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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Integrated techno-economic framework for nuclear hydrogen production: assessing the role of high temperature steam electrolysis and safety considerations

This manuscript presents a comprehensive techno-economic assessment of nuclear integrated hydrogen production through high-temperature steam electrolysis (HTSE) in the U.S. Gulf Coast region. Given the significant role of hydrogen as an energy carrier and chemical feedstock, the research evaluates the feasibility of co-locating HTSE facilities with existing nuclear power plants (NPPs) to enhance hydrogen production efficiency and cost-effectiveness. Here, the study highlights the advantages of HTSE over traditional low-temperature electrolysis, particularly in leveraging thermal and electrical energy from NPPs. A novel framework for hydrogen deployment is introduced, integrating hydrogen market analysis, techno-economic evaluation (TEA), and safety assessments. The findings underscore the economic viability of hydrogen production in light of current market conditions, including fluctuating natural gas prices and the impact of production tax credits under the Inflation Reduction Act. A case study in the Gulf Coast region demonstrates the potential for strategic hydrogen production to meet growing industrial demand while ensuring safety and regulatory compliance. Overall, this research contributes to the advancement of nuclear integrated hydrogen production as a sustainable energy solution.

08 - HYDROGEN↗
DOE OSTI2023

NMPC for Setpoint Tracking Operation of a Solid Oxide Electrolysis Cell System

Solid oxide electrolysis cells (SOECs) are a promising technology to generate hydrogen through water electrolysis. However, intermittent renewable energy requires SOECs to transition between hydrogen production setpoints as the price of electricity fluctuates. A well-functioning control system is important to avoid cell degradation during setpoint tracking operation. In this work, we apply nonlinear model predictive control (NMPC) to an SOEC module and supporting equipment and compare NMPC performance to classical PI control while ramping between hydrogen production setpoints. We find that these control methods provide similar performance in many metrics, but NMPC significantly reduces cell thermal gradients during the setpoint transition.

Allan, Douglas↗
DOE OSTI2020

LixNiO/Ni Heterostructure with Strong Basic Lattice Oxygen Enables Electrocatalytic Hydrogen Evolution with Pt-like Activity

The low-cost hydrogen production from water electrolysis is crucial for practical deployment of sustainable hydrogen economy, but is often constrained by the lack of active and robust electrocatalysts from Earth-abundant materials. We describe here an unconventional heterostructure composed of strongly coupled Ni-deficient LixNiO nanoclusters and polycrystalline Ni nanocrystals, and its exceptional activities toward hydrogen evolution reaction (HER) in aqueous electrolytes. The presence of unique lattice oxygen species with strong Brønsted basicity is a significant feature, which spontaneously split water molecules and effectively accelerate the sluggish Volmer H-OH dissociation step in neutral and alkaline HER. In combination with the unpreceded level of intimate LixNiO and Ni interfacial junctions that produces abundant “hotspots” for promoted hydride coupling, the catalyst exhibited kinetic activities almost identical as Pt/C and decent long term stability in universal pH.

Lu, Ke↗
DOE OSTI2025

Ultra-high efficiency hydrogen production using a large-scale solid oxide electrolysis cell system

Efficient and cost-effective production of clean hydrogen is key to decarbonizing the production of hard-to-abate industries, such as chemicals, fuels, steel, cement and many other commodities that form the basis of modern societies. High-temperature steam electrolysis (HTSE) has recently become commercially available and offers opportunities for producing hydrogen at higher efficiency and lower cost than competing low temperature technologies. In this work, we report world record setting hydrogen production efficiency from large-scale prototype HTSE systems based on solid oxide electrolysis cell (SOEC) technology. Independent tests performed at Idaho National Laboratory (INL) employed a Bloom Energy 100 kW SOEC system to achieve a hydrogen production direct current specific electric energy consumption as low as 36.7 kWh per kilogram of hydrogen. Remarkably, similar high efficiencies in the range of 36–39 kW/kg-H2 were obtained over a wide range of hydrogen production rates and even during dynamic ramping as the hydrogen production and electric power consumption of the system were varied between 20 % and 100 % of nominal conditions. Furthermore, these test results validate previous projections that commercial SOEC systems can produce clean hydrogen at efficiencies approaching 100 % for less than 2 U S. dollars per kilogram when located near sources of inexpensive, low-grade heat and clean electricity.

