Introduction to NASA Applications using Fuel Cell and Electrolysis Technologies
This presentation introduces NASA applications that use fuel cell and electrolysis technologies for near-term space exploration.
Fuel Cells↗
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Clean Hydrogen Production R&D at NREL
Comprehensive, concerted efforts supported by the U.S. Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy (EERE), Hydrogen and Fuel Cell Technologies Office (HFTO) are advancing research and development to demonstrate clean hydrogen production and industrial decarbonization pathways. These pathways enable an economically competitive and environmentally beneficial future energy system across sectors and can address specific applications that are difficult to decarbonize. NREL's research accelerates development, integration, and scale up of hydrogen and fuel cell technologies to enable widespread deployment across multiple energy sectors. Our work helps industry overcome technical challenges and supports DOE's H2@Scale vision for clean hydrogen across multiple applications and economic sectors. We also bridge technologies with other research areas across the lab and through multiple DOE and national lab research initiatives, consortia, and collaborations including: H2NEW: Hydrogen from Next-generation Electrolyzers of Water Consortium, HydroGEN: Advanced Water Splitting Materials Consortium, H2@Scale CRADA, and helping de-risk the hydrogen systems via large-scale validation and demonstration.
clean hydrogen↗
Overview of Clean Hydrogen Program at NREL
Comprehensive, concerted efforts supported by the U.S. Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy (EERE), Hydrogen and Fuel Cell Technologies Office (HFTO) are advancing research and development to demonstrate clean hydrogen production and industrial decarbonization pathways. These pathways enable an economically competitive and environmentally beneficial future energy system across sectors and can address specific applications that are difficult to decarbonize. NREL's research accelerates development, integration, and scale up of hydrogen and fuel cell technologies to enable widespread deployment across multiple energy sectors. Our work helps industry overcome technical challenges and supports DOE's H2@Scale vision for clean hydrogen across multiple applications and economic sectors. We also bridge technologies with other research areas across the lab and through multiple DOE and national lab research initiatives, consortia, and collaborations including: the Hydrogen Energy Earthshot, H2@Scale, National Clean Hydrogen Strategy and Roadmap, H2NEW: Hydrogen from Next-generation Electrolyzers of Water Consortium, HydroGEN: Advanced Water Splitting Materials Consortium, HyMARC Hydrogen Materials Advanced Research Consortium.
ARIES↗
Clean Hydrogen Production R&D
Comprehensive, concerted efforts supported by the U.S. Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy (EERE), Hydrogen and Fuel Cell Technologies Office (HFTO) are advancing research and development to demonstrate clean hydrogen production and industrial decarbonization pathways. These pathways enable an economically competitive and environmentally beneficial future energy system across sectors and can address specific applications that are difficult to decarbonize. NREL's research accelerates development, integration, and scale up of hydrogen and fuel cell technologies to enable widespread deployment across multiple energy sectors. Our work helps industry overcome technical challenges and supports DOE's H2@Scale vision for clean hydrogen across multiple applications and economic sectors. We also bridge technologies with other research areas across the lab and through multiple DOE and national lab research initiatives, consortia, and collaborations including: H2NEW: Hydrogen from Next-generation Electrolyzers of Water Consortium, HydroGEN: Advanced Water Splitting Materials Consortium, and BioH2. Within the plenary panel called: From the Classroom to the Lab to the Board Room, I will represent the Lab in this panel and will be talking about hydrogen technology at NREL, the lab's role in bridging university research with industry commercialization. I will also talk about my personal career path and what it's like to work at NREL, along with work force development and DEIA programs at NREL.
BIL↗
Roll to Roll (R2R) Manufacturing of Electrolysis Electrodes for Low Cost Hydrogen Production: Cooperative Research and Development Final Report, CRADA Number CRD-18-00780
NREL, Argonne National Laboratory (ANL) and Oak Ridge National Laboratory (ORNL), which are also referred to collectively herein as the "Contractors" will perform electrode ink development and characterization, focusing on 1) inks with appropriate properties for R2R (gravure and slot-die) coating onto PFSA membrane and 2) catalysts suitable for electrolysis. Participant will develop acceptance criteria and characterization methods for direct coating on the membrane. The purpose of this project is to show feasibility for cost reduction of the electrode through increased throughput and improved material utilization. Successful completion of this project will result in more affordable hydrogen production via proton exchange membrane (PEM) electrolysis by substantially reducing the anode precious metal content and catalyst-coated membrane processing costs. Assists laboratory in achieving programmatic scope, adds new capability to the laboratory's core competencies. This project uses and enhances the laboratory's core competencies, and enhances U.S. competitiveness by utilizing DOE developed intellectual property and/or capabilities. This project will benefit the Fuel Cell subprogram within the EERE Fuel Cell Technologies Office (FCTO) by actively developing materials, formulations, components, and processes for PEM electrolyzer stacks for overcoming critical technical barriers to widespread hydrogen production for zero-emission transportation applications. Through this JWS, NREL, ANL and ORNL are assisting a key domestic industry partner, Proton Energy Systems, Inc., in the area of low-cost electrolyzer electrode formulation and coating technology. After completion of this project, NREL, ANL and ORNL will be able to verify whether the direct deposit coating processes investigated are suitable for producing CCMs for PEM electrolyzers, which is of great interest and benefit to the DOE EERE Fuel Cell Technologies Office (FCTO) and H2@Scale missions.
