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Initial efforts in the development of an EVA portable contamination detector (EVA PCD) for use by the EVA crew have resulted in the selection and preliminary testing of a concept based upon time-of-flight(TOF) mass spectrometry. The EVA PCD will be a compact, man-portable device intended for use in the ambient vacuum outside the Space Station. It will be used to monitor the surfaces of the EVA suits and mobility units for the presence of potentially toxic contaminants, such as hydrazine propellants and oxidizers, which might otherwise be inadvertently carried into the interior of the Station. The EVA PCD will also be used to locate small leaks of heat exchange fluids in the outer surface of the Station. This paper describes some key performance needs for the EVA PCD system, approaches taken to interpreting those needs, and some of the results of tradeoff analyses which led to the selection of the TOF concept. Some results from initial experimental tests of a TOF unit are presented.

An approach to the isolation and concentration of volatile organic compounds from a water sample prior to chemical analysis in a microgravity environment has been previously described (Reference 1). The Volatile Organics Concentrator (VOC) system was designed for attachment to a gas chromatograph/mass spectrometer (GC/MS) for analysis of the volatile organics in water on Space Station Freedom. The VOC concept utilizes a primary solid sorbent for collection and concentration of the the organics from water, with subsequent transfer using nitrogen gas through a permeation dryer tube to a secondary solid sorbent tube. The secondary solid sorbent is thermally desorbed to a gas chromatograph for separation of the volatiles which are detected using a mass spectrometer.

A cold-start partial oxidation (POX) system was integrated with a modern flexible fuel engine to assess its impact on cold-start performance and emissions. The POX reactor, a small combustion device operating fuel rich, converts liquid fuel into gaseous fuel species (reformate). The reformate from the reactor, when mixed with combustion air, replaces or supplements the standard fuel consumed during an engine start. This prototype integrated cold-start system has successfully reduced emissions from a cold-start on fuel grade ethanol (E95) at 5°C. The integrated POX system reduced the time-averaged hydrocarbon (HC) and carbon monoxide (CO) emissions by 80 and 40 percent, respectively. Starts on E95 reformate were achieved in less than 10 seconds at temperatures as low as -20°C.

The process used to identify, select and design an approach to the isolation and concentration of volatile organic compounds from a water sample prior to chemical analysis in a microgravity environment is described. The Volatile Organics Concentrator (VOC) system described in this paper has been designed for attachment to a gas chromatograph/mass spectrometer (GC/MS) for analysis of volatile organics in water on Space Station. In this work, in order to rank the many identified approaches, the system was broken into three critical areas. These were gases, volatile separation from water and water removal/GC/MS interface. Five options involving different gases (or combinations) for potential use in the VOC and GC/MS system were identified and ranked. Nine options for separation of volatiles from the water phase were identified and ranked. Seven options for use in the water removal/GC column and MS interface were also identified and included in overall considerations.

The feasibility of using open path Fourier transform infrared (OP-FTIR) spectrometry as an ambient air sensor on spacecraft was examined. OP-FTIR is a valuable monitoring technique because the sensor requires no sample preparation or separations and compositional information obtained is along a path rather than at a sampling point. OP-FTIR monitors and quantitates in real-time, offers high sensitivity, and detection is compound-specific. The data analysis, data reduction, and hardware requirements were investigated and potential applicability of chemometric methods and state-of-the-art commercial hardware systems were discussed.

Open-path Fourier transform infrared (OP-FTIR) spectrometry was evaluated for potential application to the measurement of contaminants in spacecraft air environments. OP-FTIR provides simultaneous, real-time quantification and confirmation of identity for most contaminants on the current Spacecraft Maximum Allowable Concentration (SMAC) list. In addition, the open-path measurement configuration provides characterization of an area rather than at a point. The dynamic composition and distribution of air contaminants throughout spacecraft air systems is measured without the need for multi-point sampling. These characteristics of open path FTIR make it a valuable method for spacecraft air characterization.

In addition to high-profile fuel cell applications such as automotive propulsion and distributed power generation, the use of fuel cells as auxiliary power units (APU) for vehicles has received considerable attention. APU applications may be an attractive market because fuel cells offer some attractive features for APU applications and the APU market offers a true mass-market opportunity that does not require some of the challenging performance and cost targets required for propulsion systems for vehicles. In this paper we discuss the technical performance requirements for PEM and SOFC APUs, as well as the current status of the technology and the implications for fuel cell system configuration and cost.