08 HYDROGEN↗
DOE OSTI2022

Discovering and Demonstrating a Novel High-Performing 2D-Patterned Electrode for Proton-Exchange Membrane Water Electrolysis Devices

Proton-exchange membrane water electrolysis (PEMWE) produces hydrogen with high efficiency and purity but uses high-loading platinum-group metal (PGM) catalysts. Such concerns call for the development of novel electrode architectures to improve catalyst utilization and mass activity, thus promoting PEMWE cost competitiveness for large-scale implementation. In this study, we demonstrated, for the first time, a novel two-dimensional (2D)-patterned electrode with edge effects to address these challenges. The edge effect was induced by membrane properties, potential distribution, and counter electrode coverage and could be optimized by tuning the catalyst layer dimensions. To achieve identical PEMWE performance, the optimal pattern saved the 21% anode PGM catalyst compared with the conventional catalyst fully covered electrode. The PGM catalyst could be further reduced by 61% to boost mass activity with no significant performance loss. The results also indicated that the electrode uniformity in PEMWE cells might not be as critical as that in PEM fuel cells. Finally, the novel 2D-patterned electrode could effectively reduce PGM catalyst loading, accelerating affordable and large-scale production of hydrogen and other value-added chemicals via electrolysis.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Comparative Techno-Economic and Life Cycle Analysis of Water Oxidation and Hydrogen Oxidation at the Anode in a CO 2 Electrolysis to Ethylene System

We compare the economic viability of employing hydrogen oxidation versus water oxidation at the anode of a commercial-scale electrolysis plant that converts CO 2 to ethylene. We vary the electrolyzer capital cost, membrane lifetime, and renewable electricity price to represent a current and future market scenario. We find that anodic hydrogen oxidation with membraneless reactor design can reduce the electrolyzer capital cost by up to 48% and reduce electricity demand by at least 50% with the current underdeveloped electrolyzer market. These capital and operating cost savings could further lead to a lower ethylene production cost from anodic hydrogen oxidation than the anodic water oxidation system with hydrogen supplied at less than $\$6$ kg. In the future scenario with a fully developed electrolyzer market and cheap renewable electricity, we find that the anodic hydrogen oxidation system requires hydrogen cheaper than $0.7/kg to compete with the anodic water oxidation system. Moreover, hydrogen oxidation at the anode enables extremely low cradle-to-gate emission ethylene by utilizing negative emission hydrogen such as biomass gasification with carbon capture and sequestration, ~240% lower than ethylene produced from the wind/solar electricity-driven water oxidation system. Furthermore, this low carbon footprint ethylene can further boost the economic competitiveness for anodic hydrogen oxidation with a future carbon credit market.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Atomically dispersed Pt single sites and nanoengineered structural defects enable a high electrocatalytic activity and durability for hydrogen evolution reaction and overall urea electrolysis

The scarcity and high cost of PGM electrocatalysts are the key bottleneck in the mass-scale commercialization of many electrolysis technologies. Bifunctional single-atom electrocatalysts (SACs) are promising alternatives for PGM electrocatalysts in next-generation electrolysis technologies because of their superior intrinsic activity and perfect atom utilization. Regulating the coordination environment of platinum atomic sites identifies their electrocatalytic performance. Therefore, exploring more appropriate supports could facilitate the construction of active and durable electrocatalysts with ultralow noble metal content. Herein, we report on a reliable approach for producing a novel type of SACs composed of atomically dispersed Pt active sites stabilized on defective NiCo layered double hydroxide (Pt/D-NiCo LDH) nanosheets as an ultralow-Pt hybrid electrocatalyst for hydrogen evolution reaction (HER), urea oxidation reaction (UOR), and full urea-water electrolysis. The optimized Pt 1 /D NiCo LDH-24 SAC displays a remarkable HER and UOR performance where it yields a current density of 10 mA cm -2 at 37 mV and 1.25 V vs. RHE for HER and UOR, respectively. Finally, symmetrical urea electrolyzer constructed of Pt 1 /D-NiCo LDH-24 electrodes attains 10 mA cm -2 at a cell voltage of 1.32 V vs. RHE, demonstrating superior activity and durability over 60 h operation when compared to commercial Pt/C( + )||RuO 2 ( - ) system.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Second Target Station Project: STS Cross-Directorate Workshop on Hydrogen Fuel