08 HYDROGEN↗
Space Shuttle Upgrades: Long Life Alkaline Fuel Cell
NASA has utilized the alkaline fuel cell technology to provide electrical power for manned launch vehicles such as Gemini, Apollo, and the Space Shuttle. The current Shuttle alkaline fuel cells are procured from UTC Fuel Cells, a United Technologies Company. The alkaline fuel cells are very reliable but the operating life is limited to 2600 hours due to voltage degradation of the individual cells. The main limiting factor in the life of the cells is corrosion of the cell's fiberglass/epoxy frame by the aqueous potassium hydroxide electrolyte. To reduce operating costs, the orbiter program office approved the Long Life Alkaline Fuel Cell (LLAFC) program as a shuttle upgrade in 1999 to increase the operating life of the fuel cell powerplant to 5000 hours. The LLAFC program incorporates improving the cell by extending the length of the corrosion path, which reduces the cell frame corrosion. UTCFC performed analysis to understand the fundamental mechanisms that drive the cell frame corrosion. The analysis indicated that the corrosion path started along the bond line between the cathode and the cell frame. Analysis also showed that the oxygen available at the cathode, the catalyst on the electrode, and the electrode substrate all supported or intensified the corrosion. The new cell design essentially doubled the corrosion path to mitigate the problem. A 10-cell stack was tested for 5000 hours during the development phase of this program to verify improved cell performance. A complete 96-cell stack was then tested for 5000 hours during the full manned-space qualification phase of this program. Additional upgrades to the powerplant under this program are: replacing the aluminum body in the pressure regulator with stainless steel to reduce corrosion, improving stack insulator plate with improved resistance to stress failure and improved temperature capability, and replacing separator plate elastomer seals with a more durable material and improved seal retention.
Kerri McCurdy↗
Commercial phosphoric acid fuel cell system technology development
Reducing cost and increasing reliability were the technology drivers in both the electric utility and on-site integrated energy system applications. The longstanding barrier to the attainment of these goals was materials. Differences in approaches and their technological features, including electrodes, matrices, intercell cooling, bipolar/separator plates, electrolyte management, fuel selection, and system design philosophy were discussed.
Prokopius, P. R.↗
NASA's PEM Fuel Cell Power Plant Development Program for Space Applications
A three-center NASA team led by the Glenn Research Center in Cleveland, Ohio is completing a five-year PEM fuel cell power plant development program for future space applications. The focus of the program has been to adapt commercial PEM fuel cell technology for space applications by addressing the key mission requirements of using pure oxygen as an oxidant and operating in a multi-gravity environment. Competing vendors developed breadboard units in the 1 to 5 kW power range during the first phase of the program, and a single vendor developed a nominal 10-kW engineering model power pant during the second phase of the program. Successful performance and environmental tests conducted by NASA established confidence that PEM fuel cell technology will be ready to meet the electrical power needs of future space missions.
Hoberecht, Mark A.↗
Development of Low-cost Magnetocaloric Materials (CRADA 446)
This is the final report for a TCF funded project, supported by the Hydrogen and Fuel Cell Technology Office. PNNL worked with GE&R, a domestic US company that manufactures magnetocaloric materials (MCM), for potential applications in magnetic refrigeration. The overall goal of this project was to develop an energy-efficient technique to shorten the annealing time of MCM, from days to hours, with the expected benefits of lower costs and shorter lead times. Success in this project will enable industry partner General Engineering & Research LLC (GE&R) to commercialize their high-performance MCM, in support of DOE-Fuel Cell Technology Office’s efforts to develop energy-efficient magnetic refrigeration technology (using MCM) for hydrogen liquefaction.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA Activities in Fuel Cell and HydrogenTechnologies
This presentation provides a brief overview of Hydrogen and Fuel Cell technologies for space applications and current NASA activities involving these technologies.
Fuels Cells↗
Assessment of the environmental aspects of the DOE phosphoric acid fuel cell program
The likely facets of a nationwide phosphoric acid fuel cell (PAFC) power plant commercial system are described. The beneficial and adverse environmental impacts produced by the system are assessed. Eleven specific system activities are characterized and evaluated. Also included is a review of fuel cell technology and a description of DOE's National Fuel Cell Program. Based on current and reasonably foreseeable PAFC characteristics, no environmental or energy impact factor was identified that would significantly inhibit the commercialization of PAFC power plant technology.