The task of matching engine, control system and catalytic converter has become very complex as the automotive industry strives to meet stringent demands for pollution abatement. To address the need for a robust, accurate modeling tool we have created a microkinetics-based simulation program that describes the reactions taking place on the surface of a catalytic converter. This chemically detailed approach permits the construction of faithful simulations of both steady state and transient performance of the catalyst using a combination of experimental measurements, literature data and quantum chemical calculations. The model can be coupled to existing simulations of the engine and control elements, notably those based on GT-Power.

Cost is one of the critical factors in the commercialization of PEM fuel cells in automotive markets. Arthur D. Little has been working with the U.S. Department of Energy, Office of Transportation Technologies to assess the cost of fuel-flexible reformer proton exchange membrane (PEM) fuel cell systems based on near-term technology but cost modeled at high production volumes and to assess future technology scenarios. Integral to this effort has been the development of a system configuration (in conjunction with Argonne National Laboratories), specification of performance parameters and catalyst requirements, development of representative component designs and manufacturing processes for these components, and development of a comprehensive bill of materials and list of purchased components. The model, data, and component designs have been refined based on comments from the Freedom Car Technical Team and fuel cell system and component developers.

One of the biggest barriers to commercialization of fuel cell vehicles is the high cost of materials and manufacturing of fuel cell components. Precious metal materials in the membrane electrode assemblies (MEAs) account for more than 17 percent of the total cost of polymer electrolyte membrane (PEM) fuel cell systems. Precious metals such as platinum may also be required for fuel processing catalysts. The Department of Energy (DOE) is addressing the important issue of the cost of fuel cell components by supporting R&D projects aimed at improving the performance of fuel cells which would lead to reduced platinum loading, as well as developing low-cost automated industrial processes for the manufacture of electrodes and MEAs. Other projects include development of a supply-demand elasticity model. The long term reserves and availability of platinum is a serious issue facing the commercial viability of fuel cell vehicles.

After about a decade of considerable investments in polymer electrolyte fuel cell (PEMFC) and in solid oxide fuel cell (SOFC) technology, both are being actively considered for vehicle applications. The two vehicle applications being most actively considered for fuel cells are propulsion (mainly for PEMFC) and auxiliary power (for both PEMFC and SOFC). For all transportation applications, fuel cells promise the benefits of clean and quiet operation, potentially low maintenance and high efficiency, and ultimately greater utility to drivers and passengers. Initial system and vehicle prototypes have started to demonstrate some of these benefits, but much technology development is still needed before commercialization can occur. Not surprisingly then, there are serious hurdles to be overcome if fuel cells are to become true competitors for internal combustion engines (ICEs) in automotive applications.

The vast majority of cars and small trucks are sold with factory installed air conditioning (approximately 80% in 1989). For electric vehicles to succeed in the marketplace, air conditioning will need to be offered as optional equipment, along with adequate heating and defrosting systems. While providing the level of cooling performance expected by vehicle operators, it is important that the power consumption of the air conditioning systems used in electric vehicles be minimized, to minimize penalties to vehicle range and performance. This paper summarizes the design and performance of several air conditioning systems that have been developed for electric vans over the past two years, including systems based largely on standard automobile air conditioning components and more advanced systems using high performance heat transfer components and a variable speed refrigerant compressor.

The vast majority of cars and small trucks are sold with factory installed air conditioning (approximately 80% in 1989). For electric vehicles to succeed in the marketplace, air conditioning will need to be offered as optional equipment, along with adequate heating and defrosting systems. While providing the level of cooling performance expected by vehicle operators, it is important that the power consumption of the air conditioning systems used in electric vehicles be minimized, to minimize penalties to vehicle range and performance. Due to the ongoing CFC-12 phase-out, air conditioning systems intended for EV applications beyond the early 1990's must use an environmentally acceptable alternative refrigerant. This paper summarizes the design of a variable speed Scroll compressor based prototype air conditioning system for an electrically powered mini-van. The system refrigerant is HFC-134a and high performance heat transfer components are utilized.

A Portable Contamination/Leak Detector (PC/LD) is being developed for use by crew on Extravehicular Activity (EVA) to locate trace leaks from Space Station Freedom (SSF) systems and to monitor the surfaces of the Extravehicular Mobility Unit (EMU) for toxic contaminants being removed prior to ingress to the airlock. As with any trace level detector the background in which it operates has a significant impact on the operation and design of the instrument. The PC/LD operates in space vacuum and is sensitive to the composition and pressure which exists near the station. This paper describes the PC/LD mission, some data on the composition of ambient space environment and implications of that data on the PC/LD's design and usage.