Hydrogen, particularly green hydrogen produced through electrolysis using renewable energy, is poised to play a critical role in decarbonizing the global economy. Its ability to address the intermittency of renewable energy sources and decarbonize hard-to-electrify sectors positions it as a vital component of a sustainable energy future. Interest in hydrogen as a clean energy carrier is in a decade of unprecedented growth, with dozens of countries having released national hydrogen strategies contributing to a global hydrogen economy. In 2021, the Department of Energy (DOE) announced the Hydrogen Shot, the first of the Energy Earthshot Initiatives, which aims to lower the cost of clean hydrogen to $\$$1/kg by 2031. This initiative was followed by a considerable increase in funding for hydrogen technologies through the Bipartisan Infrastructure Law (BIL), with $\$$18 billion recently announced for regional demonstration projects (Hydrogen Hubs) and another $\$$11.5 billion aimed at research and development of electrolyzers, fuel cells, manufacturing, and recycling. The 2023 U.S. National Clean Hydrogen Strategy and Roadmap identifies the cost of clean hydrogen as a critical challenge for achieving economic scale. This includes the cost of hydrogen production by electrolysis, delivery and dispensing, onboard storage, and end-use technologies like fuel cells. Fundamental research and development into catalysts, component architectures, and material durability are critical to lower the costs of these vital technologies aimed at achieving a net-zero carbon emission economy by 2050.

08 HYDROGEN↗
DOE OSTI2025

Application of a temporal multiscale method for efficient simulation of degradation in PEM Water Electrolysis under dynamic operating conditions

Hydrogen is emerging as a vital energy carrier, driven by the need to reduce carbon emissions. Proton Electrolyte Membrane Water Electrolysis (PEMWE) enables hydrogen production under fluctuating renewable power conditions but requires improved understanding and stability of the anode catalyst layer under dynamic operating conditions, especially with low noble metal loadings. Long-term degradation experiments are both time-consuming and costly; therefore, a systematic, model-aided approach is essential. In the present work, a temporal multiscale method is applied to reduce the computational effort of simulating long-term degradation processes in PEMWE, with an exemplary focus on catalyst dissolution. A mechanistic model incorporating the oxygen evolution reaction, catalyst dissolution, and hydrogen permeation from the cathode to the anode was hypothesized and implemented. In this way, the local periodicity of transport and reaction processes in dynamic PEMWE operation, which influence the gradual degradation of the catalyst layer, is captured. The temporal multiscale method significantly reduces the computational effort of simulation, decreasing processing time from hours to mere minutes. This efficiency gain is attributed to the limited evolution of Slow-Scale variables during each period of time P of the Fast-Scale variables. Consequently, simulation is required only until local periodicity is achieved within each Slow-Scale time step. Hence, the fully resolved dynamic problem is decoupled into these two scales, employing a heterogeneous multiscale technique. The developed approach effectively accelerates parameter estimation and predictive simulations, supporting systematic modeling of PEMWE degradation under dynamic conditions.

08 HYDROGEN↗
DOE OSTI2024

Optimal Control of SOEC-Based Hydrogen Production Systems for Demand Response Using Deep Reinforcement Learning in Smart Grids

Solid oxide electrolysis cell (SOEC) hydrogen production technology can range in size from small, appliance-size equipment to large-scale, central production facilities that can be tied directly to renewable or non-greenhouse-gas-emitting forms of electricity production, making it an ideal resource for demand response (DR). The SOEC hydrogen production system is a complex integrated system that encompasses fluid dynamics, electrical dynamics, and electrochemical and thermal dynamics, all of which involve non-linearity and non-convexity. Proper control of the SOEC hydrogen production system is crucial to enable its participation in the DR program. Here, to overcome the difficulty of designing an explicit control law for such nonlinear systems with nonconvex optimization features in DR applications, deep reinforcement learning (DRL) is explored to achieve the optimal control of the SOEC system for DR participation. Specifically, a twin delayed deterministic policy gradient (TD3) control framework is applied to achieve optimal response performance during DR events by considering power tracking error and hydrogen production efficiency with a suitable reward function. Two case studies with grid connections for tracking different DR commands were investigated. The first case study involved operating conditions reaching the boundaries, while the second involved operating conditions within the boundaries. The results showed that the proposed DRL-based control for SOEC can track the DR signal in a timely manner while maintaining high energy efficiency.

