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This project relates to the loan of four Toyota Mirai FCEV-adv vehicles to NLR to provide a load (vehicles to fill with hydrogen) to our fueling station research facility to study hydrogen fueling infrastructure performance using 700 bar precooled hydrogen at ESIF’s Hydrogen Infrastructure Testing and Research Facility (HITRF) facility.
Hydrogen is an important resource for many different industries throughout the world, including refining, manufacturing, and as a direct energy source. Hydrogen production, through methods such as steam methane reforming, has been developed over several decades. There is a large global demand for hydrogen from these industries and safe production and distribution are paramount for hydrogen systems. Codes and standards have been developed to reduce the risk associated with hydrogen accidents to the public. These codes and standards are similar to those in other industries in which there is inherent risk to the public, such as gasoline and natural gas production and distribution. Although there will always be a risk to the public in these types of fuels, the codes and standards are developed to reduce the likelihood of an accident occurring and reduce the severity of impact, should one occur. This report reviews the current state of hydrogen in the United States and outlines the codes and standards that ensure safe operation of hydrogen systems. The total hydrogen demand and use in different industries is identified. Additionally, the current landscape of hydrogen production and fueling stations in the United States is outlined. The safety of hydrogen systems is discussed through an overview of the purpose, methods, and content included in codes and standards. As outlined in this safety overview, the risk to the public in operation of hydrogen generation facilities and fueling stations is reduced through implementation of appropriate measures. Codes, such as NFPA 2, ensure that the risk associated with a hydrogen system is no greater than the risk presented by gasoline refueling stations.
As the adoption of electric vehicles and hydrogen fuel-cell vehicles grows, understanding how dynamic pricing strategies influence charging and refueling behaviors becomes crucial for optimizing local energy markets. This paper proposes a simulation-based analysis of a hydrogen-electricity integrated charging station that serves both types of vehicles. A multi-agent simulation framework is developed to model the interactions between vehicles and the station, incorporating price- and delay-sensitive behaviors in decision-making. The station can dynamically adjust energy prices, while vehicles optimize their charging or refueling choices based on their utility values. A series of sensitivity analyses are conducted to evaluate how electricity pricing, infrastructure capacity, and waiting behavior impact station performance. Results highlight that moderate electricity prices maximize user participation without sacrificing profit, infrastructure should be right-sized to demand to avoid over- or underutilization, and delay-toleration also affects service outcomes, which may reach the maximum service coverage at the threshold of 45 minutes.
Zirconium alloy tubes used as nuclear fuel cladding are subject to oxidation and subsequent hydrogen pickup during their long service in commercial light water reactors. The hydrogen picked up in the cladding can precipitate as a brittle hydride rim feature on the cladding outer surface. Here, to better understand the effect of hydride rims on the fracture behavior of stress-relieved zirconium alloy cladding tubes, a procedure to produce these rim-like structures has been developed and is described herein. Extensive characterization of the ‘as hydrided’ tubes is performed. The hydrogen charging apparatus consists of a tube furnace with a quartz chamber that is connected to a vacuum pump as well as a bottle of pure hydrogen gas. The charging station uses a static charge of hydrogen as opposed to a flowing gas. The chief advantage of this approach is the ability to monitor the pressure drop in the hydriding chamber and correlate this pressure drop to a known rate of hydrogen pickup in the cladding tube. It was found that the hydrogen partial pressure, metal temperature, and surface treatment all clearly played a role in whether a hydride rim was formed. Extensive characterization of the hydride rims shows they consist of needle like platelets of δ phase hydrides (ZrH1.66) oriented in the circumferential direction with a radial spacing of several microns in a sandwich-like structure.
Conceptual designs for O2/H2 chemical and resistojet propulsion systems for the space station was developed and evaluated. The evolution of propulsion requirements was considered as the space station configuration and its utilization as a space transportation node change over the first decade of operation. The characteristics of candidate O2/H2 auxiliary propulsion systems are determined, and opportunities for integration with the OTV tank farm and the space station life support, power and thermal control subsystems are investigated. OTV tank farm boiloff can provide a major portion of the growth station impulse requirements and CO2 from the life support system can be a significant propellant resource, provided it is not denied by closure of that subsystem. Waste heat from the thermal control system is sufficient for many propellant conditioning requirements. It is concluded that the optimum level of subsystem integration must be based on higher level space station studies.
Time synchronized at distant points within nanosecond. Report describes satellite-borne time-and frequency-transfer system proposed for synchronization of clocks at stations around Earth. Orbiting hydrogen-maser clock and frequency standard communicate by microwave links with Earth stations using hydrogen masers as local clocks. Pulsed-laser time-transfer sub-system also operated concurrently, either synchronized or unsynchronized with microwave subsystems.
