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Overview

The development of cost-effective, ecologically friendly and efficient small fuel cells is one of the greatest challenges facing materials scientists, OEMs, industrial designers and portable electronics manufacturers.
In it's 3rd year as the premier symposium in this area, Small Fuel Cells 2001 will present the latest advancements in research, technology development and commercialization of portable power sources in such new areas as:

� Miniaturization challenge for portable power sources
� Fuel systems to power up miniaturized electronic devices (cell phones, laptops, PDAs)
� Systems integration vs. advanced materials and technology development
� Nanomaterials for small fuel cells - membranes, electrodes
� New role of carbon
� Hydrogen fuel: sources, storage, processing and delivery
� Development of methanol cells
� Hybrid battery / fuel cell systems development

Special Pre-Conference Workshop
Market Demand and Cost
vs. Current Technological Possibilities
Sunday, April 22, 2001

� Market analysis. Case studies.
� Cost evaluation and bringing SFC to market
� Environment packaging, safety, and reliability of small power sources
� Regulatory and standardization issues

RELATED LINKS

Advanced Fuel Cell Technology
Battery Power Products & Technology
EIN Publishing
Fuel Cell Industry Report
Fuel Cell Store
Materials Technology
Trimol Group, Inc.

Table of Contents

Sunday, April 22, 2001

1:15 Registration, Poster/Exhibit Setup, Coffee & Danish

1:45 Workshop Begins

Fuel cells can revolutionize the world. Small (or portable) fuel cells (SFC) are tried in combination with advanced batteries (hybrid power sources) or even alone to power up electronic and other portable devices. Are SFC capable to promote the development of portable power supply to the next technological and economical level? Or, even partially alternate other comprehensive power sources on the electronics market? Is the market ready for such a turn yet? Would the cost of advanced fuel cells be competitive with one of the state-of-the-art batteries? What about the feasibility of the different SFC types?
These, as well as many other emerging issues from both a marketing standpoint and technological point of view will be addressed by panelists and discussion contributors at our Special Pre-Conference Workshop.

Don't miss the opportunity of recharging your professional battery!

Workshop Moderator:

Shimshon Gottesfeld, Ph.D., Mechanical Technology Inc.

Workshop Panelists:

Peter B. Bos, Polydyne, Inc.
Charles J. Call, Ph.D., MesoSystems Technology, Inc.
Rafael Ferry, Trimol Group Inc.
Toby Hamblin, Lydall, Inc.
Mark Hampden-Smith, Ph.D., Superior MicroPowders
Donald W. Kirk, Ph.D., Trimol Group Inc.
Robert F. Lifton, Medis Technologies Ltd.
Carlos Navas, Ph.D., Manhattan Scientifics / Energy Related Devices
Dennis Sieminski, AER Energy Resources, Inc.
Eugene S. Smotkin, Ph.D., Illinois Institute of Technology

1:50 Small Power Systems Commercialization
Peter B. Bos, President, Polydyne, Inc.

The commercialization success of small power systems requires attainment of market derived specifications, commencing with the highest entry market value applications. The potential attainment of these market values by alternative power systems can be determined using production cost analysis. Combining the required market values for different applications with the projected production costs at cumulative production levels will determine whether the specific power system can attain the required market values and, if so, the economic order quantity for market entry for any possible combination of system technology and market application. This approach to commercialization has been applied to various fuel cell systems and a large number of potential stationary and mobile applications. The results always require fuel cells to be combined with battery storage (and ultra capacitors), operating in a symbiotic hybrid mode to effectively meet the varying load requirements of each specific application at the lowest cost and the most responsive operating mode. To minimize the financial and technical risks associated with commercialization of new technologies, such as fuel cells, and to maximize the benefits of production learning, the initial systems applications must be small (1 to 10 kW). Furthermore, these systems must be compatible with existing infrastructure fuels to achieve rapid penetration of their potential markets, requiring the development of small, economical fuel processors for fuel cell applications. This paper will address these issues for various stationary and mobile fuel cell systems and applications. The resulting market derived specifications for these applications, combined with their associated potential markets and projected market penetration rates, will be described in the order of starting with the highest entry market applications.

