Direct Methanol Fuel Cell Systems
for Portable Applications
Fuel Cell Seminar & Exposition
Nov 18,
Nov.
18 2009
Seong
g Kee Yoon, Youngseung
g
g Na, Y. Joung,
g J. Park,
Y. Kim, L. Hu, I. Song, H. Cho
Samsung SDI
Contents
Ⅰ
Introduction to Samsung SDI
Ⅱ
Portable Fuel Cell Activities in Samsung SDI
Ⅲ
DMFC Systems for Military Applications
Ⅳ
Summary
2/21
Business Concept of Samsung SDI
Samsung SDI is reborn as a leading environment friendly & clean energy
company with the new vision.
3/21
Samsung Portable Fuel Cells
2W Passive DMFC:
Cell Phone Charger
Performance
12--20W Active DMFC:
12
Laptop Power
Performance
25W Active DMFC:
Soldier Power
Performance
Output Power
2.6 W
Output Power
12 W
Input Voltage
2.8 V
Input Voltage
9.9~16.5 V
Output Voltage
4.2 V
Output Voltage
16.4V
Output Voltage
7
7.2~8.45
2~8 45 V
Energy Storage
8.3 Wh
Energy Storage
280Wh
Energy Storage
120 Wh
Energy Density
55 Wh/L
Energy Density
510Wh/kg
Energy Density
Lifetime
> 400 hrs
Physical
Physical
Total Volume
150.7cc
Total Weight
182.77g
Cartridge volume
26.7cc
Cartridge weight
30.97g
Environmental
Operation Temp.
Orientation Indep.
45°C
360°
Total Volume
Total Weight
202.7 Wh/L
601.9cc
738.5g
Cartridge volume
132.6cc
Cartridge weight
122.0g
Storage Temp.
Orientation Indep.
4/21
25W
Physical
Total Volume
2.52L
Total
ota Weight
eg t
1.87kg
.8 g
Cartridge volume
300.2cc
Cartridge weight
262g
Environmental
Environmental
O
Operation
i
T
Temp.
Output Power
10
10~40°C
40°C
-10°C, 60°C
360°
Operation Temp
Temp.
-5~45°C
-5~45
C
Orientation Indep.
360°
Press Release: 2W Cell Phone Charger
’06 11.
’06.
11 2
27 (SAIT – SDI)
5/21
Press Release: Laptop Power
’06. 12. 27 (SEC-SDI-SAIT)
’06. 12. 27 (MBC, KBS)
6/21
Key Technologies of DMFC
S t
System
Modules
Materials
Catalyst
Stack
HEX
Cartridge
MEA
Membrane
BOP
Recycler
Circuit
• High power density/efficiency MEA
• Efficient stack design
g technology
gy
• Low cost catalysts
S t
packaging
k i
ttechnology
h l
• System
• Reproducible stack manufacturing technology
• High efficiency operating
• MEA manufacturing technology
• Heat/water control technology
• Fuel supply control logic
• High efficiency circuit design
Core technology under development
Established core technology
• Contamination filtering technology
• Low cost manufacturing technology
To be developed
7/21
technology
• System
y
operating
g logic
g based on
environmental conditions
• Low cost manufacturing technology
25W DMFC System:
Soldier Power
8/21
Why Fuel Cell for Soldier Power?
Weight for
3-Day Mission
Energy
Density
Lifetime
Energy Cost
(USD/1kWh)
Primary Battery
(BA-5590)
8.16kg (8ea)
176Wh/kg
One time use
$421.58
y Battery
y
Secondary
(BB-2590)
10 88k (8ea)
10.88kg
(8 )
132Wh/k
132Wh/kg
220
cycle life
$21 73
$21.73
Fuel Cell
(DMFC)
3.4kg
(1unit & 6cartridges)
510Wh/kg
3,000hrs
$10.90
Power Source
66% / 75% decrease
97% / 50% decrease
in weight
in cost
vs. primary / secondary bat.
vs. primary / secondary bat.
9/21
25W DMFC System: Soldier Power
Product
- Lightweight military power for soldiers
- 25W DMFC system
Purpose
- Decrease battery weight for long-hour (72-96hr) missions
- Decrease primary battery cost for field training
- Provides
P
id green energy to
t the
th battle
b ttl fi
field
ld
Concept
- Provides 25W nominal power (55W peak) via hybridization with Li-ion battery
- Decrease power weight by 66% and 75% compared to primary and secondary batteries, respectively,
based on a 72hr-mission (primary battery: 8.16kg, secondary battery: 10.88kg, FC: 3.14kg)
- Provides instant power through fuel cartridge replacement
10/21
25W DMFC System: Features
Features
1 power: 25W
1.
2. volume/weight: 2.52L / 1.87kg (dry weight)
3. energy capacity: max. 280Wh (1 cartridge)
4. fuel: Neat Methanol
5. sound level: ~45dBA
6. type: primary power source for soldiers
eatu es
7. features
- provides instant power from inner battery
- stable stack operation independent of exterior load through inner battery charging logic
y
- thermal reliability
▶ thermal cycling : -5~45° Heat Cycle Adaptive Operation Control
- stable operation independent of on-off power cycles and operating directions (±180°)
- real-time monitoring of fuel cell operation and inner battery state
11/21
Power Unit
[Front]
[Back]
fuel cartridge cover
[Top]
air intake
air exhaust
12/21
Display & Switch
- Power Status
- Fuel & Battery Remainder
- Operation Mode
- Night Vision
Internal Battery and Fuel Cartridge

