Evolution of Fuel Cells and Batteries for the Military: Trends and Markets

SUMMARY

STUDY GOALS AND OBJECTIVES

Modern technology has been embraced by the Department of Defense (DoD) as aresource to enhance the offensive and defensive capabilities of the militaryservices. This is an important factor as our relatively small military forcesare deployed both in combat, hostile environments, peacekeeping, and continuedtraining scenarios far beyond that envisioned when the military was reduced insize by 40% in the 1990s. The focus of this technical/market report is on theground forces and how fuel cells will be employed within a 5-year horizon andinto the future. It also identifies the early market opportunities for fuelcells in military applications.

This document looks at the technologicalevolution and advances for military applications requiring primary,supplementary and backup power. It addresses applications for stationary,mobile, and portable power requirements, and includes existing and projecteduses and markets for fuel cells and advanced batteries within the military. Itis intended as an update and supplement to the Business Communications Co., Inc.(www.buscom.com) much longer report GB-248 Advanced Military Batteries for theDigital Battlefield: A Technology Challenge. This is an abbreviated report andthe reader desiring additional information on aspects of military standards,environmental issues, or little used military unique batteries will find thatinformation in the other BCC, Inc. document. There are also related publicationsmentioned at the end of this introduction.

A principal objective is toidentify what are the trends that are likely and appropriate for the use of fuelcells for large stationary power needs, mobile power, and small-scale powerneeds. Fuel cells are expected to be deployed for some military power needs by2006. Advanced batteries and generators for mobile electric power will continueto have a role. These electrochemical devices have the potential to offeragility, stability, and efficient power to replace traditional hydrocarboncombustion-driven platforms and battery-powered systems. The market for militaryfuel cells is poised to take off in 5 to 10 years, but the opportunities arebalanced by a number of barriers that must be overcome before military fuelcells can sustain the anticipated multi-billion dollar markets anticipated bymid-21st century forces.

REASONS FOR DOING THE STUDY

It is important to understand how the military will move toward the use ofhigh technology stationary, mobile, or portable power systems. Many differentgovernmental organizations are involved in shaping the broad future of advancedpower sources in the military. The present demonstration and funding programsare part of the enabling force for fuel cell and advanced battery applicationdevelopments, but there are other factors as well. Consideration must be givento the present power requirements and their deficiencies. Identifying thehurdles to be overcome in moving fuel cells into the military is a factor thatmust be recognized.

Some advanced power systems need only be cost effective,others must be robust enough for combat situations, and other systems may soonbe an effective replacement and utilized in secure or homeland sectors.Commercial off-the-shelf (COFT) military acquisition programs seem likely as thetechnology emerges, at least for peacetime or stable deployed environments.There are potential benefits as well as potential barriers to the use of fuelcells by the military.

CONTRIBUTIONS OF THE STUDY

This technical market report is intended to provide a unique analysis of thefuel cell technology potential in the U.S. military. It should be of specialinterest to those responsible for making key technology investment decisionswithin their organization. Any organization involved in developing or assemblingor hoping to deploy next-generation military platforms and systems requiringstationary, mobile or portable power will find this study valuable. This studyprovides technology and use potential applications through the year 2008.

SCOPE AND FORMAT

The military continues to seek more cost effective, reliable, and robustpower sources for its applications. A more detailed look is given to thestationary, mobile electric power, transportation and portable applications ofthe ground forces because that is where there is the most perceived need. Thereare substantial Navy and Air Force requirements as well.

INFORMATION SOURCES

An in-depth analysis of military sources, Department of Defense (DoD), andrelated technical and business literature and published dissertations, combinedwith a review of the history of the technologies involved, interviews withindustry experts, federal government researchers, and contractors provided anassessment of the outlook, the progress and the deployment of fuel cells in theUnited States military. Other information sources include product literaturefrom suppliers, scientific references, conferences, and patent searches.

Thereport makes projections for market sectors in terms of constant dollarsrepresenting real growth. Historical values are presented for the given year.The market analyzed is for the United States.

