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DOE OSTI2026

SERA: A Hydrogen Infrastructure Capacity Expansion Model

The Scenario Evaluation and Regionalization Analysis (SERA) model is an infrastructure planning optimization model that can guide hydrogen production, delivery, and end-use investment decisions and accelerate the adoption of low-cost hydrogen at scale, whether for fuel cell electric vehicles or non-transportation applications. In this talk, we will review the SERA model objective function as well as the data inputs and outputs. We will also look at a SERA case study identifying potential dispensed costs of hydrogen along major refueling corridors throughout the United States. In addition to the SERA model, Justin will also discuss his recent work for the Office of Manufacturing and Energy Supply Chains on electrolyzer supply chain readiness, and his work for the Hydrogen Fuel Cell Technologies Office and Environmental Protection Agency on the levelized cost of dispensed hydrogen for heavy-duty trucking.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2023

High-Efficiency, Medium-Voltage-Input, Solid-State-Transformer-Based 400-kW/1000V/400A Extreme Fast Charger for Electric Vehicles

Range anxiety and long battery charging time continue to be critical challenges to mass adaptation of EVs. A major identified gap to wider adoption of BEVs is the ability and availability to refuel quickly or to fast charge. Studies have shown that in areas where drivers have access to 50-kW or 120-kW fast charge stations, annual electric vehicle (EV) miles traveled (i.e., eVMT) increased by over 25%, even in cases where fast charging was used for 1% to 5% of total charging events. Charge stations of higher power not only alleviate the “range anxiety” and reduce the driver’s waiting time, but also requires less investment. Michigan Energy Office completed a study in early 2019 titled “Electric Vehicle Charger Placement Optimization in Michigan: Phase I – Highways”. This study finds a system with 150kW chargers, though more expensive individually, actually has lower total system cost when compared to a 50kW charging system when serving the same battery size EV. To be truly competitive to the ICEV refueling experience, even higher power stations are necessary. However, high power charge stations would create large power draws from the grid. If this occurs during peak demand periods, grid capacity could be overloaded. This problem needs to be addressed to reduce the impact on the electric utility infrastructure. The main goal of this project is to develop a 400-kW/400-A XFC system targeting total efficiency of 96.5 percent from the MVAC grid to a vehicle. The novel SST power cell topology, combined with a new silicon carbide (SiC) MOSFET device, enables a 3.5 percent improvement in system efficiency, a 50-percent smaller equipment footprint, and four times less weight than today’s DCFC systems. The SST technology would directly utilize MVAC at 4.8-kV or 13.2-kV. This would eliminate the line frequency transformer (LFT), which steps down medium-voltage AC to 3-Phase 480-V line-to-line voltage in current DCFC systems.

42 ENGINEERING↗
NASA NTRS1991

Intelligent systems technology infrastructure for integrated systems

A system infrastructure must be properly designed and integrated from the conceptual development phase to accommodate evolutionary intelligent technologies. Several technology development activities were identified that may have application to rendezvous and capture systems. Optical correlators in conjunction with fuzzy logic control might be used for the identification, tracking, and capture of either cooperative or non-cooperative targets without the intensive computational requirements associated with vision processing. A hybrid digital/analog system was developed and tested with a robotic arm. An aircraft refueling application demonstration is planned within two years. Initially this demonstration will be ground based with a follow-on air based demonstration. System dependability measurement and modeling techniques are being developed for fault management applications. This involves usage of incremental solution/evaluation techniques and modularized systems to facilitate reuse and to take advantage of natural partitions in system models. Though not yet commercially available and currently subject to accuracy limitations, technology is being developed to perform optical matrix operations to enhance computational speed. Optical terrain recognition using camera image sequencing processed with optical correlators is being developed to determine position and velocity in support of lander guidance. The system is planned for testing in conjunction with Dryden Flight Research Facility. Advanced architecture technology is defining open architecture design constraints, test bed concepts (processors, multiple hardware/software and multi-dimensional user support, knowledge/tool sharing infrastructure), and software engineering interface issues.