08 HYDROGEN↗
DOE OSTI2025

Quantifying Sources of Voltage Decay in Long-Term Durability Testing for PEM Water Electrolysis

Meeting a competitive 1$/kg hydrogen cost target for polymer electrolyte membrane water electrolysis (PEMWE) will require advances to significantly reduce capital costs and precious metal catalyst usage, while simultaneously enabling 40,000–80,000 h stack lifetimes under dynamic use conditions. Minimizing cell voltage decay rates is therefore a key goal for PEMWE, although the fundamental processes governing voltage decay are not yet well understood. Here we present a quantitative approach to analyze the contributions to voltage decay in long-term PEMWE testing using polarization curves, impedance spectroscopy, and post-mortem electron microscopy. We apply this approach to analyze a 28 μV h −1 decay rate observed in a 4000 h durability test of a cell using 0.5 mg cm −2 total PGM catalyst loading (0.4 mg Ir cm −2 anode, 0.1 mg Pt cm −2 cathode) and 3 A cm −2 current density. We also analyze a comparative series of 1000 h tests under different conditions. These results provide valuable insights into anode catalyst degradation processes, as well as transferrable methodology for PEMWE durability research.

08 HYDROGEN↗
NASA NTRS1975

Hydrogen generation through static-feed water electrolysis

A static-feed water electrolysis system (SFWES), developed under NASA sponsorship, is presented for potential applicability to terrestrial hydrogen production. The SFWES concept uses (1) an alkaline electrolyte to minimize power requirements and materials-compatibility problems, (2) a method where the electrolyte is retained in a thin porous matrix eliminating bulk electrolyte, and (3) a static water-feed mechanism to prevent electrode and electrolyte contamination and to promote system simplicity.

Jensen, F. C.↗
DOE OSTI2023

Renewable Electrolysis System Development (Final Report)

Renewable hydrogen is becoming globally recognized as a key component required for de-carbonization of our energy system, both as a medium for capture of excess renewable energy sources, vehicle refueling, and as an intermediate for multiple industrial processes. Hydrogen production, via low-temperature electrolysis, is a flexible grid-friendly, clean energy carrying intermediate that enables fast ramp and de-ramp rates as naturally varying solar, wind, and storage systems become a larger percentage of the electricity mix. Analysis shows that by 2050, employing renewable hydrogen at scale can decrease total U.S. CO 2 emissions by about half relative to business as usual, critical to achieving >80% greenhouse gas reduction targets. Energy storage systems help commercial customers reduce their electric bills by storing energy from the grid or from renewable electricity sources when energy is inexpensive, then using that stored energy when demand and prices are high. Proton exchange membrane (PEM) electrolysis is one of the few technologies that can produce hydrogen with zero carbon emissions at relevant scale (hundreds of MWs) in the near term. NREL's research has shown that electrolyzers are fast and flexible enough to participate in energy and ancillary service markets that can help stabilize the grid. In 2015, Proton OnSite (now NEL Hydrogen) introduced the M-series electrolyzer platform, the world's first megawatt PEM electrolyzer for the global energy storage market, offering a carbon-free source of hydrogen fuel or process gas. In addition, the ability to sell the hydrogen into a high value application like vehicle (e.g., light- and heavy-duty and material handling) fueling allows for a layering of revenue streams that creates better business cases for hydrogen energy storage systems (HES). The ability to provide multiple value streams from the fast-responding controllable electrolyzer will have a direct impact on the net cost of hydrogen.

08 HYDROGEN↗
DOE OSTI2026

Hydrogen Production Cost from Proton-Conducting Solid Oxide Electrolysis

Rigorous stakeholder-vetted techno-economic analysis (TEA) was conducted to estimate the cost of hydrogen (H 2 ) production using Proton-Conducting Solid Oxide (PSO) electrolysis. The analysis evaluates Current (2025) and Future (2035) technology cases at centralized plant scales of 50 and 500 metric tonnes per day (MTD), assuming electricity, water, and air as the only system inputs. Untaxed, unsubsidized levelized cost of hydrogen (LCOH) is projected to range from 2020 $\$$1.81 to $\$$2.47/kg H 2 at an electricity price of $\$$0.03/kWh and 97% capacity factor under Nth-of-a-kind (NOAK) deployment assumptions. Total installed capital cost was developed using bottom-up Design for Manufacture and Assembly (DFMA) stack cost modeling and detailed balance-of-plant estimates, including mechanical and electrical subsystems, installation, site preparation, engineering, and contingency. Stack performance assumptions include thermoneutral operation, degradation over time, and periodic replacement. LCOH was calculated using the Hydrogen Analysis (H2A) discounted cash flow model in constant 2020 dollars. Results indicate PSO electrolysis has potential for competitive hydrogen production costs under low-cost electricity and mature manufacturing conditions.

