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The hydrogen technology assessment, phase 1

The purpose of this phase 1 report is to begin to form the information base of the economics and energy uses of hydrogen-related technologies on which the members of the National Hydrogen Association (NHA) can build a hydrogen vision of the future. The secondary goal of this report is the development of NHA positions on national research, development, and demonstration opportunities. The third goal, with the aid of the established hydrogen vision and NHA positions, is to evaluate ongoing federal research goals and activities. The evaluations will be performed in a manner that compares the costs associated with using systems that achieve those goals against the cost of performing those tasks today with fossil fuels. From this ongoing activity should emerge an NHA information base, one or more hydrogen visions of the future, and cost and performance targets for hydrogen applications to complete in the market place.

Bain, Addison↗

The 1987 Goddard Space Flight Center Battery Workshop

This document contains the proceedings of the 20th annual Battery Workshop held at Goddard Space Flight Center, Greenbelt, Maryland on November 4-5, 1987. The workshop attendees included manufacturers, users, and government representatives interested in the latest developments in battery technology as they relate to high reliability operations and aerospace use. The subjects covered included lithium cell technology and safety improvements, nickel-cadmium electrode technology along with associated modifications, flight experience and life testing of nickel-cadmium cells, and nickel-hydrogen applications and technology.

Morrow, George↗

Thrust Enhancement in Hypervelocity Nozzles by Chemical Catalysis

In the hypersonic flight regime, the air-breathing supersonic combustion ramjet (scramjet) has been shown to be a viable propulsion system. The current designs of scramjet engines provide performance benefits only up to a Mach number of 14. Performance losses increase rapidly as the Mach number increases. To extend the applicability of scram'jets beyond Mach 14, research is being conducted in the area of inlet and wave drag reduction, skin-friction and heat-transfer reduction, nozzle loss minimization, low-loss mixing, and combustion enhancement. For high Mach number applications, hydrogen is the obvious fuel choice because of its high energy content per unit mass in comparison with conventional fuels. These flight conditions require engines to operate at supersonic internal velocities, high combustor temperatures, and low static pressures. The high static temperature condition enhances the production of radicals such as H and OH, and the low-pressure condition slows the reaction rates, particularly the recombination reactions. High-temperature and low-pressure constraints, in combination with a small residence time, result in a radical-rich exhaust gas mixture exiting the combustor. At high Mach number conditions (due to low residence time), H and OH do not have enough time to recombine ; thus, a significant amount of energy is lost as these high-energy free radical are exhausted. The objective of the present study is to conduct a flowfield analysis for a typical nozzle geometry for NASP-type vehicle to assess for thrust enhancement in hypervelocity nozzles by substituting small amount of phosphine for hydrogen.

Singh, D. J.↗

An Overview of Materials Structures for Extreme Environments Efforts for 2015 SBIR Phases I and II

Technological innovation is the overall focus of NASA's Small Business Innovation Research (SBIR) program. The program invests in the development of innovative concepts and technologies to help NASA's mission directorates address critical research and development needs for Agency projects. This report highlights innovative SBIR 2015 Phase I and II projects that specifically address areas in Materials and Structures for Extreme Environments, one of six core competencies at NASA Glenn Research Center. Each article describes an innovation, defines its technical objective, and highlights NASA applications as well as commercial and industrial applications. Ten technologies are featured: metamaterials-inspired aerospace structures, metallic joining to advanced ceramic composites, multifunctional polyolefin matrix composite structures, integrated reacting fluid dynamics and predictive materials degradation models for propulsion system conditions, lightweight inflatable structural airlock (LISA), copolymer materials for fused deposition modeling 3-D printing of nonstandard plastics, Type II strained layer superlattice materials development for space-based focal plane array applications, hydrogenous polymer-regolith composites for radiation-shielding materials, a ceramic matrix composite environmental barrier coating durability model, and advanced composite truss printing for large solar array structures. This report serves as an opportunity for NASA engineers, researchers, program managers, and other personnel to learn about innovations in this technology area as well as possibilities for collaboration with innovative small businesses that could benefit NASA programs and projects.

integrated reacting fluid dynamics and predictive ↗

Additive Manufacturing Process Development DOE for NASA HR-1 using Laser Blown Powder Directed Energy Deposition

NASA HR-1 is a Fe-Ni-Cr alloy that is used for high pressure hydrogen applications such as rocket engines, energy, and oil and gas. This investigation was focused on conducting a design of experiment program aimed at mapping the parameter process window for NASA HR-1 using the laser blown powder directed energy deposition (LP-DED) process. A two phased design of experiments (DOE), the first phase of the experiment was focused on optimizing single bead tracks while the second phase of the experiment was focused on optimizing bead overlap hatching in a multi pass bead build up. During the first phase of the deposition parameters, namely laser power, travel speed, and powder feed rate were varied. A down selection from the single bead parameter set was made and hatching experiments were conducted that focused on the overlap distance. In this paper the approach for conducting the DOE and results are discussed. The results focused on measurement of bead geometry, the as-built microstructural evolution, and porosity within the samples. The team at MSFC saw a variety of results across the process map created during the first phase of experimentation and were able to down select a parameter that created an optimal bead shape with a minimal amount of build porosity. It was determined that laser power and robot travel speed were the most sensitive parameters. The results from this investigation will inform future laser powder directed energy deposition parameter developments.

