ONR Manhattan Project Montana Tech - Butte, MT

ONR Manhattan ProjectMontana Tech – Butte, MTMarch 18, 2011Kevin CenteckUnclassifiedUnclassified

Form ApprovedOMB No. 0704-0188Report Documentation PagePublic reporting burden for the collection of information is estimated to average 1 hour per response, including the time for reviewing instructions, searching existing data sources, gathering andmaintaining the data needed, and completing and reviewing the collection of information. Send comments regarding this burden estimate or any other aspect of this collection of information,including suggestions for reducing this burden, to Washington Headquarters Services, Directorate for Information Operations and Reports, 1215 Jefferson Davis Highway, Suite 1204, ArlingtonVA 22202-4302. Respondents should be aware that notwithstanding any other provision of law, no person shall be subject to a penalty for failing to comply with a collection of information if itdoes not display a currently valid OMB control number.1. REPORT DATE2. REPORT TYPE18 MAR 2011N/A3. DATES COVERED-4. TITLE AND SUBTITLE5a. CONTRACT NUMBERONR Manhatten Project5b. GRANT NUMBER5c. PROGRAM ELEMENT NUMBER6. AUTHOR(S)5d. PROJECT NUMBERKevin Centeck5e. TASK NUMBER5f. WORK UNIT NUMBER7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES)8. PERFORMING ORGANIZATION REPORT NUMBERUS Army RDECOM-TARDEC 6501 E 11 Mile Rd Warren, MI48397-5000, USA216259. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES)10. SPONSOR/MONITOR’S ACRONYM(S)TACOM/TARDEC/RDECOM11. SPONSOR/MONITOR’S REPORT NUMBER(S)12. DISTRIBUTION/AVAILABILITY STATEMENTApproved for public release, distribution unlimited13. SUPPLEMENTARY NOTESThe original document contains color images.14. ABSTRACT15. SUBJECT TERMS16. SECURITY CLASSIFICATION OF:17. LIMITATIONOF ABSTRACTa. REPORTb. ABSTRACTc. THIS EROF PAGES19a. NAME OF RESPONSIBLE PERSON11Standard Form 298 (Rev. 8-98)Prescribed by ANSI Std Z39-18

Army APU NeedsAbrams Tank has the greatest need for an APU A 2008 study* concluded an Abrams APU could save 74 gallons ofJP-8 per tank per battlefield day, which calculates to saving 4,300gallons per brigade per day Time at idle, estimated to be as much as 83% of total operatingtime Abrams tactical idle at 1250 rpm consumes 17gal/hr Current APU solutions consume 1.5 gal/hr Study also showed benefit to Abrams main engine 10 yearreplacement costs by over 75,000 if the APU has over 500 hoursmean-time between failure (due to reduced main engine idle time). Current band-aid solution does not meet requirements or powerneeds 6 additional batteries integrated into the available space claimallow engine off operation Vehicle has to idle to meet 8kW power requirement (baselineturret with OIF upgrades)*AMSAA Study Lead: Mr. Robert M. Roche In Response To: RDECOM Tasker 2990: Per AMC CurrentOperations Update, 10 June 08;Adapted from Brief to CG, RDECOM, 2 Apr 08Unclassified2

Common APU PerformanceRequirementsRequirement Traceability: APU requirement traces back to the M1A2 ORD page 11, paragraph 4.b (4) to require anunder armor APU (UAAPU) on the tank. The PEO GCS/TARDEC Common APU IPT completed a gap analysis of Abrams, Bradley andStryker on-board power requirements. This resulted in the Common APU performance specification and a Request for Information(RFI) was sent to industry 1st QTR 2006Abrams, Bradley and StrykerAPU Performance RequirementsContinuous Power8 kW (Threshold) / 10 kW (Objective)Mission DurationFuel Consumption12 hours1.75 gal / hour (Threshold) / 1.5 gal / hour (Objective)6 in12 inches21 inAir Intake5 in17 in17 inches49 inAir Exhaust5 in30 inches3 inNPS Volume2 inScavengeOutlet12 inLeftSide ofVehicle4 in9 inAbrams275 LRear ofVehicleNPS WeightStryker200 LBradley100 L453 lbs. Abrams/Bradley (internal cooling system)254 lbs. Stryker (can use engine’s cooling system)Procurement Cost 40KUnclassified3

