NaBH₄ (sodium borohydride) hydrogen generator with a volume-exchange fuel tank for small unmanned aerial vehicles powered by a PEM (proton exchange membrane) fuel cell

A proton exchange membrane fuel cell system integrated with a NaBH₄ (sodium borohydride) hydrogen generator was developed for small UAVs (unmanned aerial vehicles). The hydrogen generator was composed of a catalytic reactor, liquid pump and volume-exchange fuel tank, where the fuel and spent fuel exchange the volume within a single fuel tank. Co–B catalyst supported on a porous ceramic material was used to generate hydrogen from the NaBH₄ solution. Considering the power consumption according to the mission profile of a UAV, the power output of the fuel cell and auxiliary battery was distributed passively as an electrical load. A blended wing-body was selected considering the fuel efficiency and carrying capability of fuel cell components. First, the fuel cell stack and hydrogen generator were evaluated under the operating conditions, and integrated into the airframe. The ground test of the complete fuel cell UAV was performed under a range of load conditions. Finally, the fuel cell powered flight test was made for 1 h. The volume-exchange fuel tank minimized the fuel sloshing and the change in center of gravity due to fuel consumption during the flight, so that much stable operation of the fuel cell system was validated at different flight modes. - Highlights: • PEMFC system with a NaBH₄ hydrogen source was developed for small UAVs. • Volume-exchange fuel tank was used to reduce the size of the fuel cell system. • Passive power management was used for a stable power output during the flight. • BWB UAV was selected by taking the fuel cell integration into consideration. • Stable operation of the fuel cell system was verified from the flight test