Lum, Henry↗
DOE OSTI2025

Integrated Systems-to-Atoms (S2A) Framework for Designing Resilient and Efficient Hydrogen Infrastructure Solutions

The success of a future clean hydrogen infrastructure will depend on technology performance, operating conditions, and system configuration, which will be integrated to meet specific end-use requirements. We introduce a Systems-to-Atoms framework to cosimulate material, device, and system design for clean hydrogen storage and transport. Here we present a demonstration scenario in which hydrogen is distributed using a liquid organic hydrogen carrier to 700 bar refueling stations. Cross-scale analysis on hydrogen release at the refueling station reveals that while a high reaction pressure (up to 100 bar) may not enhance the catalyst performance, it can lead to system-level cost savings (up to 5% of total refueling station cost) due to savings in downstream gas compression. Further, a typically low-performing dehydrogenation catalyst material (e.g., copper) may be preferred over a high-performing catalyst (e.g., palladium) at different operating conditions when considering overall system affordability and supply chain resilience.

08 HYDROGEN↗
NASA NTRSDate not supplied

ISRU Potential Water Mine Sites; Preliminary Evaluation for NASA Artemis Campaign

The NASA Artemis Campaign aims to return to the Moon to maintain a sustainable presence [1], and In-Situ Resource Utilization (ISRU)is a key part of sustainability. The regions of interest for the Artemis campaign, as outlined in [1] and shown in Fig 1, are at Lunar the South Pole where water ice has been identified. The potential use of this water, and oxygen/hydrogen, for NASA and commercial applications such as refueling vehicles and power systems, and supplying life support consumables is one of the considerations the NASA Artemis team is using to evaluate these regions. As such, analyses are underway to evaluate the ISRU ice mining potential of these regions of interest. To do so, a set of ground rules for ISRU sites have been developed to align with current assumptions for customer needs, hardware capabilities, initially limited infrastructure, and lunar environments/terrain. The customer could be a lander, habitat, or other asset that makes use of ISRU product within the Artemis architecture. At this time, four of the regions of influence (the ‘western’ cluster in Fig. 1) have undergone preliminary ISRU evaluation. It should be noted that variety of other efforts have done similar evaluations of this nature with different assumptions or viewpoints, such as the most recent[2]. However, most evaluations focus on large permanently shadowed regions (PSRs) and craters due to orbital data resolution limitations, whereas early ice mining operations will likely occur in much smaller PSRs

In situ resource utilization↗
NASA NTRSDate not supplied

Analysis of Alternative Architectures for Cargo Lunar Landers

NASA’s Human Landing System (HLS) program has been working with commercial partners to develop human-class lunar landers to return the first American woman and next American man to the lunar surface in the mid 2020’s. In an effort to expand human presence beyond low Earth orbit, NASA’s Artemis program aims to facilitate a sustainable, long-term human presence in cis-lunar space. A component of this will require significant infrastructure to be delivered to the lunar surface. Delivering this infrastructure will require a significant lander capability that has yet to be developed. A thorough understanding of cargo lunar lander architectures is required such that select alternatives can be identified that best support the Artemis program’s objective of sustainability. The goal of this study is to aid NASA and its partners in the understanding of the cargo lunar lander trades space, as well as identify potential robust alternatives. The results will support NASA as it moves forward with key activities such as requirements formulation, agency strategic planning, and potential cargo lunar lander procurements. The study builds off of recent work performed by the Human Landing System program’s Architecture and Systems Analysis group to encompass a broad trade space of cargo lunar lander architecture alternatives. The current trade space as depicted by the morphological matrix and mission graph in Fig. 1 and Fig. 2, respectively, includes key alternative options that have become highly relevant due to current HLS activities and include on-orbit refueling, active cryogenic fluid management, Earth orbit aggregation, and global lunar access. The authors believe that there is also a statistically relevant impact of lander-payload configuration on the primary structure of the vehicle that could greatly impact alternative selection. Because of this, several conceptual lander-payload configurations will be evaluated to determine the level of impact. The current set of conceptual configurations are shown in Fig. 3 and Fig. 4. To aid the conceptual evaluation of these configurations, a catalogue of notional payloads has been developed that represent a wide range of masses and volumes that are expected to be delivered in support of a sustained human lunar presence, including pressurized and unpressurized rovers, surface habitats, power systems, and other support infrastructure. In order to execute this study in a timely fashion, a similar approach to that utilized in a similar 2019 study focused on 2024 human lunar sorties will be employed [1]. The team utilized a novel architecture synthesis framework currently being developed by NASA/MSFC to evaluate over 600,000 lunar lander architectures over a two month time frame [2]. From this large data set, varying ground rules and assumptions were applied as filters to explore the trade space to identify alternatives which exhibited robustness, as measured by launch vehicle payload margin, to absorb the natural growth that occurs during design maturation. The set of Earth-Moon system Delta-Vs assumed from the 2019 study, shown in Fig. 5, will be repurposed to accelerate model formulation for this effort. Additionally, current efforts in collaboration with the Georgia Institute of Technology’s Aerospace System Design Lab will be integrated to provide probabilistic modeling of the cargo lunar lander architectures to aid in identifying robust design alternatives [3]. The approach will help minimize potential impacts due to large levels of uncertainty inherent to pre phase-A conceptual design. By leveraging these past and present studies and partnerships, a highly detailed set of data can be generated in a short time period to aid NASA in the coming years to support the goal of a sustained human lunar presence.