Increasing PowerRequirements70kWCurrent Platform RequirementX Fielded Army APU SolutionX TARDEC APU Program20kWAbramsSEPv4 CDD 40kWTurbine APU25 kW5 205kWRotary Engine 5NextGen APU17 kW18 kWMarvin Land 5HBCTSystems APU10 kWCommon APURotary Engine 6 10 kWRotary APU9 kWContinuous PowerIncreasing Power40kWX Unfunded APU ProgramX Technology Readiness LevelSmall Engine DevelopmentStrykerModernization22 kWBradleyUpgradeTARDEC4Fuel CellProgram 10 kWPredictedM1A2 EAPUDiesel APU 83 kWNoise LevelDecreasing NoiseUnclassifiedM1A2 SEP v2 8 1 kW8 Hawker AGMLead AcidBatteries4

Rotary Engine APU:Integrated, Demonstrated, TestedProgram Status:Project Purpose & Goal:o Develop, integrate, test and demonstrate a 9kWrotary engine APU in Abrams M1A2 SEP V1 tanko Completed 200 hours (2000 miles) of in-vehicleoperational conditionso Ruggedize design to meet vibration requirementsof tanko Completed two 100 hour high temperature (125F)tests at TARDEC Propulsion Labo Optimize component placement for ease ofmaintenanceo Completed M1A2 SEP V1 Integration Test of 300 tank commandso Produce 6 units for testing at various governmenttest facilitieso Delivered performance specification to PM HBCT,which may be used for open competitiono Delivered test report of all testing completedChallenges:Schedule/Fundingo Consumes oilo Requires constant use of glow plugFY06 FY07 FY08 FY09 FY10 FY11Generation 1 – Proof of Concepto High maintenance requirementGeneration 2 – Test Prototypeo Minimal noise mitigation work doneGeneration 3 - 9 kW APU- TARDEC Testing- Shock and Vibration Tests- Vehicle TestsUnclassified5

Diesel Engine APUProject Purpose & Goals:Technology Description:o Produce APU for Abrams space claimo10kW electrical output (360A)o Utilize COTS Direct Injection (DI) compressionignition engineoSingle Cylinder 4-stroke engineoLiquid CooledoIn-cylinder fuel injectiono420 lbsoFits in Abrams space (including muffler)oTrue compression ignition State of the art in reducing fuel consumptionand optimizing fuel controlo Integrate muffler inside space claimChallengesSchedule/Fundingo Consumes oilo Not a drop-in designo Minimal noise mitigation work doneFY08 FY09 FY10 FY11Component DesignComponent TestingAir Cooled Unit FabricationAir Cooled Unit TestingLiquid Cooled Unit DesignLiquid Cooled Unit FabricationLiquid Cooled Unit TestingTARDEC Test & EvaluationUnclassified6

JP8 Fuel Cell AuxiliaryPower Unit (APU)FY17Purpose:JP8 Reformerand Fuel CellAPU Provide quiet, continuous, non-primaryelectrical power for extended engine-offoperation with reduced acoustic and thermalsignatures in a fuel cell-based auxiliarypower unit.Product: Electric Power forSilent 4 FY15System M&SPayoff:System Refinement Provide low signature, non-primary vehiclepower generation for C4ISR and auxiliarysystems (engine off)Prototype DevelopmentBreadboard test5 Increase the Warfighter’s survivability andlethality through decreased signature duringextended silent watch missions.Field HardeningIncrease Power DensityPreliminary TTAAPU DemonstrationMultiple ruggedized, power dense, JP8 FuelCell Auxiliary Power Units for Abramscapable of producing 15 kilowatts ofvehicle electrical power demonstrated atTRL 6 ; to include shock and vibrationtesting, hot and cold temperature testing,on-vehicle testing, adverse weather andstorage testing.6 Increase overall vehicle fuel efficiencyUnclassified