2:30 Panel Discussion & Case Study Presentations

5:30 Close of Workshop

Monday, April 23, 2001

8:00 Registration, Poster/Exhibit Viewing, Coffee & Danish

Advances in Fuel Cell and Battery Technology Development

8:55 Chairperson's Opening Remarks

Mark Daugherty, Ph.D., Chief Scientist, Enable Fuel Cell Corporation - a DCH Technology Company

9:00 Key-Note Address
Fuel Cells for Transportation - Strategy for Cost Reduction
JoAnn Milliken, Ph.D., Program Manager, U.S. Department of Energy, Fuel Cell R&D

The major impediment to successful commercialization of proton-exchange membrane fuel cells for automotive applications is the cost of the fuel cell power system. The Department of Energy (DOE) Transportation Fuel Cell Power Systems Program is addressing this issue by conducting cost studies, and by supporting research and development aimed at reducing the cost of fuel cell stack and fuel processor components. Cost reduction R&D is currently focused on
(1) developing continuous processes for fabricating low-platinum, high-performance MEAs at high volume,
(2) developing pilot manufacturing for composite bipolar plates, and
(3) developing water-gas-shift catalysts having greater activity and less precious metal content.
Because the first widespread market for fuel cells will likely be in the consumer electronics industry, the DOE Program plans to expand cost reduction activities to include development of fuel cells for portable power as well as auxiliary power units. This paper will describe DOE R&D plans and activities to reduce the cost of fuel cell systems.

9:30 Sandia's �FuelCell Program
Alan P. Sylwester*, Ph.D., Manager, Catalysis and Chemical Technologies Department, Sandia National Laboratories

We have fabricated a proton exchange membrane fuel cell (PEMFC) on a silicon chip using the processes and tools of the microelectronics industry. Porous gas diffusion electrodes, electrical interconnects and gas manifolds were created using lithography and etching processes and industry standard solid polymer electrolytes were deposited using thin film deposition techniques. Several novel fuel cell architectures have been investigated, including a planar design in which anodes and cathodes are side-by-side in the same plane. Integration with hydrides for fuel storage promises a compact power source with a volumetric energy density greater than the best available batteries. In addition to high energy densities, small silicon PEMFCs have other key advantages including flexible form factors and manufacturability. Small silicon-based PEMFC/hydride systems could be used in a wide range of portable electronic applications and help to overcome some of the limitations of batteries.
Sandia is a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin Company, for the United States Department of Energy under contract DE-AC04-94AL85000.
*In collaboration with: A. Hecht, and S. Kravitz, Sandia National Labs

10:00 Catalysis and Performance of Mini-Fuel-Cell
William H. Smyrl*, Ph.D., Professor of Chemical Engineering & Materials Science, Corrosion Research Center, University of Minnesota

The present paper will describe investigations dealing with the effects of varying pore size and spacing on the performance of a miniature polymer electrolyte fuel cell. Further, the results of preliminary mini-fuel cell stock behavior for methanol/air and for hydrogen/air will be discussed.
*In collaboration with: T.L. Knutson, University of Minnesota

10:30 Refreshment Break, Exhibit and Poster Viewing

11:00 Overcoming the Limitations of Air-Breathing Electrodes in Zinc-Air Power Sources for Portable Electronic Products
Dennis Sieminski, Technical Marketing Manager, AER Energy Resources, Inc.

Air-breathing electrodes used in fuel cells and metal-air batteries confer significant advantages on these electrochemical systems in the areas of energy density and safety. However, the downside is air electrodes can come with serious limitations in power density, life and the ability to respond to changing electrical loads. These problems are related to water vapor transpiration and the oxygen diffusion rate at the air electrode surface. Successful solutions to these problems are examined with their implementation in practical applications of zinc-air batteries to handheld electronic consumer products.

11:30 PEMcoat: The Advanced Bipolar Plate System
David R. Hodgson*, PhD, Senior Research Scientist, INEOS Chlor Ltd., ETB Technical Centre, United Kingdom

As the bipolar plate in a PEM fuel cell stack is the largest volume component, the development of compact, lightweight PEM fuel cell stacks requires the use of thin bipolar plates. By using metallic bipolar plates, the thickness of the plate is determined by the depth and design of the flow field, enabling plate thicknesses from 20 microns to be used. Unfortunately, metals form passive oxide layers (which often account for their resistance to corrosion) increasing the voltage drop through the plate. To avoid the formation of, or at least control the formation of the passive film, coating systems need to be developed for metal plates that can provide the properties of:
- low electrical resistance
- corrosion resistance
- low cost
- volume manufacture
- reasonable throwing power
The PEMcoat range of coatings for metal bipolar plates has been developed in response to the above requirements. This paper describes the performance of the PEMcoat range.
In collaboration with: M.J. Barton, J.C. Harper, B. May, and G. Walker, INEOS Chlor Ltd., ETB Technical Centre, United Kingdom

12:00 Advantages and Viablity of Al-Air Fuels Cells for Portable Electronic Devices
Donald W. Kirk, Ph.D., Chief Scientific Officer, Trimol Group, Inc.