Li-ion Battery
[Battery Charger]
- Dimension: 7.4cm×9.0cm×2.5cm (166.5cc)
- Weight: 228g
- Type:
T
4S1P Li
Li-ion
i Pack
P k
- Capacity: 2.6Ah
- Output Voltage: DC 14.8V

Fuel Cartridge
- Dimension:
Di
i
7.5cm×13.8cm×2.9cm
7 5 ×13 8 ×2 9
(300
(300.2cc)
2 )
- Weight: 262g (260cc Fuel included)
- Fuel Connector: Type D (IEC TC 105 standard)
- Energy Capacity: ~260Wh
- Data Communication w/ Power Unit (ID,
(ID Remainder)
13/21
[Fuel Charger]
Monitoring Program
14/21
Key Features to be Highlighted
Ⅰ
High System Efficiency
Ⅱ
Orientation Independent Operation
Ⅲ
Optimized Heat & Water Management
15/21
I. High System Efficiency
1) High system efficiency
efficiency, 2) Low noise level,
level 3) Orientation independent operation
Test Results
(670.1b) Fuel Consumption Test
Fuel
Efficiency
1.13Wh/cc
(661.2) Sound Level Test
45dBA
(eq i to 20dBA@30m)
(equiv.
@50cm
Sound Level @
Orientation Test
1-Hour
Operation
@ 6-Dir
Avg. stack power variation: 33.4 ± 1W
16/21
I. High System Efficiency
High system efficiency achieved through battery SOC cycling
1) operate at most efficient mode for nominal power
2) operate stack at nominal power mode for partial power loads & apply
battery SOC cycling
75% load
50% load
25% load
Battery SOC cycling
P_stack
Batt remainder (%)
100
0.8
0
8
Load power following
0.6
0.4
0.2
0
10
20
30
Load (W)
Battery SOC cycling vs. Load power following
P_load
1.2
80
1
60
0.8
40
0.6
20
0.4
0
-20
0.2
-40
0
0
5000
10000
15000
TIme (s)
FC off
17/21
P_batt
Fuel eff. (Wh/cc)
FC on
Fuel E
Efficiency (Wh/cc)
1.0
Power (W) / Battery Remainde
er (%)
Fuel Efficiency ((Wh/cc)
1.2
II. Orientation Independent Operation
Multifunctional recycler utilizing centrifugal force
1) gas & liquid separation
2) mixing dilute methanol solution with neat methanol
1) gas & liquid
separation
2) mixer
no performance change
18/21
III. Optimized Heat & Water Management
N performance
No
f
change
h
iin the
h temperature range off -5~45C°
5 45C°
Based on MIL-STD-810G
(501.4)
(501
4) High Temperature Test
(502.4) Low Temperature Test
Thermal Cycling Condition
25oC  -5oC(2hrs)  25oC
 45oC(2hrs)  25oC
System/Stack Power@25 degree C: 25W/ 34
34.5W
5W
System/Stack Power@ -5 degree C: 25W/ 34W
System/Stack Power@45 degree C: 24W/ 34.5W
19/21
III. Optimized Heat & Water Management
Th
Thermal
l stability
bili is
i achieved
hi
d via
i 1) proprietary
i
layout
l
& 2) controll logic
l i
cathode out
cathode in
Stack
anode out
anode in
separator
liquid
ion
filter
anode
HEX


gas
Stack power
System power
Performance
2nd separator
vapor
HEX
mixer
L
gas
Water
ate level
e e is
s co
controlled
t o ed through
t oug
cathode fan control
Stack temperature is controlled
through anode fan control
Water level
Cathode fan
control
20/21
Anode inlet T
Anode fan
control
Stack T & water level
PI control of Fans
Future Applications for Samsung Fuel Cells
Extending Battery Operation Time
For Portable Electronics
APU Application
(requires long operating time and light
weight)
Develop High Energy
Density & Robust System
Cellular Phone
Sales : 1002 million
Units in 2006
FC Technollogy Challen
nge
Military APU
Educational Robot
Leisure APU
Note PC
Sales : 110 million
Units In 2007
Electric
Scooter
10
Electric Wheel
Chair
50
System Power (W)
1st author : seongkee.yoon@samsung.com
21/21
100