Architectures↗
DOE OSTI2024

Hydrogen Detection Strategies to Support H2@SCALE - The NREL Sensor Laboratory

Hydrogen represents a major pathway to decarbonize and stabilize the national and international energy industry and select manufacturing markets. To facilitate the development of hydrogen markets, the US Department of Energy initiated H2@Scale to bring together stakeholders to advance affordable hydrogen production, transport, storage, and utilization to increase revenue opportunities in multiple energy sectors. One major impediment to hydrogen implementation is cost. To expedite the use of hydrogen in energy and other markets, the United States announced in 2021 the Hydrogen Shot, which seeks to reduce the cost of clean hydrogen by 80% to $1 per 1 kilogram in 1 decade ("1 1 1"). As the cost of hydrogen drops, new applications will emerge that will require unique configurations of existing equipment and infrastructure, and eventually lead to advances in the generation and utilization of hydrogen. As the hydrogen economy expands, sensors and detection methods will need to adapt to changing infrastructure demands to address the primary targets of health & safety, emissions monitoring, and process control. The NREL Sensor Laboratory is playing a pivotal role in advancing the use of hydrogen sensors and detection methodologies in each of these categories to support DOE's mission for safe and efficient utilization in emerging markets. Health & safety monitors are required to ensure that operators and facilities can react to unintended hydrogen releases, either as GH2, LH2, or as a constituent of blends (e.g., natural gas or ammonia). Current detection methodologies focus on safety applications to detect near its lower flammable limit (4 vol %), and typically include point sensors in applications such as fixed or mobile detectors (e.g., personal gas monitors). Methodologies amenable for area detection include acoustic, emerging optical imaging methods, and flame detectors. Comparable detection strategies can be utilized for emissions monitoring and quantization, however few methods can simultaneously cover both low (emissions) and high (health & safety) levels. Deployment of emission level detectors will be required to 1) reduce product loss through small but potentially significant leaks from an environmental or cost perspective, 2) reduce downtime of high demand systems by early identification of eminent system failures (leaks through pump or compressor seals indicative of impending failure), and 3) address potential emission monitoring requirements that may be set by regulating bodies. The first two points should be adopted by industry to reduce the cost-of-goods-sold. The third main category for hydrogen detection relates to process control and may be advantageous for many existing applications. Two main applications are emerging. For example, the purity requirements for hydrogen that is dispensed from refueling systems for hydrogen fuel cell electric vehicles (FCEV) is rigorously regulated by the Standard SAE J2719, which prescribes maximum allowable levels of multiple impurities in the hydrogen fuel and must be verified by a regulatory body. Hydrogen contaminant detectors (HCD) integrated to the fueling station can assure this compliance. HCDs must be able operate in 100% H2 backgrounds and be able to distinguish between multiple contaminants at low ppm to low ppb levels. Secondly, as a strategy to decarbonize the natural gas grid, there are proposals to blend hydrogen with natural gas. This blending will affect transport applications (pipeline infrastructure), stationary combustion systems (turbines), and consumer and commercial appliances. In the short-term, hydrogen levels up to 20% are proposed. Variations in the hydrogen level can have dramatic impact on the combustion process and on the potential response of safety sensors. These mixtures may be regulated so that the concentration at a delivery point must be monitored with high precision. However, routine maintenance may introduce background gases such as ambient air (with water) or maintenance gases (introduced with welding processes or adhesive outgassing.) Therefore, the detection methodology must be robust enough to recover or respond to various contaminants. Several reviews can be found in literature addressing sensing and detection technologies, including their limitations and applications. However, for most applications, limitations can be alleviated by combining various detection techniques either through system integration or implementation of machine learning methods (artificial intelligence). In this presentation, we will discuss several applications, highlight their current approach for hydrogen detection, and suggest detection strategies to supplement their limitations.