TABLE OF CONTENTS

INTRODUCTION

• STUDY GOALS AND OBJECTIVES
• REASONS FOR DOING THE STUDY
• CONTRIBUTIONS OF THE STUDY
• SCOPE AND FORMAT
• INFORMATION SOURCES
• AUTHORS' CREDENTIALS
• RELATED BCC, INC. CREDENTIALS
  • REPORTS
  • MONTHLY NEWSLETTERS
• ABOUT BCC
• DISCLAIMER
• BCC ONLINE SERVICES

SUMMARY

• Summary Table:
  ADVANCED POWER SOURCES FOR MILITARY APPLICATIONS BY TYPE, THROUGH 2008 ($MILLION)
• Summary Figure:
  ADVANCED POWER SOURCES FOR MILITARY APPLICATIONS BY TYPE, 1980-2008 ($MILLION)

OVERVIEW

• IMPACT OF ADVANCED TECHNOLOGY
  • IMPACT OF ADVANCED TECHNOLOGY (CONTINUED)
• BACKGROUND
• OBSERVATIONS
• DEPLOYED AND NON-DEPLOYED MILITARY APPLICATION REQUIREMENTS
• DOD ORGANIZATIONAL INVOLVEMENT IN FUEL CELL DEVELOPMENT
• FUEL CELL TEST AND EVALUATION CENTER (FCTEC)
• Table 1 DOD FUEL CELL TEST AND EVALUATION CENTER OBJECTIVES
  • CAPABILITIES
• Table 2 SUMMARY FCTEC CAPABILITIES
  • Concurrent Technologies Corporation (CTC)
  • DEFENSE ADVANCED RESEARCH PROJECTS AGENCY (DARPA)
    • TECHNICAL OFFICES
    • Support Offices
    • Palm Power Program
    • RESEARCH, DEVELOPMENT & ENGINEERING COMMAND (RDECOM)
• Figure 1: RDECOM ORGANIZATION (PROVISIONAL)
  • TACOM/National Automotive Center (NAC)
• Table 3 NATIONAL AUTOMOTIVE CENTER ORGANIZATIONAL STRUCTURE
  • Communications-Electronic Command (CECOM)/Communications-ElectronicResearch, Development and Engineering Command (CERDEC)
  • Communications-Electronic Command...(Continued)
  • Army Research Lab (ARL)
  • TACTICAL TO PRACTICAL
    • DEPARTMENT OF HOMELAND SECURITY (DHS)
    • Directorates
• Table 4 DEPARTMENT OF HOMELAND SECURITY DIRECTORATES
  • FUNDING: ENABLING FACTOR OR PROBLEM FOR FUEL CELLS?
• Table 5 FUEL CELLS FOR MILITARY APPLICATIONS BY TYPE, THROUGH 2008 ($MILLIONS)
• Figure 2 FUEL CELLS FOR MILITARY APPLICATIONS BY TYPE, 1980-2008 ($MILLIONS)
  • FUNDING: ENABLING FACTOR OR...(CONTINUED)