Parker Shake↗

Analytical investigation of two hydrogen oxygen rocket engine systems for low-thrust application

Two hydrogen oxygen rocket engine system concepts were analyzed parametrically over a thrust range from 100 to 1000 pounds and a chamber pressure range from 175 to 1000 psia. Both concepts were regeneratively cooled with hydrogen and were pump fed by electric motor driven positive displacement pumps. Electric power was provided by either a turboalternator (turboalternator concept) or some means external to the engine system (auxiliary power concept). The turboalternator concept is discussed. The computer program used to conduct the analyses along with the design characteristics of the major engine system components is described. The feasible design range of the systems over the parametric range of thrust is discussed in terms of allowable chamber pressure. Engine system estimated performance, mass, and dimensional envelope parametric data within the feasible design range are presented.

Scheer, D. D.↗

Investigation of a para-ortho hydrogen reactor for application to spacecraft sensor cooling

The utilization of solid hydrogen in space for sensor and instrument cooling is a very efficient technique for long term cooling or for cooling at high heat rates. The solid hydrogen can provide temperatures as low as 7 to 8 K to instruments. Vapor cooling is utilized to reduce parasitic heat inputs to the 7 to 8 K stage and is effective in providing intermediate cooling for instrument components operating at higher temperatures. The use of solid hydrogen in place of helium may lead to weight reductions as large as a factor of ten and an attendent reduction in system volume. The results of an investigation of a catalytic reactor for use with a solid hydrogen cooling system is presented. Trade studies were performed on several configurations of reactor to meet the requirements of high reactor efficiency with low pressure drop. Results for the selected reactor design are presented for both liquid hydrogen systems operating at near atmospheric pressure and the solid hydrogen cooler operating as low as 1 torr.

Nast, T. C.↗

A review of the interactions between ceria and H2 and the applications to selective hydrogenation of alkynes

Cerium oxide (ceria) has found a wide variety of applications in catalysis including as a catalyst, a modifier, or a support, largely thanks to its robust redox properties and versatile acid-base function. While it is often utilized for oxidation reactions, ceria has recently attracted intense research interest for its unusual ability to selectively hydrogenate alkynes to alkenes. The intriguing hydrogenation ability of ceria has sparked renewed research efforts to understand how pure ceria works as a hydrogenation catalyst. In this review, recent advances in both experimental and computational studies of ceria are summarized, focusing on the interaction of ceria with H 2 and in hydrogenation reactions. Significant insights from various studies including in situ spectroscopy/microscopy and theoretic modeling of ceria in hydrogen-involved reactions are discussed, which shed light on the origin of the hydrogenation ability of ceria and the reaction mechanisms involved in ceria-catalyzed alkyne hydrogenation. Ways to further improve both the mechanistic understanding and catalytic performance of ceria-based materials for hydrogenation reactions are proposed at the end in the summary and outlook section.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Bipolar Nickel-hydrogen Batteries for Aerospace Applications

A bipolar nickel-hydrogen battery which effectively addresses all key requirements for a spacecraft power system, including long-term reliability and low mass, is discussed. The design of this battery is discussed in the context of system requirements and nickel-hydrogen battery technology in general. To achieve the ultimate goal of an aerospace application of a bipolar Ni-H2 battery several objectives must be met in the design and development of the system. These objectives include: maximization of reliability and life; high specific energy and energy density; reasonable cost of manufacture, test, and integration; and ease in scaling for growth in power requirements. These basic objectives translate into a number of specific design requirements, which are discussed.