ENERGY STORAGE,HYDROGEN↗
DOE OSTI2020

Advanced Electrochemical Hydrogen Compressor

U.S. automakers have invested significant resources in the research and development of hydrogen fuel cell electric vehicles (FCEVs). However, to enable the widespread deployment of FCEVs, an additional major investment is required to achieve an infrastructure for compressing hydrogen in hydrogen fueling stations. In order to dispense hydrogen to FCEV tanks quickly, the hydrogen must be compressed above a pressure of 875 bar (12,687 psi) at the fueling station. Mechanical compressors currently in use have high maintenance costs, poor reliability, and are noisy. To eliminate the need for mechanical compressors, Plug Power is extending its extensive experience in high-pressure proton-exchange-membrane (PEM), to develop an electrochemical hydrogen compressor (EHC) system for refueling applications that can deliver hydrogen at pressures greater than 875 bar. The work performed during this project was a collaboration between the Nation Renewable Energy Laboratory (NREL), Rensselaer Polytechnic Institute (RPI), and Gaia Energy Research Institute LLC (GAIA).

08 HYDROGEN↗
NASA NTRS2018

Robotic Asteroid Prospector (RAP)

This report presents the results from the nine-month, Phase 1 investigation for the Robotic Asteroid Prospector (RAP). This project investigated several aspects of developing an asteroid mining mission. It conceived a Space Infrastructure Framework that would create a demand for in space-produced resources. The resources identified as potentially feasible in the near-term were water and platinum group metals. The project's mission design stages spacecraft from an Earth Moon Lagrange (EML) point and returns them to an EML. The spacecraft's distinguishing design feature is its solar thermal propulsion system (STP) that can provide for three functions:propulsive thrust, process heat for mining and mineral processing, and electricity. The preferred propellant is water since this would allow the spacecraft to refuel at an asteroid for its return voyage to Cis-Lunar space thus reducing the mass that must be staged out of the EML point.The spacecraft will rendezvous with an asteroid at its pole, match rotation rate, and attach to begin mining operations. The team conducted an experiment in extracting and distilling water from frozen regolith simulant.

Cohen, Marc↗
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

Turboexpander for Direct Cooling in Hydrogen Vehicle Fueling Infrastructure

Hydrogen fuel cell electric vehicles (FCEVs) have been identified as one of a few options for zero carbon emissions transportation. A major advantage of FCEVs is that they can fuel quickly and follow a familiar fueling behavior to hydrocarbon-fueled vehicles. Whether light duty or heavy duty, the goal for a hydrogen dispenser is to fuel a vehicle in the same amount of time as the fossil fuel equivalent. When hydrogen is dispensed into the vehicle storage system, however, the temperature rises due to the Joule-Thomson effect and the heat of compression. Typically, vehicles store the compressed hydrogen in composite overwrapped pressure vessels that have a polymer liner with an operational temperature limit of 85°C. This temperature limit can be exceeded during fast fueling if hydrogen is not precooled. Precooling allows for a dispenser to fuel a vehicle at a faster flow rate by preventing the storage tank on the vehicle from overheating. Fueling protocols and requirements are presented in SAE J2601 Fueling Protocols for Light Duty Gaseous Hydrogen Surface Vehicles [1]. A heavy-duty equivalent is under development with similar requirements for precooling. Currently, conventional precooling for light-duty vehicle refueling uses a heat exchanger and chiller to cool the hydrogen gas to -40°C before entering the vehicle. The precooling system represents a significant part of the station capital and operating costs, so if the cost of the precooling system can be reduced by improving its efficiency, the overall station capital and operating cost can be reduced. In this project, National Renewable Energy Laboratory (NREL) and Sandia National Laboratories (SNL) researchers teamed up to investigate the turboexpander precooling application. A turboexpander is a device that places a turbine in a flow path where a pressure differential can be attained. This expansion device will extract work and lower the temperature of the fluid as the pressure reduces. While initial calculations based on established principles showed potential for a turboexpander to generate cooled gas, much work needs to be done to prove the concept. Turboexpanders typically work best under steady state conditions, while the dispenser is a very dynamic flow system. Dynamic turboexpander systems have been proven, such as a turbocharger on a gasoline vehicle. The inlet pressure at a dispenser is also much higher than any other known turboexpander system but should behave similarly to higher density fluids at lower pressures. Having both performed initial calculations, NREL and SNL researchers teamed up to investigate the turboexpander precooling application further. A project was soon built around the idea with SNL performing system modeling using previously proven capabilities and NREL performing hardware characterization with established station capabilities. Creare LLC was contracted as the turbomachinery expert to design and build the concept device. Part way through the project, however, contracting issues with the funding partner caused the project to terminate early before building and characterizing the concept device. While the project could not continue, many key findings were already learned. This paper is a summary of those findings.