DEPARTMENT OF DEFENSE FUEL CELL APPLICATIONS

• STATIONARY POWER
  • KEY CONSTRUCTION ENGINEERING RESEARCH LABORATORY (CERL) FUEL CELLPROGRAMS
• Table 6 ADVANCED POWER AND ENERGY PROGRAM GOALS
• Table 7 ADVANCED POWER AND ENERGY PROGRAM OBJECTIVES
• Table 7 (CONTINUED)
  • Activities Supporting Fuel Cell Deployment
• Table 8 ADVANCED POWER AND ENERGY PROGRAM TASKS
  • FIRST GENERATION FUEL CELL PROGRAM
  • Monies Appropriated
  • Phosphoric Acid Sites and Performance
  • CERL RESIDENTIAL FUEL CELL PROGRAM
• Table 9 CERL SITE PERFORMANCE, FY 2001-2002
  • INSTALLATION CASE STUDIES
  • Watervliet Arsenal
  • McChord AFB
  • Preliminary Project Description
  • Hydrogen Storage and Supply
  • Data Acquisition
  • Economic Analysis
  • Geiger Field Air National Guard Facility
  • Hydrogen Supply
  • Economic Analysis
  • VALUE OF FUEL CELLS FOR STATIONARY MILITARY APPLICATIONS
• Table 10 VALUE OF FUEL CELLS BY TYPE FOR STATIONARY MILITARY APPLICATIONS,THROUGH 2008 ($ MILLIONS)
  • TRANSPORTATION
    • STRYKER 8-WHEEL DRIVE ARMORED VEHICLE
    • EVOLUTIONARY VARIANTS
    • Overseas Delivery Requirements
    • COMBATT Program
    • Dodge Ram 2500 COMBATT C-11 Hybrid
    • GM COMBATT Initiatives
    • Reality Check
    • FUEL SUPPLY
• Table 11 ENERGY DENSITY FOR DOD MAIN FUEL TYPES
  • Desulfurizing Gasoline or Diesel Fuel
  • Surrogate JP-8 into Hydrogen
  • VALUE OF FUEL CELLS IN MILITARY TRANSPORTATON
• Table 12 VALUE OF FUEL CELLS FOR MILITARY TRANSPORTATION, BY TYPE, THROUGH2008 ($ MILLIONS)
  • MOBILE ELECTRIC POWER (MEP)
    • TACTICAL ELECTRIC POWER
    • EVOLVING FUEL CELL PROJECTS
    • Logistic Fuel Processor
    • VALUE OF MOBILE ELECTRIC POWER FUEL CELLS BY TYPE
• Table 13 VALUE OF FUEL CELLS BY TYPE FOR MOBILE ELECTRIC POWER, THROUGH2008 ($ MILLIONS)
  • PORTABLE POWER
    • INFLUENCE OF DEVICES
    • Fuel Cell or Advanced Battery
• Table 14 ZINC-AIR BA/8180/U SPECIFICATIONS
  • VALUE OF FUEL CELLS IN MILITARY PORTABLE APPLICATIONS
• Table 15 VALUE OF FUEL CELLS BY TYPE FOR MILITARY PORTABLE APPLICATIONS,THROUGH 2008 ($ MILLIONS)
  • ADDITIONAL INITIATIVES
    • DRONES FOR THE MARINES
    • SHIP POWER
    • AIRPLANES AND OTHER EQUIPMENT
    • COUNTERTERRORISM
    • SmarTruck II
    • Smartruck II (Continued)
    • NON-U.S. INITIATIVES
    • U-31/U-32 Submarines (Germany)
    • VALUE OF ADDITIONAL INITIATIVES FOR FUEL CELLS
• Table 16 VALUE OF ADDITIONAL INITIATIVES FOR FUEL CELLS BY TYPE, THROUGH2008 ($ MILLIONS)

