efficient, and continuous power sources to replace existing battery-based systems. Functional Coating Technology (Evanston, Ill.) will contribute design concepts and thin film materials and fabrication expertise, and Oak Ridge National Laboratory (Oak Ridge, Tenn.) will help develop the glass-ceramic seals.

For project information:

William J. Dawson, (614) 842-6606
dawson@nextechmaterials.com

ATP Project Manager

Gerald Castellucci, (301) 975-2435
gerald.castellucci@nist.gov