As a renewable and sustainable source of energy, aluminum-air based fuel cells offer tremendous advantages in many applications. The aluminum-air fuel cell's high-energy output results from the characteristic energy density of aluminum and the fact that three electrons are released for every atom of aluminum reacted. Recent developments in aluminum-air fuel cell chemistry will enable widespread application of aluminum-air fuel cells in a number of applications with power requirements from 1 watt to 30 kW. This paper discusses the chemistry of aluminum-air fuel cells and problems that have recently been overcome, the advantages of using aluminum as a fuel, and the feasibility of recycling aluminum-hydroxide, the principle by-product of the aluminum-air fuel cell. Development efforts of aluminum-air fuel cells have faced significant chemistry challenges: activation of the aluminum anode, controlling the aluminum oxidation reaction, preventing fouling of the reaction anode surface, supplying oxygen to the reaction and controlling hydrogen generation. Through careful construction of the anode, cathode and electrolyte solution, the company has solved these problems and is achieving energy densities of 800 Wh/kg with current densities of up to 360 mA/cm2. The company�s first product is a wireless phone battery that delivers 12Ah electrical capacity. Future products include stationary back-up power systems and electric vehicle power units.

12:30 Lunch Sponsored by Trimol Group, Inc.

Miniaturization and Application in Electronics

1:55 Chairperson's remarks

William H. Smyrl, Ph.D., Professor of Chemical Engineering & Materials Science, Corrosion Research Center, University of Minnesota

2:00 KEY-NOTE ADDRESS
U.S. Fuel Cell Council Activities on Portable Power
Jerald A. Hallmark, Manager, Energy Technologies Laboratory, Motorola Labs - Solid State Research Center; for: U.S. Fuel Cell Council Portable Power Working Group

An overview of the U.S. Fuel Cell Council (USFCC) activities directed towards commercialization of fuel cells is discussed with particular focus on "Portable Power". An attempt is made to classify a range of applications into the portable power domain, and the council's mission targeted on commercializing fuel cells in this power range will be discussed by means of on-going and planned activities centered on, but not limited to:
(i) fuels/fuel sources - to compare potential fuel sources for applications in this power range;
(ii) deployment and transportation - to review existing regulations that will impact fuel transportation and work towards removing potential barriers; and
(iii) standards - to address target performance and safety of power source products.

2:30 Latest Progress in MicroFuel Cell^TM Development
Carlos Navas, Ph.D., Electrochemist, Manhattan Scientifics / Energy Related Devices
Manhattan Scientifics, Inc. (MSI) is developing a MicroFuel Cell^TM electrical power system for portable electronics. The MicroFuel Cell^TM is simply refueled with a mixture of methanol and water and can be manufactured using vacuum deposition techniques, thus minimizing costs. Using this approach, we have developed the Power Holster^TM, a portable lightweight cellular phone charger which continuously charges the phone battery. We have demonstrated its durability and higher specific energy than existing rechargeable batteries. Our latest efforts to improve the system will be presented.

3:00 Materials and Design for Small Fuel Cells:
600mW DMFC cell pack & 200W PEMFC stack
Hyuk Chang, Ph.D., Principal Researcher, Electrochemistry Lab, Samsung Advanced Institute of Technology, Korea

Since we announced (Small Fuel Cells 2000, New Orleans) the development of 40W PEMFC stack operating lap top computer in ambient condition, more studies on the materials and design for portable fuel cell have been proceeded. In this presentation, monopolar cell pack of DMFC (600mW) for mobile phone and PEMFC stack (200W) for portable power source will be considered. Studies on nanophase catalyst layer, efficient fuel flow field and composite membrane with partially fluorinated sulfonated ionomer will be also discussed.

3:30 Refreshment Break, Exhibit and Poster Viewing

4:00 Portable Fuel Cells for Consumer Products
Mark Daugherty, Ph.D., Chief Scientist, Enable Fuel Cell Corporation - a DCH Technology Company

Enable^TM Fuel Cell (Enable^TM) is developing small passive proton exchange membrane (PEM) fuel cells. These fuel cells are well-suited for use with many portable consumer products. The fuel cells have been demonstrated with applications such as radios, flat screen TVs, CD players, fluorescent and incandescent lighting, global positioning systems and toy trains. In this paper we present Enable^TM portable fuel cell designs and discuss operational data under a variety of different test conditions.