08 HYDROGEN↗
DOE OSTI2020

Validation of an Advanced High-Pressure PEM Electrolyzer and Composite Hydrogen Storage

One of the challenges associated with transitioning our nation’s transportation economy to any alternative fuel is bringing fuel production, storage, transportation, and end-customer delivery infrastructure online. There are challenges associated with planning and implementing hydrogen fueling stations at locations relevant to the parallel effort of bringing the related transportation vehicles into the market. There are additional challenges associated with the operation of hydrogen fueling stations and reducing operating costs through energy reduction. Through calculation and design efforts it was concluded that elevating the pressure of a PEM cell stack and further developing hydrogen processing equipment that support elevated pressures while maintaining similar characteristics to their current production counterparts will yield in energy savings and by extension cost reductions. In this report, the design of a 57-bar (827-psig) electrolysis system and electrolysis cell stack is described. Furthermore, the fabrication, component verification, and integrated testing are summarized. Prior to this development effort, Proton had demonstrated thousand of hours of durability on 30-bar (435-psig) differential pressure PEM electrolysis hardware. Proton has sold and installed many of these 30-bar devices at customer sites. Through this project, Proton has developed and tested 57-bar PEM electrolysis, thereby extending the proven capability of PEM electrolysis as a hydrogen generation and electrochemical compression device. A design and validation effort to arrange hydrogen processioning equipment for refueling OEM vehicles was also undertaken within this project. By arranging equipment within two 6-meter ISO shipping containers and further developing NFPA 2 Hydrogen Technologies Code to support containerized hydrogen equipment, efforts to site, install, and commission, and approve hydrogen fueling stations were reduced and now provide a groundwork for future installations.

08 HYDROGEN↗
NASA NTRS2019

Key Technologies, Systems, and Infrastructure Enabling the Commercialization and Human Settlement of the Moon and Cislunar Space

Over 50 years have passed since 2001: A Space Odyssey debuted in April 1968. In the film, Dr. Heywood Floydflies to a large artificial gravity space station orbiting Earth aboard a commercial space plane. He then embarks on acommuter flight to the Moon arriving there 25 hours later. Today, in this the 50th anniversary year of the Apollo 11lunar landing, the images portrayed in 2001 still remain well beyond our capabilities. This paper examines keytechnologies and systems (e.g., in-situ resource utilization, fission power, advanced chemical and nuclearpropulsion), and supporting orbital infrastructure (providing a propellant and cargo transfer function), that could bedeveloped by NASA and industry over the next 30 years allowing the operational capabilities presented in 2001 to beachieved, albeit on a more spartan scale. Lunar-derived propellants (LDPs) will be essential to developing a reusablelunar transportation system that can allow initial outposts to evolve into settlements supporting a variety ofcommercial activities. Deposits of icy regolith discovered at the lunar poles can supply the feedstock material neededto produce liquid oxygen (LO2) and hydrogen (LH2) propellants. On the lunar nearside, near the equator, iron oxiderichvolcanic glass beads from vast pyroclastic deposits, together with mare regolith, can provide the feedstockmaterials to produce lunar-derived LO2 plus other important solar wind implanted (SWI) volatiles, including H2and helium-3. Megawatt-class fission power systems will be essential for providing continuous "24/7" power toprocessing plants, human settlements and commercial enterprises that develop on the Moon and in orbit. Reusablelunar landing vehicles will provide cargo and passenger "orbit-to-surface" access and will also transport LDP toSpace Transportation Nodes (STNs) located in lunar polar (LPO) and equatorial orbits (LLO). Reusable space-based,lunar transfer vehicles (LTVs), operating between STNs in low Earth orbit, LLO, and LPO, and able to refuel withLDPs, offer unique mission capabilities including short transit time crewed cargo transports. Even commuter flightssimilar to that portrayed in 2001 appear possible, allowing 1-way trip times to and from the Moon as short as 24hours. The performance of LTVs using both RL10B-2 chemical rockets, and a variant of the nuclear thermal rocket(NTR), the LO2-Augmented NTR (LANTR), are examined and compared. If only 1% of the LDP obtained from icyregolith, volcanic glass, and SWI volatile deposits were available for use in lunar orbit, such a supply could supportroutine commuter flights to the Moon for many thousands of years. This paper provides a look ahead at what mightbe possible in the not too distant future, quantifies the operational characteristics of key in-space and surfacetechnologies and systems, and provides conceptual designs for the various architectural elements discussed.

