Space & Defense
UTC Power designed, developed, and produced the fuel cell power plants for NASA's Space Shuttle Orbiter and is working with NASA and aerospace companies to evaluate fuel cells for future applications.
Our pioneering work with fuel cells for space flights came much earlier when we developed fuel cells for NASA's Apollo moon missions. Fuel cells are critically important to manned space missions. Their high-energy density a factor of five better than batteries reduces launch weight, and the H2O they generate provides drinking and cooling water for the spacecraft.
NASA's Space Shuttle Orbiter
Electrical power for NASA's Space Shuttle Orbiter is provided by fuel cell power plants designed, developed, and built by UTC Power. In the Orbiter, a complement of three 12-kilowatt fuel cells produces all onboard electrical power; there are no backup batteries, and a single fuel cell is sufficient to ensure safe vehicle return. In addition, the water produced by the electrochemical reaction is for the crew to drink and for spacecraft cooling.
Each fuel cell is a self-contained unit 14 x 15 x 45 inches, weighing 270 pounds. They are installed under the payload bay, just aft of the crew compartment. Hydrogen and oxygen from cryogenic tanks fuel the power plants. Each fuel cell is capable of providing 12 kilowatts continuously, and up to 16 kilowatts for short periods.
Each power plant contains 96 individual cells of the alkaline (KOH) electrolyte technology, which are connected to achieve a 28-volt output. The cells are over 70 percent efficient (a typical combustion engine is about only 25 percent efficient); this high efficiency and lightweight led NASA to select fuel cells to power the Space Shuttle Orbiter.
In the Shuttle program, the fuel cells have demonstrated outstanding reliability (over 99 percent availability), with a cumulative operating time in excess of 101,000 hours.
NASA's Space Apollo Program
UTC Power designed, developed, qualified and manufactured the fuel cell power plants for NASA's Apollo, Apollo-Soyuz, and Skylab programs. These were the world's first operational fuel cells, and used the Bacon (molten KOH) technology. A complement of three 28-volt power plants provided all the onboard electrical power to the Apollo Command and Service Modules.
Each power plant was rated at 1.5 kilowatts, with a maximum power of 2.2 kilowatts for brief periods. Each unit weighed 250 pounds and was fueled by cryogenic hydrogen and oxygen. The three cells operated in parallel; a single power plant was enough to ensure safe return.
Fuel cell performance during Apollo was exemplary. Over 10,000 hours of operation were accumulated in 18 missions, without an in-flight incident.
Undersea and Aboard Ship
There has been considerable interest in fuel cells for marine applications, both undersea and shipboard. UTC Power has played a leading role in development and demonstration programs.
The 1980's brought the design and delivery of a complete 30-kilowatt fuel cell power system to the U.S. Navy for the Lockheed Deep Quest vehicle. The alkaline (KOH) electrolyte fuel cell was packaged in a pressure-tight containment vessel, which also served as a heat exchanger. Hydrogen and oxygen were provided from pressurized gas tanks.
The system was operated for several years, at depths of over 5,000 feet. The early 1990's brought the development and demonstration of a 10-kilowatt prototype unit for a Navy unmanned undersea vehicle; this unit used the proton exchange membrane (PEM) technology.
Frequently Asked Questions
- How long have UTC Power fuel cells been used for US space flight?
Since 1966, UTC fuel cells have provided electric power and drinking water on all U.S. manned space flights.
- When was the first flight of the Apollo fuel cell powerplant?
The first flight of the Apollo fuel cell powerplant occurred in 1966 and there were 17 other missions, including the first lunar landing in July 1969.
- When did UTC Power win the Space Shuttle Orbiter program?
In 1973, UTC Power was declared the winner of the competition for the Space Shuttle Orbiter fuel cell powerplant and began developing a new fuel cell system. The first flight of the Space Shuttle was in April of 1981 and UTC Power fuel cells spent more than 110,000 hours aboard Shuttle Orbiters in space.
- How did UTC Power fuel cells power the space shuttles?
Each Space Shuttle Orbiter has three fuel cells onboard that provide all of the shuttleÕs electric power and drinking water for the astronauts. The fuel cells fly an average of five missions before being returned to UTC Power for maintenance and overhaul. Each fuel cell is capable of producing up to 12 kilowatts of continuous power and is more than 70 percent efficient, which is two to three times better than a typical combustion engine. Cryogenic hydrogen and oxygen feed each of the self-contained units, which are installed under the payload bay, just behind the crew compartment.
- Is UTC Power still developing fuel cells for space?
No. UTC Power shipped its last Space Shuttle Orbiter fuel cell powerplant to United Space Alliance, NASAÕs prime shuttle contractor in April of 2010.
- Does UTC Power develop fuel cells for submarines?
Yes. In 2006, UTC Power began to design and develop a 300 kW PEM fuel cell power module for use in submarines. These 300 kW PEM fuel cells are designed to operate on reformed ethanol and pure oxygen.