Koehler, C. W.↗

Hydrogen for Maritime Applications

The maritime industry is investigating a number of fuel options for reducing emissions, including liquefied natural gas (LNG), biofuels, and electrical drive systems powered by batteries and/or hydrogen-fueled fuel cells. Hydrogen-fueled ships offer the potential to significantly reduce, if not eliminate, regulated and unregulated pollutants in maritime applications. Argonne National Laboratory conducted preliminary comparisons of the total cost of ownership (TCO) of several classes of ships to determine how fuel cell technology compares to the current diesel technology, what advancements are needed for hydrogen fuel cell technology to be competitive in the future, and what applications may be appropriate for introducing fuel cells into the maritime industry. These studies included feeder container ships, harbor tugboats, river pushboats, and auto/passenger ferries. For this study, TCO was defined to include the cost of fuel, propulsion system, and fuel storage system, the levelized cost of propulsion/auxiliary engines, and the cost of annual maintenance and consumables. It did not include the cost of the vessel frame or other components, aside from the propulsion system, that the fuel cell and diesel ships have in common. A 10% internal rate of return (IRR) was applied to the initial capital investment and an installation cost factor of 20% was applied to the capital cost. The capital cost of each component (e.g., engine, fuel tank, motor, etc.) was amortized over a period of 20 years, except for the fuel cell system, which was amortized over 6 or 10 years depending on ship class. The initial comparisons for container ships indicate that fuel costs are by far the dominant contributor to the TCO. With the current low cost of low-sulfur marine gasoil (LSMGO) and relatively high cost of hydrogen, it is difficult for hydrogen to compete with LSMGO in container ship applications. The large energy demand for container ships also favors the use of the higher volumetric energy density LSMGO fuel, especially for longer voyages. The space required to store enough hydrogen for the same journey is larger than that needed to store diesel fuels and can reduce the available cargo carrying and revenue generating space available on the ship.

08 HYDROGEN↗

Epoxy-based vitrimeric semi-interpenetrating network/MXene nanocomposites for hydrogen gas barrier applications

Herein, we report MXene-filled epoxy-based vitrimeric nanocomposites featuring a semi-interpenetrating network (S-IPN) to develop a hydrogen gas (H 2 ) barrier coating with self-healing characteristics for compressed H 2 storage applications. The reversible epoxy network was formed by synthesizing linear epoxy chains with pendent bis-hydroxyl groups using amino diol, which were then crosslinked with 1,4-benzenediboronic acid to generate dynamic boronic ester linkages. To achieve the S-IPN-type molecular arrangement, the epoxy chains were in situ crosslinked in the presence of poly(ethylene-co-vinyl alcohol) (EVOH), giving rise to a self-healing network (EEP) with a healing efficiency of 87%. Into the S-IPN vitrimer (EEP), a 2D platelet-type nanofiller MXene was incorporated to introduce a tortuous path for H 2 gas diffusion along with improved mechanical properties. The nanocomposite coating was applied to nylon 6 liner material, which is conventionally used in all-composite H 2 storage vessels. Further, the application of a 2 wt% MXene/EEP nanocomposite coating showed a permeability coefficient of 0.062 cm 3 mm m -2 d -1 atm -1 exhibiting ~96% reduction in gas permeability compared to uncoated nylon 6. The same nanocomposite exhibited a healing efficiency of 79%. Increasing the MXene loading to 10 wt% further reduced the permeability coefficient to 0.002 cm 3 mm m -2 d -1 atm -1 ; however, the healing efficiency decreased due to restricted chain mobility. In essence, the current work highlights the potential of vitrimeric S-IPN nanocomposite coatings for H 2 gas-barrier applications, enhancing safety and performance.

42 ENGINEERING↗

The Development of Fuel Cell Technology for Electric Power Generation - From Spacecraft Applications to the Hydrogen Economy

The fuel cell uses a catalyzed reaction between a fuel and an oxidizer to directly produce electricity. Its high theoretical efficiency and low temperature operation made it a subject of much study upon its invention ca. 1900, but its relatively high life cycle costs kept it as "solution in search of a problem" for its first half century. The first problem for which fuel cells presented a cost effective solution was, starting in the 1960's that of a power source for NASA's manned spacecraft. NASA thus invested, and continues to invest, in the development of fuel cell power plants for this application. However, starting in the mid-1990's, prospective environmental regulations have driven increased governmental and industrial interest in "green power" and the "Hydrogen Economy." This has in turn stimulated greatly increased investment in fuel cell development for a variety of terrestrial applications. This investment is bringing about notable advances in fuel cell technology, but these advances are often in directions quite different from those needed for NASA spacecraft applications. This environment thus presents both opportunities and challenges for NASA's manned space program.

Scott, John H.↗

Vapor condensation rate at a turbulent liquid interface, for application to cryogenic hydrogen

The condensation of hydrogen vapor onto turbulent liquid hydrogen is simulated experimentally using steam and water at elevated pressure, where water has a Prandtl number comparable to that of liquid hydrogen. A correlation is presented for the condensation rate in terms of the intensity and macroscale of the turbulence on the liquid side. The rate correlation should be applicable to low-gravity conditions at the higher turbulence intensities; at the lower turbulence intensities, however, the data are affected by thermal stratification resulting from buoyancy effects.