Lundblad, H. L.↗
Update on NASA Applications using Solid Oxide Fuel Cell and Electrolysis Technologies
This presentation discusses where the solid oxide fuel cell and electrolysis technologies could address the In Situ Resource Utilization (ISRU) and Sustainable Power needs in NASA Exploration activities.
Electrolyzer↗
Study of component technologies for fuel cell on-site integrated energy systems
Heating, ventilation and air conditioning equipment are integrated with three types of fuel cells. System design and computer simulations are developed to utilize the thermal energy discharge of the fuel in the most cost effective manner. The fuel provides all of the electric needs and a loss of load probability analysis is used to ensure adequate power plant reliability. Equipment cost is estimated for each of the systems analyzed. A levelized annual cost reflecting owning and operating costs including the cost of money was used to select the most promising integrated system configurations. Cash flows are presented for the most promising 16 systems. Several systems for the 96 unit apartment complex (a retail store was also studied) were cost competitive with both gas and electric based conventional systems. Thermal storage is shown to be beneficial and the optimum absorption chiller sizing (waste heat recovery) in connection with electric chillers are developed. Battery storage was analyzed since the system is not electric grid connected. Advanced absorption chillers were analyzed as well. Recommendations covering financing, technical development, and policy issues are given to accelerate the commercialization of the fuel cell for on-site power generation in buildings.
Lee, W. D.↗
Study of component technologies for fuel cell on-site integrated energy system. Volume 2: Appendices
This data base catalogue was compiled in order to facilitate the analysis of various on site integrated energy system with fuel cell power plants. The catalogue is divided into two sections. The first characterizes individual components in terms of their performance profiles as a function of design parameters. The second characterizes total heating and cooling systems in terms of energy output as a function of input and control variables. The integrated fuel cell systems diagrams and the computer analysis of systems are included as well as the cash flows series for baseline systems.
Lee, W. D.↗
Advanced technology lightweight fuel cell program
The potential of the alkaline electrolyte fuel cell as the power source in a multi hundred kilowatt orbital energy storage system was studied. The total system weight of an electrolysis cell energy storage system was determined. The tests demonstrated: (1) the performance stability of a platinum on carbon anode catalyst configuration after 5000 hours of testing has no loss in performance; (2) capability of the alkaline fuel cell to operate to a cyclical load profile; (3) suitability of a lightweight graphite electrolyte reservoir plate for use in the alkaline fuel cell; (4) long life potential of a hybrid polysulfone cell edge frame construction; and (5) long term stability of a fiber reinforced potassium titanate matrix structure. The power section tested operates with passive water removal eliminating the requirement for a dynamic hydrogen pump water separator thereby allowing a powerplant design with reduced weight, lower parasite power, and a potential for high reliability and extended endurance. It is concluded that two perovskites are unsuitable for use as a catalyst or as a catalyst support at the cathode of an alkaline fuel cell.
Martin, R. E.↗
Gas cooled fuel cell systems technology development
The first phase of a planned multiphase program to develop a Phosphoric is addressed. This report describes the efforts performed that culminated in the: (1) Establishment of the preliminary design requirements and system conceptual design for the nominally rated 375 kW PAFC module and is interfacing power plant systems; (2) Establishment of PAFC component and stack performance, endurance, and design parameter data needed for design verification for power plant application; (3) Improvement of the existing PAFC materials data base and establishment of materials specifications and process procedes for the cell components; and (4) Testing of 122 subscale cell atmospheric test for 110,000 cumulative test hours, 12 subscale cell pressurized tests for 15,000 cumulative test hours, and 12 pressurized stack test for 10,000 cumulative test hours.
Feret, J. M.↗
U.S. Department of Energy Hydrogen Program: 2021 Annual Merit Review and Peer Evaluation Report; June 7-11, 2021
This document summarizes peer review comments and scores for the fiscal year 2021 U.S. Department of Energy (DOE) Hydrogen Program Annual Merit Review and Peer Evaluation Meeting (AMR), held virtually June 7-11, 2021. In response to direction from various stakeholders, including the National Academies, this review process provides project- and program-level evaluations of DOE-funded research, development, demonstration, and analysis of hydrogen and fuel cell technologies.
AMR↗
U.S. Department of Energy Hydrogen Program: 2023 Annual Merit Review and Peer Evaluation Report; June 6-9, 2023
This document summarizes peer review comments and scores for the fiscal year 2023 U.S. Department of Energy (DOE) Hydrogen Program Annual Merit Review and Peer Evaluation Meeting (AMR), held June 6-9, 2023. This review process provides project- and program-level evaluations of DOE-funded research, development, demonstration, and analysis of hydrogen and fuel cell technologies.
AMR↗