Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “hydrogen station”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Next Generation Multi-Use Heavy-Duty High-Flow Direct-Fill Hydrogen Refueling Station with Standardized Design (CRADA Final Report)

The Contractor will build a liquid hydrogen (LH2) fueling station model that is capable of simulating the amount of hydrogen transferred from the liquid storage tank to the vehicle, depending on the station’s design and control scheme. This modeling work will allow the Parties to seek the design and control scheme of an LH2 station that can fill a targeted number of vehicles while meeting a time-average flow rate of 10 kg/min for each fill. While evaluating a high dispensing performance station design and control scheme, the Contractor will analyze the design and control scheme are economically viable.

08 HYDROGEN↗
DOE OSTI2024

Heavy-Duty Hydrogen Fueling Station Corridors

In this short technical report, we explore the range of levelized costs of dispensed hydrogen (H2) from hydrogen refueling (or fueling) stations (HRS) for H2 heavy-duty fuel cell electric vehicles (FCEVs) that are feasible in the 2030 timeframe. We explore different scenarios by varying hydrogen delivery distances, HRS sizes, HRS utilization rates, and economies of scale in the Hydrogen Delivery Scenario Analysis Model (HDSAM). Thus, we observe how the contribution to the levelized cost of each supply chain component changes.

DIRECT ENERGY CONVERSION,HYDROGEN↗
DOE OSTI2023

H2@Scale CRADA: CA Research Consort. (Ref. Station, Fueling Perf. Test Device, Station Cap Model)

Heavy-duty (HD) hydrogen stations are an essential part of building a clean energy infrastructure by lowering greenhouse gas emissions and criteria pollutants from the trucking industry. Clean fuel at HD stations also supports energy, environmental, and social justice by preventing pollution near the stations and on truck routes while strengthening U.S. manufacturing and providing pathways to private sector uptake. The goal of the CA Research Consortium is to continue the research partnership between national laboratories, DOE, and California public agencies for the advancement of hydrogen fueling infrastructure for HD vehicles. This cooperative work directly impacts California's transition to Zero Emission Trucks and will provide tools and information that lead to more efficient design, acceptance, and commissioning of these larger capacity, higher flow rate stations serving HD hydrogen trucks such as class 8 trucks in long haul applications.

AMR↗
DOE OSTI2023

Heavy-Duty Hydrogen Fueling Station Corridors

Developing zero-emissions fueling corridors requires assessment of technologies that may be utilized in the M/HDV sector. BEVs and FCEVs are leading choices of zero emissions technology and work is required to understand how infrastructure may be deployed and at what cost to facilitate M/HDV decarbonization goals.

class 6↗
DOE OSTI2023

Design and requirements of a hydrogen component reliability database (HyCReD)

Hydrogen technologies are expected to play a key role in the decarbonization of several sectors including energy storage and transportation. Rigorous investigation and quantification of the risk and reliability issues associated with hydrogen technologies will be critical to ensuring both their wider adoption and safe, economical operations. Quantitative risk assessment (QRA) is an important tool that has been used to enable the safe deployment of many engineering systems, including hydrogen fueling stations and hydrogen storage systems. However, QRA studies require reliability data which is currently lacking for expanding applications of hydrogen systems. Here, to address this gap, we present a new structure for a hydrogen component reliability database (HyCReD) that can be used to generate reliability data to be used in QRA, reliability, safety studies, maintenance planning, and more. Building on our previous work examining four major hydrogen safety data collection tools (West et al., 2022) [1], our approach in this work was to consult scientific literature on reliability data collection as well as a number of existing reliability engineering databases in the oil & gas, chemical processing, and nuclear power plant sectors. The evaluation of these databases led to identifying best practices to be implemented in a data collection framework for a hydrogen component reliability database. Based on these best practices, a set of 24 requirements for the proposed database are presented, covering its characteristics and the types of data to be collected. We define the structure of the HyCReD database and 25 data elements to be collected, spanning system description, failure, shutdown, or near-miss events, and maintenance events. The data elements are then defined according to international standards used in the safety and reliability practice and potential choice lists are provided for each field. Since this database is being piloted for hydrogen fueling stations, a generic station component hierarchy developed by West (2021) [2] is used to standardize system data. Finally, we demonstrate populating the database with information extracted from five narrative reports on hydrogen fueling station incidents.