Efficient aftertreatment management requires accurate sensing of both particulate filter soot and ash levels for optimized feedback control. Currently a combination of pressure drop measurements and predictive models are used to indirectly estimate the loading state of the filter. Accurate determination of filter soot loading levels is challenging under certain operating conditions, particularly following partial regeneration events and at low flow rate (idle) conditions. This work applied radio frequency (RF)-based sensors to provide a direct measure of the particulate filter soot levels in situ. Direct measurements of the filter loading state enable advanced feedback controls to optimize the combined engine and aftertreatment system for improved DPF management. This study instrumented several cordierite and aluminum titanate diesel particulate filters with RF sensors. The systems were tested on a range of light- and heavy-duty applications, which included on- and off-road engines.

Radio frequency (RF)-based sensors provide a direct measure of the particulate filter loading state. In contrast to particulate matter (PM) sensors, which monitor the concentration of PM in the exhaust gas stream for on-board diagnostics purposes, RF sensors have historically been applied to monitor and control the particulate filter regeneration process. This work developed an RF-based particulate filter control system utilizing both conventional and fast response RF sensors, and evaluated the feasibility of applying fast-response RF sensors to provide a real-time measurement of engine-out PM emissions. Testing with a light-duty diesel engine equipped with fast response RF sensors investigated the potential to utilize the particulate filter itself as an engine-out soot sensor.

An approach to the isolation and concentration of volatile organic compounds from a water sample prior to chemical analysis in a microgravity environment has been previously described (Reference 1). The Volatile Organics Concentrator (VOC) system was designed to attach to a gas chromatograph/mass spectrometer (GC/MS) for analysis of volatile organic compounds in water on Space Station Freedom. The VOC utilizes a primary solid sorbent for collection and concentration of the volatile compounds, transfer of the volatiles through a permeation dryer to a secondary solid sorbent, followed by thermal desorption of volatiles from the secondary sorbent onto a GC/MS system. Fabrications and preliminary testing of the VOC breadboard using a gas chromatography equipped with flame ionization detector has been previously described (Reference 2). These results have indicated that the VOC will meet or exceed the goals set for the program.

Arthur D. Little in conjunction with the Department of Energy and the Illinois Department of Commerce and Community Affairs are developing an ethanol fuel processor for fuel cell vehicles. Initial studies were carried out on a 25 kWe catalytic partial oxidation (POX) reformer to determine the effect of equivalence ratio, steam to carbon ratio, and residence time on ethanol conversion. Results of the POX experiments show near equilibrium yields of hydrogen and carbon monoxide for an equivalence ratio of 3.0 with a fuel processor efficiency of 80%. The size and weight of the prototype reformer yield power densities of 1.44 l/kW and 1.74 kg/kW at an estimated cost of $20/kW.

Industrial grade ethanol, in concentrations ranging from 130 proof to 200 proof, can be used as a feedstock for a 50kWe advanced fuel processor developed by Arthur D. Little, Inc. for fuel cell vehicles. At 180 proof concentration, hydrated ethanol showed no performance degradation compared with both 200 proof (pure) ethanol and E95 (95% ethanol and 5% gasoline) at equivalence ratios ranging from 3.0 to 4.0. Environmental benefits associated with the use of ethanol in fuel cell power systems include its production from renewable biological sources, low toxicity in the event of an accidental spill, and recycling of carbon dioxide released by the process back to the plant matter used as ethanol feedstock. Cost savings associated with the use of hydrated ethanol are expected to include lower production costs, lower distribution costs, and lower powerplant costs due to the possibility of system simplification.

A study was conducted to determine the potential reduction in automotive fuel consumption based on the use of innovative systems and improved components. Technological areas investigated were: spark ignited engines with and without turbocharging, electronic feedback controlled fuel injection with duel bed catalytic converters, stratified charge combustion, light weight diesels, lock-up torque converters, continuously variable ratio transmission, tires aerodynamic drag, vehicle weight, engine accessories and optional equipment. Standard and compact-size 1973 model year vehicles were selected for analysis using a computer-simulation program to predict fuel usage and performance with and without incorporation of the improvements. In addition estimates were made as to whether modified vehicles complied with study constraints such as emission, safety, noise and user requirements.