Borowski, Stanley K.↗
NASA NTRS2019

Key Technologies, Systems, and Infrastructure Enabling the Commercialization and Human Settlement of the Moon and Cislunar Space

Over 50 years have passed since 2001: A Space Odyssey debuted in April 1968. In the film, Dr. Heywood Floydflies to a large artificial gravity space station orbiting Earth aboard a commercial space plane. He then embarks on acommuter flight to the Moon arriving there 25 hours later. Today, in this the 50th anniversary year of the Apollo 11lunar landing, the images portrayed in 2001 still remain well beyond our capabilities. This paper examines keytechnologies and systems (e.g., in-situ resource utilization, fission power, advanced chemical and nuclearpropulsion), and supporting orbital infrastructure (providing a propellant and cargo transfer function), that could bedeveloped by NASA and industry over the next 30 years allowing the operational capabilities presented in 2001 to beachieved, albeit on a more spartan scale. Lunar-derived propellants (LDPs) will be essential to developing a reusablelunar transportation system that can allow initial outposts to evolve into settlements supporting a variety ofcommercial activities. Deposits of icy regolith discovered at the lunar poles can supply the feedstock material neededto produce liquid oxygen (LO2) and hydrogen (LH2) propellants. On the lunar nearside, near the equator, iron oxiderichvolcanic glass beads from vast pyroclastic deposits, together with mare regolith, can provide the feedstockmaterials to produce lunar-derived LO2 plus other important solar wind implanted (SWI) volatiles, including H2and helium-3. Megawatt-class fission power systems will be essential for providing continuous "24/7" power toprocessing plants, human settlements and commercial enterprises that develop on the Moon and in orbit. Reusablelunar landing vehicles will provide cargo and passenger "orbit-to-surface" access and will also transport LDP to Space Transportation Nodes (STNs) located in lunar polar (LPO) and equatorial orbits (LLO). Reusable space-based,lunar transfer vehicles (LTVs), operating between STNs in low Earth orbit, LLO, and LPO, and able to refuel with LDPs, offer unique mission capabilities including short transit time crewed cargo transports. Even commuter flights similar to that portrayed in 2001 appear possible, allowing 1-way trip times to and from the Moon as short as 24hours. The performance of LTVs using both RL10B-2 chemical rockets, and a variant of the nuclear thermal rocket(NTR), the LO2-Augmented NTR (LANTR), are examined and compared. If only 1% of the LDP obtained from icyregolith, volcanic glass, and SWI volatile deposits were available for use in lunar orbit, such a supply could support routine commuter flights to the Moon for many thousands of years. This paper provides a look ahead at what might be possible in the not too distant future, quantifies the operational characteristics of key in-space and surface technologies and systems, and provides conceptual designs for the various architectural elements discussed.

Borowski, Stanley K.↗
NASA NTRS2019

Commercialization and Human Settlement of the Moon and Cislunar Space – A Look Ahead at the Possibilities over the Next 50 Years