4:30 Simulation, Construction and Characterization of Small Fuel Cells for Low Power Applications
Christopher Hebling, Ph.D., Head of Micro-Energy Technology, Fraunhofer Institute for Solar Energy Systems, Energy Technology Department, Germany

Small fuel cells can play an important role in the power supply of portable and remotely located off-grid electronic appliances. At Fraunhofer ISE, miniaturized fuel cell systems are under development in various geometries within an output power range of 250 mW and about 50 W. Computational simulations of the thermal and the water management are performed and are correlated subsequently with the results from the spatially resolved characterization of realized cells.

5:00 Small Fuel Cells for Portable Power Applications
Shimshon Gottesfeld, Ph.D., Vice President of R&D and Chief Technology Officer, Micro-Fuel Cell Initiative, Mechanical Technology Inc.

Direct methanol fuel cells have a clear advantage over advanced batteries thanks to superior energy density, particularly in applications associated with longer durations. Considering a real power source, in which various losses originate from the cell itself as well as from BOP components, the realistic energy density to be expected from small scale DMFCs exceeds 1000 Wh/kg, i.e., 5-10 times higher than the energy density of advanced batteries. State of the art DMFC technology will be discussed in this presentaion in the context of portable power sources for potential commercial applications.

5:30 Open Discussion and Close of Day One

Tuesday, April 24, 2001

8:15 Exhibit/Poster Viewing, Coffee & Danish

Small Fuel Cells Application and Fuel Supply

8:55 Chairperson's Remark

Dennis Sieminski, Technical Marketing Manager,
AER Energy Resources, Inc.

9:00 Key-Note Address
Small Fuel Cells for Department of Defense Applications
Robert J. Nowak, Ph.D., Program Manager, DARPA / Defense Sciences Office

The Department of Defense has a pressing need for lighter and more compact electrical power sources. Batteries will not have sufficient specific energy to meet the needs of critical future missions. Recently, small fuel cells have been deployed successfully in military exercises. While these early demonstrations are encouraging, significant barriers need to be addressed if this technology is to enjoy wide application in the Department of Defense.

9:30 Portable Fuel Cell Systems Integration
Jeffrey A. Schmidt, Ph.D., Staff Consultant, Ball Aerospace & Technologies Corp.

Ball Aerospace & Technologies Corp. fuel cell systems have been used primarily to date for DoD and other government applications. We have successfully done the systems engineering and integration for more than five varieties of PEM fuel cell power systems ranging in power level from 15-watts to greater than 100-watts, and based on fuel cell stacks provided by a variety of manufacturers including H Power, Ballard and Los Alamos National Lab (LANL). The fuel cell portable power systems development activities have been accompanied by the engineering, integration and testing of more than eight types of hydrogen-storage/generation solutions. These have included high-pressure gas, metal hydride and several state of the art chemical hydride hydrogen generators. Hydrogen sources have been tailored to meet specific power and energy profiles for a variety of scenarios in energy ranges from 400 to 15,000-watthours. Our capabilities also include the development of a fully integrated, ruggedized, autonomous, portable 60-watt direct methanol fuel cell (DMFC) system based on DMFC PEM stack technology developed by LANL for DARPA. We are also aggressively developing miniature 15-watt hydrogen PEM hybrid power system to satisfy the individual soldier's power needs. These experiences make Ball Aerospace & Technologies Corp. uniquely qualified to successfully perform the systems integration and packaging of enabling Portable Power technologies for miniature rugged hydrogen and direct methanol PEM Fuel Cell power systems.

10:00 Portable Fuel Cells for Military Applications
Kristopher E. Gardner, Chemical Engineer, US ARMY Communications-Electronics Command, Fuel Cell Technology Team

Powering the modern soldier is of great concern to the
Army. The soldiers have unique portable power
requirements. They must operate in extreme environments for long periods without the luxury of the corner drugstore to obtain batteries. Currently, the Army has some of the best batteries in the world. Even so, the modern soldier will be equipped with many new electronic technologies that dramatically increase their lethality. Unfortunately, these technologies are increasing the burden on the soldier's power source. As a result, the Army is developing future fueled hybrid power sources that greatly increase the energy density without increasing the power sources total weight on a soldier. This paper will describe the Army's efforts in developing hybrid fuel cell power sources for the individual soldier.