08 HYDROGEN↗
DOE OSTI2023

Experimental Comparison of Hydrogen Refueling with Directly Pressurized vs. Cascade Method

This paper presents a comparative analysis of two hydrogen station configurations during the refueling process: the conventional “directly pressurized refueling process” and the innovative “cascade refueling process.” The objective of the cascade process is to refuel vehicles without the need for booster compressors. The experiments were conducted at the Hydrogen Research and Fueling Facility located at California State University, Los Angeles. In the cascade refueling process, the facility buffer tanks were utilized as high-pressure storage, enabling the refueling operation. Three different scenarios were tested: one involving the cascade refueling process and two involving compressor-driven refueling processes. On average, each refueling event delivered 1.6 kg of hydrogen. Although the cascade refueling process using the high-pressure buffer tanks did not achieve the pressure target, it resulted in a notable improvement in the nozzle outlet temperature trend, reducing it by approximately 8 °C. Moreover, the overall hydrogen chiller load for the two directly pressurized refuelings was 66 Wh/kg and 62 Wh/kg, respectively, whereas the cascading process only required 55 Wh/kg. This represents a 20% and 12% reduction in energy consumption compared to the scenarios involving booster compressors during fueling. The observed refueling range of 150–350 bar showed that the cascade process consistently required 12–20% less energy for hydrogen chilling. Additionally, the nozzle outlet temperature demonstrated an approximate 8 °C improvement within this pressure range. These findings indicate that further improvements can be expected in the high-pressure region, specifically above 350 bar. This research suggests the potential for significant improvements in the high-pressure range, emphasizing the viability of the cascade refueling process as a promising alternative to the direct compression approach.

08 HYDROGEN↗
DOE OSTI2025

Operational optimization for multi-functional charging station with electric and hydrogen-powered vehicles

The rapid adoption of electric vehicles (EVs) and hydrogen fuel cell vehicles (HFCVs), combined with global efforts to reduce carbon emissions, has accelerated the development of EV charging and hydrogen refueling stations. In response to this demand, this paper introduces the concept of Multi-Functional Charging Station (MFCS) that integrates power generation, EV charging, battery swapping, and hydrogen refueling. A comprehensive operational model is developed for the MFCS that couples electricity and hydrogen conversion and storage technologies to enhance infrastructure utilization and improve overall system efficiency. The model also considers multiple revenue streams, including participation in energy and ancillary markets. To validate the effectiveness of the proposed model and evaluate its performance, a series of numerical experiments are conducted with different charger numbers, different electricity purchase limits, and different charger allocations. Numerical results demonstrate that shared charger configurations can lead to 8.11 % improvement in operational profit by improving resource utilization and reducing the number of depleted batteries at the end of operations compared to allocated charger setups. By varying the number of chargers, sensitivity analysis identifies diminishing marginal returns beyond about 45 chargers, suggesting it as an optimal sizing point under current settings. The integration of electricity and hydrogen conversion is also explored under scenarios with limited external electricity purchases. In conclusion, these findings indicate that optimizing charger allocation and energy management can significantly enhance station productivity and profitability, ultimately supporting the broader adoption of electrified and hydrogen-based transportation solutions.

Charging station↗
DOE OSTI2023

Maritime Fuel Cell Generator Project: 2018 – 2023

This report summarizes activity in the Maritime Fuel Cell (MarFC) Generator Project from 2018 – 2023. FY 2018 saw the implementation of upgrades and repairs, making the unit more reliable and operator friendly. In FY2019 the team engaged the Scripps Institution of Oceanography (SIO) to use the MarFC to provide zero-emission shore power to the research vessel R/V Robert Gordon Sproul while in port at the Nimitz Marine Facility in San Diego, CA. In FY2020, the MarFC unit was shipped to San Diego, CA. A fueling contract with IGX was established to support MarFC operations at SIO, with renewable hydrogen provided by the California State University Los Angeles (CSULA) hydrogen station. The project team (Sandia, Cummins/Hydrogenics) provided training to SIO staff on the technical details of the MarFC, the safe use of hydrogen in general and the MarFC in particular. The first fueling of the unit at the SIO pier was successfully completed by IGX. The first powering of a vessel with fuel-cell shore power was conducted with the R/V Robert Gordon Sproul. While the mechanical systems (lights, AC, ventilation, hydraulics, pumps and cranes) were powered without incident, problems arose when powering the computer systems. Inspections carried out in FY2021 revealed the MarFC needed routine maintenance. Maintenance was performed and the unit was upgraded. The MarFC was turned on after the year pause, and initial test data on power levels and stability were collected. FY2022 was a year spent repairing, upgrading and testing the MarFC unit. Spikes in power and voltage were observed above 60 kW that could potentially extend below 60 kW with time. Such spikes could cause problems with the Sproul electrical systems. These age-related problems, the extended time for the Sproul spent in dry dock for scheduled upgrades, and the associated need to reschedule the vessel’s high-priority science missions made it no longer possible to deploy the unit at SIO. After due consideration, the decision was made by DOE, MARAD and the project team to cease the deployment, remove the MarFC from SIO, and not pursue further deployment activities. On December 2, 2022, the MarFC unit was removed from the Scripps Nimitz Marine Facility and shipped to Fridley, Michigan. The Cummins/Hydrogenics plan for the unit is to assess the condition of the MarFC subcomponents, and then use it as a training/learning system for technical employees new to hydrogen fuel-cell technology. After summarizing project activity from 2018 – 2023, this report provides a review of lessons learned. This report provides next steps in contemplating a follow-on project that would further advance the use of fuel-cell-based shore power in a marine setting. A comparison is made of the project results to the original objectives. This report ends with an accounting of presentations stemming from the project, and a list of references.