HYDROGEN FUEL CELLS FOR MILITARY DEVICES AND SYSTEMS

• TECHNICAL SETTING
  • CONSIDERATIONS FOR CURRENT MILITARY FUEL CELL RESEARCH
• Table 17 RESEARCH MOST RELEVANT FOR MILITARY FUEL CELL APPLICATIONS
  • EVOLUTION OF FUEL CELLS AND THERMODYNAMICS
  • PROTON EXCHANGE MEMBRANE (PEM) FUEL CELL
    • OPERATION COMPLEXITIES
• Figure 3 WATER TRANSPORT IN A PEM FUEL CELL
  • Needed Components
  • R&D HIGHLIGHTS
  • Development at Gas Technology Institute
  • Development at Plug Power
  • Patent Developments of the United States Army
  • Development at Lynntech
  • Developments at Altergy Systems
  • Synopsis of Polymers for Ion Selective Membranes for Pems
• Table 18 SYNOPSIS OF POLYMERS FOR ION SELECTIVE MEMBRANES FOR PEM FUELCELLS
  • DIRECT METHANOL FUEL CELL (DMFC)
  • Operation
  • Los Alamos National Laboratory
  • R&D Highlights
  • Developments at Ball Aerospace
  • Developments at Energy Visions
  • Developments at Genesis Fueltech, Inc.
  • Developments at Giner Electrochemical Systems
  • Developments at Hewlett Packard
  • Developments at Manhattan Scientifics, Inc.
  • Developments at MTI Micro
  • Developments at Medis Technologies
  • Progress at Other Organizations
  • VALUE OF PEM FUEL CELLS FOR THE MILITARY
• Table 19 VALUE OF PEM FUEL CELLS FOR THE MILITARY, THROUGH 2008 ($MILLIONS)
  • INDUSTRY STRUCTURE AND INFORMATION BANK FOR MILITARY PEM/DM FUELCELLS
  • Industry Structure and Information Bank...(Continued)
  • Industry Structure and Information Bank...(Continued)
  • SOLID OXIDE FUEL CELLS (SOFC)
  • OPERATION
  • Components and Construction
  • Electrolyte
  • Electrodes
  • Tubular Configuration
  • Tubular Configuration (Continued)
  • Closed-End Ceramic Tubes
  • Planar Configuration
  • Flat Plate Design
  • Monolithic
  • R&D Highlights
  • Development at Acumentrics
  • Developments at Adaptive Materials, Inc.
  • Developments at Gas Technology Institute
  • Developments at Siemens Westinghouse
  • VALUE OF SOLID OXIDE FUEL CELLS FOR THE MILITARY
• Table 20 VALUE OF SOLID OXIDE FUEL CELLS FOR THE MILITARY, THROUGH 2008 ($MILLIONS)
  • INDUSTRY STRUCTURE AND INFORMATION BANK FOR MILITARY SOFC
  • MISCELLANEOUS TYPES OF FUEL CELLS
    • MOLTEN CARBONATE FUEL CELLS (MCFC)
    • Operation
    • Manifolds
    • Electrodes
    • Process at the Electrodes
    • R&D HIGHLIGHTS
    • Improved Lifetimes
    • Improved Lifetimes Continued)
    • INFORMATION BANK FOR MCFC MANUFACTURERS AND SUPPLIERS
    • PHOSPHORIC ACID
    • PROTONIC CERAMIC FUEL CELL
    • REGENERATIVE
  • HYBRIDS
• Figure 4 REALATED ADVANCED TECHNOLOGIES
  • ULTRACAPACITOR
  • SUMMARY VALUE OF HYDROGEN FUEL CELLS FOR MILITARY APPLICATIONS
• Table 21 VALUE OF HYDROGEN FUEL CELLS FOR MILITARY APPLICATIONS, BY TYPE,THROUGH 2008 ($ MILLION)
• Figure 5 VALUE OF HYDROGEN FUEL CELLS FOR MILITARY APPLICATIONS, BY TYPE,1980-2008 ($ MILLION)
  • SUMMARY VALUE ... APPLICATIONS (CONTINUED)

METAL-AIR FUEL CELLS

• INTRODUCTION
• BACKGROUND
  • ELECTRONEGATIVITY
  • OPERATION
  • Operation (Continued)
  • ELECTROCHEMICAL PACK
• HYBRIDS
• DEVELOPMENTS IN THE ZINC-AIR FUEL CELL INDUSTRY
  • PROGRESS AT AROTECH/ELECTRIC FUEL CORP
  • Progress at Arotech/Electric Fuel Corp (Continued)
  • PROGRESS AT EVIONYX, INC.
  • PROGRESS AT GILLETTE/DURACELL
  • PROGRESS AT POWERZINC ELECTRIC, INC.
  • ADVANCES AT METALLIC POWER
  • STATUS OF RAYOVAC
• VALUE OF ZINC-AIR BATTERIES IN MILITARY SYSTEMS/DEVICES
• Table 22 VALUE OF ZINC-AIR BATTERIES IN MILITARY SYSTEMS/DEVICES, THROUGH2008 ($ MILLIONS)
• Figure 6 VALUE OF ZINC-AIR BATTERIES IN MILITARY SYSTEMS/DEVICES,1980-2008 ($ MILLIONS)
  • INFORMATION BANK FOR ZINC-AIR MANUFACTURERS AND SUPPLIERS