Helmick, M. R.↗

Hydrogen uses and demands through the year 2025

The magnitude and markets for applications of hydrogen produced by water-splitting through thermal or electrolytic means are projected up to the year 2025. Uses are divided into energy and nonenergy categories, with U.S. synfuels programs accounting for 65% of the increased demand for hydrogen. Applications for transportation fuel, as a natural gas supplement, in fuel cells, in refinery and synfuels industries, for synthesizing chemicals, and for manufacturing semiconductors are summarized. Electrolytic processes are noted to be more suitable for smaller scale production, where use is on-site or local. An annual growth of 8.4-9.2% is foreseen in the energy sector and 3-3.6% in the nonenergy sector, with a total contribution to the primary energy uses of 12-13% by the year 2025. Hydrogen's negligible environmental impact and the ability to interface hydrogen systems with existing equipment are seen as factors encouraging hydrogen-use growth.

Kelley, J. H.↗

Overview of the Design, Development, and Application of Nickel-hydrogen Batteries

This document provides an overview of the design, development, and application of nickel-hydrogen (Ni-H2) battery technology for aerospace applications. It complements and updates the information presented in NASA RP-1314, NASA Handbook for Nickel- Hydrogen Batteries, published in 1993. Since that time, nickel-hydrogen batteries have become widely accepted for aerospace energy storage requirements and much more has been learned. The intent of this document is to capture some of that additional knowledge. This document addresses various aspects of nickel-hydrogen technology including the electrochemical reactions, cell component design, and selection considerations; overall cell and battery design considerations; charge control considerations; and manufacturing issues that have surfaced over the years that nickel-hydrogen battery technology has been the major energy storage technology for geosynchronous and low-Earth-orbiting satellites.

Thaller, Lawrence H.↗

LASSO for CALPHAD Model Selection Enables Data-Efficient Thermodynamic Modeling: An Application in Thermochemical Hydrogen Production Materials

Phenomenological CALPHAD (CALculation of PHAse Diagrams) models, widely used for multicomponent materials, often contain a considerable number of parameters and require fitting using data from a relatively small number of experimental measurements or theoretical calculations. Sometimes these parameters are introduced for the purpose of improving model fits but without clear physical justification, which leads to overparametrized models with poor generalization performance. Automated approaches for optimal model selection based on the available data therefore become critical. Here, in this work, a least absolute shrinkage and selection operator (LASSO)-based approach is developed for model selection by leveraging the linearity of the CALPHAD model with respect to its parameters to convert the model selection and fitting to a LASSO minimization problem. We demonstrate its utility for thermodynamic modeling of thermochemical hydrogen (TCH) production materials using lanthanum strontium manganite (LSM) as an example. Various TCH-relevant properties, including oxygen stoichiometry as a function of oxygen partial pressure, enthalpy of reduction, and entropy of reduction, are successfully predicted with reasonable accuracy using a minimal set of model parameters. Importantly, the model selection and fitting involve minimal human decision; it can therefore be applied to high-throughput DFT defect calculations and yield efficient workflows for TCH material modeling and optimization.

CALPHAD↗

Techno-Economic Analysis of Solid Oxide Fuel Cell-Gas Turbine Hybrid Systems for Stationary Power Applications Using Renewable Hydrogen

Solid oxide fuel cell (SOFC)–gas turbine (GT) hybrid systems can produce power at high electrical efficiencies while emitting virtually zero criteria pollutants (e.g., ozone, carbon monoxide, oxides of nitrogen and sulfur, and particulate matters). This study presents new insights into renewable hydrogen (RH 2 )-powered SOFC–GT hybrid systems with respect to their system configuration and techno-economic analysis motivated by the need for clean on-demand power. First, three system configurations are thermodynamically assessed: (I) a reference case with no SOFC off-gas recirculation, (II) a case with cathode off-gas recirculation, and (III) a case with anode off-gas recirculation. While these configurations have been studied in isolation, here we provide a detailed performance comparison. Moreover, a techno-economic analysis is conducted to study the economic competitiveness of RH 2 -fueled hybrid systems and the economies of scale by offering a comparison to natural gas (NG)-fueled systems. Results show that the case with anode off-gas recirculation, with 68.50%-lower heating value (LHV) at a 10 MW scale, has the highest efficiency among the studied scenarios. When moving from 10 MW to 50 MW, the efficiency increases to 70.22%-LHV. These high efficiency values make SOFC–GT hybrid systems highly attractive in the context of a circular economy as they outcompete most other power generation technologies. The cost-of-electricity (COE) is reduced by about 10% when moving from 10 MW to 50 MW, from USD 1976/kW to USD 1668/kW, respectively. Renewable H 2 is expected to be economically competitive with NG by 2030, when the U.S. Department of Energy’s target of USD 1/kg RH 2 is reached.

25 ENERGY STORAGE↗