10:30 Refreshment Break, Exhibit and Poster Viewing

11:00 Microchannel-Based Fuel Processor Development for Portable and Miniature Fuel Cell Systems
Jamelyn D. Holladay*, Research Engineer, Environmental Technology Division, Battelle, Pacific Northwest National Laboratory

Battelle is currently developing and demonstrating small-scale, hydrocarbon-fuel-based fuel processors to produce high-purity hydrogen for fuel cell applications. Each of these projects (sub-watt and 15-50 watt) employs microchannel technology to minimize the footprint of each device such that a 15-watt fuel processor would be roughly the size of a deck of cards. The sub-watt system promises to have a proportionally small footprint. This presentation will outline our progress to date, including catalyst development and fuel processor system performance.
*In collaboration with: E. Jones, R. Orth, R. Rozmiarek, S. Perry, D. Palo, M. Phelps, C. Guzman, Y. Wang, J. Hu, R. Dagle, and E. Baker, Battelle

11:30 Hydrogen Solution for Small Fuel Cells
David R. Martin, Program Director, Stuart Energy Systems, Canada

Stuart Energy has over 50 years of experience in hydrogen-producing equipment. Stuart's proprietary technology has allowed the Company to expand into the portable fuel markets. Stuart Fuel Appliances use only electricity and water to produce high quality hydrogen. Renewable sources such as wind or solar, make the entire process, from fuel production to consumption in a fuel cell, zero emission. Stuart is currently developing a complete line of products; but the focus of the paper is the Personal Fuel Appliance, a prototype developed for use anywhere including the family home, providing the ultimate in distributed and convenient hydrogen. Making your own fuel will empower small fuel cells by liberating the energy source from its traditional tethers.

12:00 Ammonia-Based Hydrogen Generation for Portable Power
Charles J. Call, Ph.D.*, President and CEO,
MesoSystems Technology, Inc.

Compact sources of hydrogen continue to be a critical
issue or small fuel cell commercialization. This presentation will describe the recent progress by MesoSystems in the development of a compact system for ammonia storage, reforming and hydrogen purification. Our objective is to produce a power supply with an energy density of 1kW-hr/kg. The technology is scaleable, but is currently focused on a 50W power supply.
*In collaboration with: M. Powell, and M. Fountain, MesoSystems Technology, Inc.

12:30 Lunch on your own, Exhibit/Poster Viewing

Methanol Fuel Cells. Technology Development

1:55 Chairperson's Remarks
C.G. Michael Quah, Ph.D., Group Vice President and General Manager, LydallSeparations and Energy Initiatives, Lydall

2:00 High Energy Density Portable Power Sources Based on Direct Methanol Fuel Cells
Sekharipuram R. Narayanan, Ph.D., Senior Member Technical Staff, Jet Propulsion Laboratory

The demand for compact power sources with high energy density has been steadily increasing. Direct methanol fuel cells are potentially capable of overcoming these limitations and offering energy densities as high as 1500 Wh/kg. By replenishing the fuel operating times can be extended as long as needed, eliminating the need for electrical recharging. The direct methanol fuel cell starts up at room temperature, is truly load following, does not require pre-processing of the fuel to hydrogen, and allows for easy liquid fuel storage. These characteristics make the direct methanol fuel cell an excellent candidate for a miniature power source. The recent efforts at the Jet Propulsion Laboratory on the development of small direct methanol power sources will be presented.

2:30 The Design & Performance of Electrocatalysts Produced by Spray Based Routes and Gas Diffusion Layers for Fuel Cell and Battery Applications
Mark Hampden-Smith, Ph.D., Director of Emerging Technologies, Superior MicroPowders LLC

Superior MicroPowders (SMP) has developed a highly reproducible, patented spray-based process for the manufacture of electrocatalyst powders. This process allows for control over morphology, microstructure, and composition that is unique and can be applied to a wide variety of compositions. This gives SMP the flexibility to design catalyst powders with a range of compositions and microstructures that is challenging by other manufacturing methods. Excellent performance has been achieved at low precious metal loading in low temperature fuel cell applications (PEMFC and DMFC) as well as in metal-air battery applications. These materials have also been integrated into state-of-the-art deposition processes to construct high performance gas diffusion electrodes for both batteries and fuel cells.

3:00 Direct Methanol Fuel Cell Catalysis
Eugene S. Smotkin, Ph.D., Associate Professor of Chemistry and Chemical Engineering, Associate Director, Center for Electrochemical Science and Engineering, Illinois Institute of Technology

Abstract not available at time of print

3:30 Selected Oral Poster Presentations

4:00 General Discussion

4:30 Concluding Remarks and End of Conference