High Specific Power Primary Fuel Cell System

Precision Combustion, Inc. (PCI) proposes to further mature a Primary Fuel Cell (PFC) System that will meet NASA’s lunar mission target specifications of (i) high specific power (>2,000 W/kg), (ii) high current density (>200 mA/cm2), (iii) long service life (a final operational life of >10,000 hrs is targeted), and (iv) operability with H2/O2, CH4/O2, and other propellants. The PFC system contains multiple innovations and will comprise SOFC and internal reforming catalyst that permit a potential for high fuel utilization and very high specific power, while allowing SOFC operation with hydrocarbon fuels (e.g., CH4 and scavenged propellants). The innovative design and integration of at-anode reforming elements have been demonstrated for effective internal heat exchange and moderate the operating temperature of the stack. The approach also offers the potential to operate with a wide range of input fuels without forming carbon. At the end of Phase II, a 250 W PFC system prototype will be developed based on sub-scale test data. In the follow-on Phase II-E, we will mature the PFC system for air-independent operation (with CH4 fuel), suitable for NASA mission requirements. The resulting prototype configuration has the potential to be a core component within overall fuel cell systems to provide capabilities that supersede low temperature PEM stacks (i.e., enable operation directly with CH4) while overcoming shortcomings of other traditional alternative technologies (i.e., faster start-up, higher power density). This effort would be valuable to NASA as it would significantly reduce the known long-duration mission technical risks and increase mission capability/durability/efficiency while at the same time increasing the TRL of the solid oxide systems for lunar/Mars power generation and ISRU application. The technology also offers multiple terrestrial/earthbound spinoffs ranging from low-carbon power generation to hydrogen and chemicals production.

Targeted applications include power generation for Lunar and Martian bases and surface operations, such as rovers. Extending the technology in a future phase to electrolysis and energy storage for base operations can be implemented. Once qualified for air-independent operation, the system can generate electrical power for habitats and next generation ISRU components and docking stations. For NASA aeronautics applications, it can be implemented on terrestrial aircraft with requirements of rapid transient and turnaround time, and lower weight.

These include SOFC-based military generators and vehicle APUs; civilian vehicle APUs and range extenders; electrified aircraft power generation; and distributed power generation for large stationary and mobile fuel cell applications. It is also applicable for unmanned applications such as Unmanned Ground Vehicles (UGVs) for power/propulsion and use in H2 generation systems for vehicle refueling.

This is early/mid-stage (TRL 5) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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