UPDATED LOOK AT ADVANCED BATTERIES FOR MILITARY SYSTEMS/DEVICES

• LEGACY TECHNOLOGY
  • TYPICAL MILITARY BATTERY USES
• LITHIUM BATTERIES
  • LITHIUM-SULFUR DIOXIDE BATTERIES
  • Developments at Saft
  • VALUE OF LITHIUM SULFUR DIOXIDE BATTERIES IN MILITARYSYSTEMS/DEVICES
• Table 23 VALUE OF LITHIUM SULFUR DIOXIDE BATTERIES IN MILITARYSYSTEMS/DEVICES, THROUGH 2008 ($ MILLIONS)
  • LITHIUM-MANGANESE DIOXIDE BATTRIES
  • Secondary Li-MnO₂
  • Primary Li-MnO₂
  • Pouch Design
  • Developments at Ultralife
  • Technology at Duracell, Inc.
  • VALUE OF LITHIUM-MANGANESE DIOXIDE BATTERIES IN MILITARYSYSTEMS/DEVICES
• Table 24 VALUE OF LITHIUM-MANGANESE DIOXIDE BATTERIES IN MILITARYSYSTEMS/DEVICES, THROUGH 2008 ($ MILLIONS)
  • LITHIUM-ION/POLYMER
  • Temperature Performance
  • CECOM Electrolytes
  • Battery Engineering and Hitachi Maxell Electrolytes
  • Design of "Smart" Cells
  • Army Research Laboratory (ARL) Anode Research
  • Development at Litech
  • Developments at Oak Ridge Micro-Energy
  • Developments at Saft Lithium-Ion/Polymer Technology
  • Developments at Alliant Techsystems
  • VALUE OF LITHIUM-ION/POLYMER BATTERIES IN MILITARY SYSTEMS/DEVICES
• Table 25 VALUE OF LITHIUM-ION/POLYMER BATTERIES IN MILITARYSYSTEMS/DEVICES, THROUGH 2008 ($ MILLIONS)
  • NICKEL METAL HYDRIDE
    • INDUSTRY CHANGES
    • OPERATION IN MILITARY COMMUNICATIONS
    • VALUE OF NIMH BATTERIES IN MILITARY SYSTEMS/DEVICES
• Table 26 VALUE OF NICKEL METAL HYDRIDE BATTERIES IN MILITARYSYSTEMS/DEVICES, THROUGH 2008 ($ MILLIONS)
  • OTHER
  • SUMMARY VALUE OF ADVANCED MILITARY BATTERIES BY CHEMICAL TYPE
• Table 27 ADVANCED MILITARY BATTERIES, BY TYPE, THROUGH 2008 ($ MILLIONS)
• Figure 7 ADVANCED MILITARY BATTERIES, BY TYPE, 1980-2008 ($ MILLIONS)
  • INFORMATION BANK FOR MILITARY LITHIUM BATTERY MANUFACTURERS ANDSUPPLIERS
  • Information Bank for Military Lithium...(Continued)
  • Information Bank for Military Lithium...(Continued)
  • Information Bank for Military Lithium...(Continued)
  • Information Bank for Military Lithium...(Continued)

LIST OF TABLES

Summary Table:
ADVANCED POWER SOURCES FOR MILITARY APPLICATIONS BY TYPE, THROUGH 2008 ($MILLION)

Table 1 DOD FUEL CELL TEST AND EVALUATION CENTER OBJECTIVES

Table 2 SUMMARY FCTEC CAPABILITIES

Table 3 NATIONAL AUTOMOTIVE CENTER ORGANIZATIONAL STRUCTURE

Table 4 DEPARTMENT OF HOMELAND SECURITY DIRECTORATES

Table 5 FUEL CELLS FOR MILITARY APPLICATIONS BY TYPE, THROUGH 2008 ($MILLIONS)