Over 50 years have passed since the movie 2001: A Space Odyssey debuted in April 1968. In the film, Dr. Heywood Floyd flies to a large artificial gravity space station orbiting Earth aboard a commercial space plane. He then embarks on a commuter flight to the Moon arriving there 25hours later. Today, on the 50th anniversary of the Apollo 11 lunar landing, the images portrayed in 2001 still remain well beyond our capabilities. This paper examines key technologies and systems (in-situ resource utilization, fission power, advanced chemical and nuclear propulsion),and orbiting infrastructure elements (providing a propellant depot and cargo transfer function),that could be developed by NASA and the private sector in future decades allowing the operational capabilities presented in 2001 to be achieved, albeit on a more spartan scale. Lunar derived propellants (LDPs) will be essential to reducing the launch mass requirements from Earth and developing a reusable lunar transportation system (LTS) that can allow initial outposts to evolve into settlements supporting a variety of commercial activities like in-situ propellant production. Deposits of icy regolith found within permanently shadowed craters at the lunar pole scan supply the feedstock material to produce liquid oxygen (LO2) and hydrogen (LH2) propellan tneeded by surface-based lunar landing vehicles (LLVs) using chemical rocket engines. Along the Moon's nearside equatorial corridor, iron oxide-rich volcanic glass beads from vast pyroclasticdeposits, together with mare regolith, can provide the materials to produce lunar-derived LO2plus other important solar wind implanted (SWI) volatiles, including H2 and helium-3. Mega watt classfission power systems will be essential for providing continuous "24/7" power to LLVs will provide cargo and passenger "orbit-to-surface" access and willalso be used to transport LDP to Space Transportation Nodes (STNs) located in lunar polar(LPO) and equatorial orbits (LLO). Spaced-based, reusable lunar transfer vehicles (LTVs),operating between STNs in low Earth orbit (LEO), LLO, and LPO, and able to refuel with LDPs,can offer unique mission capabilities including short transit time crewed cargo transports. Even acommuter shuttle service similar to that portrayed in 2001 appears possible, allowing 1-way trip times to and from the Moon as short as 24 hours. The performance of LTVs using both RL10B-2chemical rockets, and a variant of the nuclear thermal rocket (NTR), the LO2-Augmented NTR(LANTR), are examined and compared. The bipropellant LANTR engine utilizes its divergent nozzle section as an afterburner into which oxygen is injected and supersonically combusted with reactor-heated hydrogen emerging from the engine's sonic throat. If only 1% of the LDP obtained from icy regolith, volcanic glass, and SWI volatile deposits were available for use in lunar orbit,such a supply could support routine commuter flights to the Moon for many thousands of years!This paper provides a look ahead at what might be possible in the not too distant future,quantifies the operational characteristics of key in-space and surface technologies and systems,and provides conceptual designs for the various architectural elements discussed.

Borowski, Stanley K.↗
DOE OSTI2022

WIRE-21 Sensor Irradiation Experiment Ready for HFIR Insertion

The ability to deploy new nuclear fuels for current or future reactor concepts requires a wealth of data regarding fuel performance during normal operation, anticipated operational occurrences, and design-basis accidents. Most of these data have historically been collected during experiments in materials test reactors, ideally with online instrumentation to collect as much data as possible. However, advanced instrumentation could also allow for in situ monitoring of fuel operating conditions during commercial reactor operation to maximize fuel utilization, reduce unnecessary conservativism in design margins, and improve operator understanding of limiting peaking factors. The latter approach would complicate fuel handling, particularly during refueling, unless the instrumentation could be placed inside the fuel rods and transmitted wirelessly to a receiver located outside the fuel’s primary pressure boundary. To this end, Westinghouse Electric Company (WEC) developed wireless sensors based on inductive coupling that can transmit information regarding fuel centerline temperatures and rod internal pressures wirelessly from within a fuel rod to a nearby instrument thimble. After testing these sensors in lower-power university research reactors, the next step is to perform high neutron fluence testing to characterize the performance of these wireless sensors under conditions that are more representative of the intended application—in this case, light-water reactors (LWRs). The removable Be (RB) positions of the High Flux Isotope Reactor (HFIR) at Oak Ridge National Laboratory (ORNL) provide the neutron flux, experiment volume, and access to instrument leads required to achieve these sensor testing goals. This report summarizes the design, analysis, and assembly of the Wireless Instrumented RB Experiment 2021 (WIRE-21). This is the most highly instrumented irradiation experiment ever performed in HFIR. The experiment will use seven different sensing techniques to measure temperature, pressure, neutron flux, and neutron fluence during reactor operation. In addition to WEC’s wireless temperature and pressure sensors, WIRE-21 includes an array of thermocouples, self-powered neutron detectors, spatially distributed fiber optic temperature sensors, passive SiC temperature monitors, and flux wires. The design of WIRE-21 and the cabling that was installed in HFIR also provide the infrastructure to enable accelerated, economical testing of advanced sensor technologies while leveraging the extremely high neutron flux that is available in HFIR. The containment for WIRE-21 is similar to previous RB irradiation vehicles but includes a few modifications, most notably the use of integrated compression seals to pass a larger number of sensor leads through the experiment’s pressure boundary. In addition to the sensor leads, inert gas lines are passed into the experiment to enable active temperature control and the ability to pneumatically actuate a bellows-driven pressure sensor. WIRE-21 is targeting component temperatures (300–350°C) and neutron fluence levels (~10 22 n/cm 2 ) that would be expected in the plenum region of LWR fuels, except for the active sensing region of the wireless temperature sensor, which is targeting LWR fuel centerline temperatures (~800–1,100°C). WIRE-21 was successfully assembled, passed all nondestructive examination, and was delivered to HFIR for insertion during upcoming cycle 498 (April 2022).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS2019