08 HYDROGEN↗
NASA NTRS2003

Update on International Space Station Nickel-Hydrogen Battery On-Orbit Performance

International Space Station (ISS) Electric Power System (EPS) utilizes Nickel-Hydrogen (Ni-H2) batteries as part of its power system to store electrical energy. The batteries are charged during insolation and discharged during eclipse. The batteries are designed to operate at a 35% depth of discharge (DOD) maximum during normal operation. Thirty-eight individual pressure vessel (IPV) Ni-H2 battery cells are series-connected and packaged in an Orbital Replacement Unit (ORU). Two ORUs are series-connected utilizing a total of 76 cells, to form one battery. The ISS is the first application for low earth orbit (LEO) cycling of this quantity of series-connected cells. The P6 (Port) Integrated Equipment Assembly (IEA) containing the initial ISS high-power components was successfully launched on November 30, 2000. The IEA contains 12 Battery Subassembly ORUs (6 batteries) that provide station power during eclipse periods. This paper will discuss the battery performance data after two and a half years of cycling.

Dalton, Penni↗
NASA NTRS2002

International Space Station Nickel-Hydrogen Battery On-Orbit Performance

International Space Station (ISS) Electric Power System (EPS) utilizes Nickel-Hydrogen (Ni-H2) batteries as part of its power system to store electrical energy. The batteries are charged during insolation and discharged during eclipse. The batteries are designed to operate at a 35 percent depth of discharge (DOD) maximum during normal operation. Thirty-eight individual pressure vessel (IPV) Ni-H2 battery cells are series-connected and packaged in an Orbital Replacement Unit (ORU). Two ORUs are series-connected utilizing a total of 76 cells to form one battery. The ISS is the first application for low earth orbit (LEO) cycling of this quantity of series-connected cells. The P6 (Port) Integrated Equipment Assembly (IEA) containing the initial ISS high-power components was successfully launched on November 30, 2000. The IEA contains 12 Battery Subassembly ORUs (6 batteries) that provide station power during eclipse periods. This paper will discuss the battery performance data after eighteen months of cycling.

Dalton, Penni↗
DOE OSTI2023

Fuel Cell Stack Model for Real-Time Simulation of Grid-Connected Applications

Fuel cell stacks coupled with electrolyzers and hydrogen storage sites can be a promising category of distributed energy resources for both grid-connected and stand-alone power systems. However, because of high costs, at-scale hardware testing of fuel cell stacks for grid-connected applications is not economically viable at present. A model-based system that can accurately captures the steady-state and dynamic response of fuel cell stacks over long time periods (hours), is needed. This paper demonstrate a real-time electromagnetic transient model of a megawatt-scale, grid-connected proton exchange membrane fuel cell stack, coupled with a mass-based hydrogen storage system. This model can emulate the electrical steady-state and dynamic response of grid-connected fuel cell stacks. We validate the model using the response of commercial hardware fuel cell stacks and analytical models in the literature - using a digital real-time simulator (RSCAD). The proposed real-time model is then used to simulate cases spanning different time horizons and to design controller-hardware-in-the-loop experiments to evaluate controllers for hydrogen stations.

activation potential↗
DOE OSTI2022

A liquid hydrogen tube moderator arrangement for SNS second target station

Liquid hydrogen filled tubes arranged in a triangular shape surrounded by light-water premoderators were investigated as cold moderators coupled to a neutron production zone of a tungsten target fed by a 1.3 GeV proton beam in a short-pulse mode. A moderator concept optimized for the tube length, premoderator thickness, and target position was found to deliver the highest pulse-integrated neutron brightness suitable to send cold neutron beams for neutron scattering instrumentation geared toward medium resolution and small samples. Reducing the tube diameter from 50 to 10 mm boosts the cold neutron brightness (E < 10 meV) by a factor of 2.25, also with enhancements seen by downsizing the height of cylindrical moderators in earlier studies. Attempts were made to characterize this novel moderator system with regard to pulse shapes, local brightness distribution, and angular distribution of emission at the neutron emission port.

Gallmeier, Franz X. (ORCID:0000000171500764)↗
DOE OSTI2024

Assessment of Heavy-Duty Fueling Methods and Components

Building on the successful commissioning and demonstration of NREL's heavy-duty (HD) fast flow research facility under the Innovating Hydrogen Station's Project, researchers advanced R&D activities to the next phase under a new project titled, Assessment of Heavy-Duty Fueling Methods and Components. This Cooperative Research and Development Agreement (CRADA) is led by NREL in partnership with NextEnergy, Argonne National Laboratory, and Chevron with NextEnergy representing a larger group of industry partners that includes AirLiquide, Hyundai, Nel, Nikola, Shell, and Toyota. The CRADA seeks to develop a comprehensive assessment of HD fuel cell electric vehicle fueling protocols and fueling hardware to understand the effects of fueling protocol architectures on station design, vehicle design, functional safety requirements, and the implications on the total cost of ownership (TCO) and techno economic assessment (TEA).

class 8 truck↗