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
Introduction to Samsung SDI Portable Fuel Cell Activities in Samsung SDI DMFC Systems for Military Applications Summary

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Business Concept of Samsung SDI

Samsung SDI is reborn as a leading environment friendly & clean energy company with the new vision.

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Samsung Portable Fuel Cells

2W Passive DMFC: Cell Phone Charger 1212 -20W Active DMFC: Laptop Power 25W Active DMFC: Soldier Power

Performance Output Power Input Voltage Output Voltage Energy Storage Energy Density Lifetime Physical Total Volume Total Weight Cartridge volume Cartridge weight Environmental Operation Temp. Orientation Indep. 45C 360 150.7cc 182.77g 26.7cc 30.97g 2.6 W 2.8 V 4.2 V 8.3 Wh 55 Wh/L > 400 hrs

Performance Output Power Input Voltage Output Voltage Energy Storage Energy Density Physical Total Volume Total Weight Cartridge volume Cartridge weight Environmental O Operation i T Temp. Storage Temp. Orientation Indep. 10 10~40C 40C -10C, 60C 360 601.9cc 738.5g 132.6cc 122.0g 12 W 9.9~16.5 V 7 7.2~8.45 2~8 45 V 120 Wh 202.7 Wh/L

Performance Output Power Output Voltage Energy Storage Energy Density Physical Total Volume Total ota Weight eg t Cartridge volume Cartridge weight Environmental Operation Temp Temp. Orientation Indep. -5~45C -5~45 C 360 2.52L 1.87kg .8 g 300.2cc 262g 25W 16.4V 280Wh 510Wh/kg

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Press Release: 2W Cell Phone Charger

06 11. 06. 11 2 27 (SAIT SDI)

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Press Release: Laptop Power

06. 12. 27 (SEC-SDI-SAIT) 06. 12. 27 (MBC, KBS)

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Key Technologies of DMFC

Materials Modules S t System

Catalyst

Stack

HEX

Cartridge

MEA
Membrane BOP Recycler Circuit

High power density/efficiency MEA Low cost catalysts MEA manufacturing technology

Efficient stack design g technology gy Reproducible stack manufacturing technology Heat/water control technology Fuel supply control logic High efficiency circuit design

S t packaging k i t technology h l System High efficiency operating technology System y operating g logic g based on environmental conditions Low cost manufacturing technology

Core technology under development Established core technology To be developed

Contamination filtering technology Low cost manufacturing technology

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25W DMFC System: Soldier Power

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Why Fuel Cell for Soldier Power?

Power Source Primary Battery (BA-5590) y Battery y Secondary (BB-2590) Fuel Cell (DMFC) Weight for 3-Day Mission 8.16kg (8ea) Energy Density 176Wh/kg Lifetime Energy Cost (USD/1kWh) $421.58

One time use

10 88k (8ea) 10.88kg (8 )

132Wh/k 132Wh/kg

220 cycle life

$21 73 $21.73

3.4kg (1unit & 6cartridges)

510Wh/kg

3,000hrs

$10.90

66% / 75% decrease in weight vs. primary / secondary bat.

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97% / 50% decrease in cost vs. primary / secondary bat.

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

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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

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Power Unit
[Front] [Back]
fuel cartridge cover

[Top]

air intake

air exhaust

Display & Switch - Power Status - Fuel & Battery Remainder - Operation Mode - Night Vision

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Internal Battery and Fuel Cartridge

Li-ion Battery
- Dimension: 7.4cm9.0cm2.5cm (166.5cc) - Weight: 228g - Type: T 4S1P Li Li-ion i Pack P k - Capacity: 2.6Ah - Output Voltage: DC 14.8V

[Battery Charger]

Fuel Cartridge
- Dimension: Di i 7.5cm 7 5 13.8cm 13 8 2.9cm 29 (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)

[Fuel Charger]

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Monitoring Program

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Key Features to be Highlighted

High System Efficiency Orientation Independent Operation Optimized Heat & Water Management

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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 (661.2) Sound Level Test @50cm Sound Level @ Orientation Test 45dBA (eq i to 20dBA@30m) (equiv.

1.13Wh/cc

1-Hour Operation @ 6-Dir Avg. stack power variation: 33.4 1W

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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 Battery SOC cycling
1.2 Fuel Efficiency ( (Wh/cc)
100 Power (W) / Battery Remainde er (%)
P_stack Batt remainder (%) P_batt Fuel eff. (Wh/cc) P_load

50% load

25% load
1.2 1 0.8 0.6 Fuel E Efficiency (Wh/cc)

1.0 0.8 0 8 0.6 0.4 0.2 0 10 Load (W) 20 30

80 60 40 20 0 -20 -40

Load power following

0.4 0.2 0 0 5000 TIme (s) 10000 15000

Battery SOC cycling vs. Load power following

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FC off

FC on

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

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III. Optimized Heat & Water Management

N performance No f change h i in the h temperature range of f -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
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III. Optimized Heat & Water Management

Th Thermal l stability bili is i achieved hi d via i 1) proprietary i layout l & 2) control l logic l i

cathode in

cathode out

Stack
anode in

anode out

separator liquid gas

Stack power

ion filter anode HEX mixer L

System power

Performance

2nd separator vapor HEX 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

Anode inlet T

Stack T & water level

Cathode fan control 20/21

Anode fan control

PI control of Fans

Future Applications for Samsung Fuel Cells

Extending Battery Operation Time For Portable Electronics
Cellular Phone Sales : 1002 million Units in 2006 Military APU Educational Robot Leisure APU

Develop High Energy Density & Robust System

APU Application (requires long operating time and light weight)

FC Technol logy Challen nge

Note PC Sales : 110 million Units In 2007

Electric Scooter

Electric Wheel Chair

10

50 System Power (W)

100

1st author : seongkee.yoon@samsung.com 21/21