08 HYDROGEN↗
DOE OSTI2026

Designing the Platinum Catalyst Layer for Improved Performance and Durability in Anion Exchange Membrane Water Electrolysis

To lower the cost of hydrogen produced by anion exchange membrane water electrolysis (AEMWE), it is critical to reduce the use of platinum group metal (PGM) catalysts within the device. While iridium has been successfully replaced with PGM-free catalysts at the anode, platinum-based (Pt) cathode catalysts are still required to meet the activity and durability targets. This study investigates the impact of commercial Pt/C catalyst loading, ionomer type and content, and electrode fabrication method on the cathode catalyst layer properties and AEMWE performance with the aim of determining the feasibility of reduced Pt loadings. While increased Pt loading is found to improve beginning-of-life performance, the effects are minimal above 0.6 mg/cm 2 . Ink characterization shows that ionomer type and content affect the ink stability, particle size, and percent of unbound ionomer, which further impact the homogeneity of the sprayed catalyst layers. The 5% PiperION cathode exhibited the highest performance, which may be attributed to a balance between the small particle size and the low proportion of unbound ionomer, minimizing kinetic and transport losses. Theoretical calculations show that the ionomers interact differently with the Pt surface, causing different surface charges and water adsorption strength and activating different mechanisms for hydrogen evolution. Pt-PiperION lowered the enthalpy of water-splitting by 0.1 eV compared to Pt alone and allowed for equal site access between adsorbed H* and OH* (both adsorbed at circa −2.2 eV). Although catalyst-coated membrane (CCM) fabrication techniques are desirable for scale-up, no performance enhancement is observed compared with the catalyst-coated substrate approach. Durability, as measured by degradation rates, Pt loss, and catalyst layer restructuring, was found to improve with increased Pt loadings, higher ionomer content, and CCM architectures. These findings provide important insight into the significant role of the cathode in AEMWE and strategies for maintaining the performance with low Pt loading or PGM-free catalysts.

08 HYDROGEN↗
DOE OSTI2025

Investigating the Effects of Copper Impurity Deposition on the Structure and Electrochemical Behavior of Hydrogen Evolution Electrocatalyst Materials

Electrolysis of impure water (such as seawater) has recently garnered research interest as it may enable hydrogen production at reduced costs. However, the tendency of impurity ions and other species to degrade electrocatalysts and membranes within an electrolyzer is a serious challenge. Here, we investigate the effects of copper impurities of varying concentrations on the hydrogen evolution reaction (HER) using platinum electrocatalysts. A decrease of current density is observed with an increasing copper concentration. By comparing the effect of ionic impurities on current density at different concentrations, we gain insight into how impurities can interfere with the HER at different potentials. Surface characterization of the electrodes reveals differences in the morphology and extent of copper deposition on HER-active platinum vs inactive gold electrodes. This enables an improved understanding of how copper nucleates and grows on the two types of electrodes under different electrochemical conditions while also confirming deposition in low-concentration cases, as present in seawater. The results indicate that copper electrodeposition competes with the HER, and the nature of copper electrodeposition varies depending on the electrocatalytic activity of the electrode. This study provides insight toward catalyst design that can withstand the effects of impurity-induced degradation over extended use.

08 HYDROGEN↗
NASA NTRS1977

Thermochemical water decomposition

At present, nearly all of the hydrogen consumed in the world is produced by reacting hydrocarbons with water. As the supply of hydrocarbons diminishes, the problem of producing hydrogen from water alone will become increasingly important. Furthermore, producing hydrogen from water is a means of energy conversion by which thermal energy from a primary source, such as solar or nuclear fusion of fission, can be changed into an easily transportable and ecologically acceptable fuel. The attraction of thermochemical processes is that they offer the potential for converting thermal energy to hydrogen more efficiently than by water electrolysis. A thermochemical hydrogen-production process is one which requires only water as material input and mainly thermal energy, or heat, as an energy input. Attention is given to a definition of process thermal efficiency, the thermodynamics of the overall process, the single-stage process, the two-stage process, multistage processes, the work of separation and a process evaluation.

Funk, J. E.↗