Commercial and Human Settlement of the Moon and Cislunar Space – A Look Ahead at the Possibilities over the Next 50 Years

Over 50 years have passed since the movie 2001: A Space Odyssey debuted in April 1968. In the film, Dr. Heywood Floyd flies to a large artificial gravity space station orbiting Earth aboard a commercial space plane. He then embarks on a commuter flight to the Moon arriving there 25 hours later. Today, on the 50th anniversary of the Apollo 11 lunar landing, the images portrayed in 2001 still remain well beyond our capabilities. This paper examines key technologies and systems (in-situ resource utilization, fission power, advanced chemical and nuclear propulsion), and orbiting infrastructure elements (providing a propellant depot and cargo transfer function), that could be developed by NASA and the private sector in future decades allowing the operational capabilities presented in 2001 to be achieved, albeit on a more spartan scale. Lunar-derived propellants (LDPs) will be essential to reducing the launch mass requirements from Earth and developing a reusable lunar transportation system (LTS) that can allow initial outposts to evolve into settlements supporting a variety of commercial activities like in-situ propellant production. Deposits of icy regolith found within permanently shadowed craters at the lunar poles can supply the feedstock material to produce liquid oxygen (LO2) and hydrogen (LH2) propellant needed by surface-based lunar landing vehicles (LLVs) using chemical rocket engines. Along the Moon’s nearside equatorial corridor, iron oxide-rich volcanic glass beads from vast pyroclastic deposits, together with mare regolith, can provide the materials to produce lunar-derived LO2 plus other important solar wind implanted (SWI) volatiles, including H2 and helium-3. Megawatt-class fission power systems will be essential for providing continuous “24/7” power to processing plants, evolving human settlements, and other commercial activities that develop on the Moon and in orbit. Reusable LLVs will provide cargo and passenger “orbit-to-surface” access and will also be used to transport LDP to Space Transportation Nodes (STNs) located in lunar polar (LPO) and equatorial orbits (LLO). Spaced-based, reusable lunar transfer vehicles (LTVs), operating between STNs in low Earth orbit (LEO), LLO, and LPO, and able to refuel with LDPs, can offer unique mission capabilities including short transit time crewed cargo transports. Even a commuter shuttle service similar to that portrayed in 2001 appears possible, allowing 1-way trip times to and from the Moon as short as 24 hours. The performance of LTVs using both RL10B-2 chemical rockets, and a variant of the nuclear thermal rocket (NTR), the LO2-Augmented NTR (LANTR), are examined and compared. The bipropellant LANTR engine utilizes its divergent nozzle section as an afterburner into which oxygen is injected and supersonically combusted with reactor-heated hydrogen emerging from the engine’s sonic throat. If only 1% of the LDP obtained from icy regolith, volcanic glass, and SWI volatile deposits were available for use in lunar orbit, such a supply could support routine commuter flights to the Moon for many thousands of years! This paper provides a look ahead at what might be possible in the not too distant future, quantifies the operational characteristics of key in-space and surface technologies and systems, and provides conceptual designs for the various architectural elements discussed.

Borowski, Stanley K.↗
DOE OSTI2020

Empirically verified analysis of dual pre-cooling system for hydrogen refuelling station

The dual cooling system at the California State University Los Angeles Hydrogen Research and Fueling Facility is analysed to predict the output hydrogen temperature in different ambient conditions. Initially, the facility was built with a coil chiller T20 cooling, sufficient for occasional fuelings. A flat plate evaporator system was added in series to resolve any issues for multiple fuelings even in the hottest weather. This study was commenced to verify the set points and determine the control requirements for the dual setup in order to inform future designs. A numerical-empirical model of the cooling system was developed by reverse engineering, using the station experimental measurements and database records. The subsystems are characterized separately but validated as a whole system imposing specific and standard operating conditions. The cooling model is tested with different inputs to validate the pre-set parameter variation of the cooling components. Ten scenarios were investigated to evaluate the fueling output parameters, testing two hydrogen temperature input trends (according to the facility initial conditions) and five ambient temperatures (from 15 °C to 35 °C). In closing, the simulation results have confirmed that the hydrogen output temperature remains within the range imposed by the SAE J2601 for each scenario studied, around -22 °C and -25 °C.

08 HYDROGEN↗