JP8 Fuel Cell AuxiliaryPower Unit (APU)Technology Solution 1Technology Solution 210 kW7.2 kWSystem Components:System Components: Fuel Preprocessor (FPP) Subsystemo Fractionator: Separates JP-8 fuel to light and heavy portions;reforms light end fuel for fuel cell, burns heavy end fuels forsystem heato Regenerable Organic Sulfur Trap (OST): Reduces sulfur levelsto below 15 parts per million (ppm);o Polishing OST: Removes any remaining sulfur in fuel Fuel Processor (FP) Subsystemo Pre-reformer: Partially reforms desulfurized JP-8 fuel; 2 stepreformation reduces operating temperature versusconventional reformerso Reformer: Completes fuel reformation processo Water-Gas Shift (WGS): Converts residual Carbon Monoxide(CO) from the reforming process to hydrogen utilizing steam High Temperature Proton Exchange Membrane (HTPEM)Fuel Cello More efficient and power dense than conventional PEM fuelcells; operating at 160 C - 180 C; converts fuel reformate topower Regenerable Liquid-phase Sulfur Removal Systemo Reduces sulfur levels in fuel from 3000 ppm to 40 ppm;when less than 400 ppm sulfur is used; the sulfur removalsystem is bypassed Auto-thermal / Catalytic Partial Oxidation (ATR/CPOX)Fuel Reformero Reformer starts in a CPOX reformer mode and transitions toa more efficient ATR mode once system is at temperature forATR to begin. Solid Oxide Fuel Cell (SOFC)o Converts fuel reformate to power; operates between 600 C –1000 C; Extremely sulfur tolerant.Unclassified

Status: NewJP8 Fuel Cell AuxiliaryPower Unit (APU)1. What is the problem? The need exists for improved non-primary electric powerthat will support military ground vehicle engine-offoperations. The means of generating this electricity mustoffer better fuel efficiency and have lower thermal andacoustic signatures than idling the main engine. Currentbattery, alternator and APU technology cannot meetsilent watch requirements.2. What are the barriers to solving this problem? There is no technology in the Army inventory besidesbatteries that can meet the acoustic signaturerequirements of silent watch. Army mandated use of JP8 fuel as only fuel optioneliminated simpler prepackaged fuel APU options.3. How will you overcome those barriers? Fully integrate the complex components of reformation,energy storage and fuel cell technologies; design formilitary use; operate for 1000 hours. Develop fully characterized M&S tools for optimization ofreformer, fuel cell and energy storage interactions acrossmultiple mission profiles. Leverage heavily off of on-going JP8 reformationprograms DOD wide.4. What is the capability you are developing? Warfighter Outcome Title – Alternative Power forPlatforms, Alternative Power for Dismounted Soldiers,Alternative Energy Sources, Increased Fuel Efficiency,FOC 09-03, 09-04, 09-015. What is the result of this effort? A never before designed JP8 reformer system and fuelcell combined into a defined space claim to produce nonprimary power for engine-off operations.6. Quantitative Metrics:ComponentTechnologyCurrentProgram Obj.XXmPEO GCS CNPSHalf as loud as mainengineUndetectable3Noise LevelArmy ObjectivesatTRLStart 4End 5Start 4End 5SW Avg Power1.2 kW 15kW (T) 10 kW (O)8 kW (T) 10kW (O)SW Duration 5 hrs112 hrs12 hrsStart 3End 5System Efficiency15%225%18%Start 3End 5System Reliability /MTBF500 hrs1140 hrs*1140 hrsStart 3End 515.5 W/L235 W/L32 W/LStart 4End 5Power Density1. From M1A2 SEP v2 w/ UAAPU compartment filled with 6 extra 6T VRLA batteries. * Design to goalfor follow on2. From PM-MEP 5 kW APU, MEP model # 952B 3. Defined by MIL-STD-1474D Level I auralnondetectability limits7. How are we leveraging other tech programs:DOD program leveraging OSD High Temperature Fuel Cell (SOFC) Based AuxiliaryPower Unit program (ONR managed) AFRL Power Dense Solid Oxide Fuel Cell Power Units forMilitary Applications program ARL JP8 reformer laboratory testing and sulfur sensordevelopment.TARDEC program leveraging In-house reformer and fuel cell modeling (ASPEN) FY06 JP8 Reformation for Alternative Power Sources8. Endorsements: TRADOC 13 Apr 09 Maneuver COE Mounted Requirements Division, 13 Apr 09 Marine Corps Systems Command PM Tanks: 11 Dec 09 PEO GCS, PM HBCT: 29 Apr 09 PM MEP: 26 Feb 09 (Written Concurrence)Unclassified