Table 6 ADVANCED POWER AND ENERGY PROGRAM GOALS

Table 7 ADVANCED POWER AND ENERGY PROGRAM OBJECTIVES

Table 8 ADVANCED POWER AND ENERGY PROGRAM TASKS

Table 9 CERL SITE PERFORMANCE, FY 2001-2002

Table 10 VALUE OF FUEL CELLS BY TYPE FOR STATIONARY MILITARY APPLICATIONS,THROUGH 2008 ($ MILLIONS)

Table 11 ENERGY DENSITY FOR DOD MAIN FUEL TYPES

Table 12 VALUE OF FUEL CELLS FOR MILITARY TRANSPORTATION, BY TYPE, THROUGH2008 ($ MILLIONS)

Table 13 VALUE OF FUEL CELLS BY TYPE FOR MOBILE ELECTRIC POWER, THROUGH2008 ($ MILLIONS)

Table 14 ZINC-AIR BA/8180/U SPECIFICATIONS

Table 15 VALUE OF FUEL CELLS BY TYPE FOR MILITARY PORTABLE APPLICATIONS,THROUGH 2008 ($ MILLIONS)

Table 16 VALUE OF ADDITIONAL INITIATIVES FOR FUEL CELLS BY TYPE, THROUGH2008 ($ MILLIONS)

Table 17 RESEARCH MOST RELEVANT FOR MILITARY FUEL CELL APPLICATIONS

Table 18 SYNOPSIS OF POLYMERS FOR ION SELECTIVE MEMBRANES FOR PEM FUELCELLS

Table 19 VALUE OF PEM FUEL CELLS FOR THE MILITARY, THROUGH 2008 ($MILLIONS)

Table 20 VALUE OF SOLID OXIDE FUEL CELLS FOR THE MILITARY, THROUGH 2008 ($MILLIONS)

Table 21 VALUE OF HYDROGEN FUEL CELLS FOR MILITARY APPLICATIONS, BY TYPE,THROUGH 2008 ($ MILLION)

Table 22 VALUE OF ZINC-AIR BATTERIES IN MILITARY SYSTEMS/DEVICES, THROUGH2008 ($ MILLIONS)

Table 23 VALUE OF LITHIUM SULFUR DIOXIDE BATTERIES IN MILITARYSYSTEMS/DEVICES, THROUGH 2008 ($ MILLIONS)

Table 24 VALUE OF LITHIUM-MANGANESE DIOXIDE BATTERIES IN MILITARYSYSTEMS/DEVICES, THROUGH 2008 ($ MILLIONS)

Table 25 VALUE OF LITHIUM-ION/POLYMER BATTERIES IN MILITARYSYSTEMS/DEVICES, THROUGH 2008 ($ MILLIONS)

Table 26 VALUE OF NICKEL METAL HYDRIDE BATTERIES IN MILITARYSYSTEMS/DEVICES, THROUGH 2008 ($ MILLIONS)

Table 27 ADVANCED MILITARY BATTERIES, BY TYPE, THROUGH 2008 ($ MILLIONS) 

LIST OF FIGURES

Summary Figure:
ADVANCED POWER SOURCES FOR MILITARY APPLICATIONS BY TYPE, 1980-2008 ($MILLION)

Figure 1: RDECOM ORGANIZATION (PROVISIONAL)

Figure 2 FUEL CELLS FOR MILITARY APPLICATIONS BY TYPE, 1980-2008 ($MILLIONS)

Figure 3 WATER TRANSPORT IN A PEM FUEL CELL

Figure 4 REALATED ADVANCED TECHNOLOGIES

Figure 5 VALUE OF HYDROGEN FUEL CELLS FOR MILITARY APPLICATIONS, BY TYPE,1980-2008 ($ MILLION)

Figure 6 VALUE OF ZINC-AIR BATTERIES IN MILITARY SYSTEMS/DEVICES,1980-2008 ($ MILLIONS)

Figure 7 ADVANCED MILITARY BATTERIES, BY TYPE, 1980-2008 ($ MILLIONS)