The Advanced Space Propulsion Laboratory at the NASA Johnson Space Center has been engaged in the development of a magneto-plasma rocket for several years. This type of rocket could be used in the future to propel interplanetary spacecraft. One feature of this concept is the ability to vary its specific impulse so that it can be operated in a mode that maximizes propellant efficiency or a mode that maximizes thrust. For this reason the system is called the Variable Specific Impulse Magneto-plasma Rocket or VASIMR. This ability to vary specific impulse and thrust will allow for optimum low thrust interplanetary trajectories and results in shorter trip times than is possible with fixed specific impulse systems while preserving adequate payload margins. In the development of the VASIMR technology, a series of ground-based experiments and space demonstrations are envisioned. A ground-based experiment of a low-power VASIMR prototype rocket is currently underway at the Advanced Space Propulsion Laboratory. The next step is a proposal to build and fly a 25-kilowatt VASIMR rocket as an external payload on the International Space Station. This experiment will provide an opportunity to demonstrate the performance of the rocket in space and measure the induced environment. The experiment will also utilize the space station for its intended purpose as a laboratory with vacuum conditions that cannot be matched by any laboratory on Earth. The VASIMR experiment will also blaze the trail for the wider application of advanced electric propulsion on the space station. An electric propulsion system like VASIMR, if provided with sufficient electrical power, could provide continuous drag force compensation for the space station. Drag compensation would eliminate the need for reboosting the station, an operation that will consume about 60 metric tons of propellant in a ten-year period. In contrast, an electric propulsion system would require very little propellant. In fact, a system like VASIMR can use waste hydrogen from the station's life support system as its propellant. This waste hydrogen is otherwise dumped overboard. Continuous drag compensation would also improve the microgravity conditions on the station. So electric propulsion can reduce propellant delivery requirements and thereby increase available payload capacity and at the same time improve the conditions for scientific research.
This paper estimates the expected ranges of levelized cost of dispensed hydrogen at heavy-duty refueling stations. The analysis assesses a range of scenarios including type of production (centralized vs. onsite, market size in terms of number of vehicles, size of refueling station, utilization rates of the refueling stations, and pathway of delivery of hydrogen). Because delivery of liquid hydrogen is more cost effective at higher volumes than delivery of gaseous hydrogen, this paper only considers delivery of liquid hydrogen except in the case of onsite production.
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.
This paper provides a description of the hydrogen sensor Orbital Replacement Unit (ORU) used on the Oxygen Generation Assembly (OGA), to be operated on the International Space Station (ISS). The hydrogen sensor ORU is being provided by Makel Engineering, Inc. (MEI) to monitor the oxygen outlet for the presence of hydrogen. The hydrogen sensor ORU is a triple redundant design where each sensor converts raw measurements to actual hydrogen partial pressure that is reported to the OGA system controller. The signal outputs are utilized for system shutdown in the event that the hydrogen concentration in the oxygen outlet line exceeds the specified shutdown limit. Improvements have been made to the Micro-Electro-Mechanical Systems (MEMS) based sensing element, screening, and calibration process to meet OGA operating requirements. Two flight hydrogen sensor ORUs have successfully completed the acceptance test phase. This paper also describes the sensor s performance during acceptance testing, additional tests planned to extend the operational performance calibration cycle, and integration with the OGA system.
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Evaluation testing of the cell pair design of an electrochemical carbon dioxide collection subsystem was conducted. The system is proposed for use with the space station prototype. The objectives of the analytical and miscellaneous tasks in support of the test program are explained. An analysis was made of the number of cells required for the space station prototype. It was determined that 33 cell pairs would satisfy the space station prototype performance.
The heritage of the Ni-H2 technology that makes the space station application feasible is discussed. It also describes a design for a potential space station Ni-H2 battery system. Specific design values presented here were developed by Ford Aerospace as part of the Rocketdyne team effort on the Phase B Definition and Preliminary Design of the Space Station Power System in support of NASA Lewis Research Center.
This report considers the technological and market pathways that will enable better use of photovoltaic (PV) electricity as fuel for future transportation demand. Most of the pathways identified will require collaborative research and development (R&D) efforts to improve the capabilities of multiple technologies, including PV, energy storage, vehicles, electrolyzers, electrofuels, and infrastructure. For plug-in electric vehicles (PEVs), technologies that enable wide-scale managed and coordinated charging are among the highest priorities for continued research, development, and deployment in the near term. Furthermore, managed and coordinated charging capabilities are foundational for future vehicle-to-grid (V2G) functionality in the long term. For hydrogen fuel cell electric vehicles (FCEVs), the use of PV electricity for electrolysis provides an opportunity to increase PV deployment. For rail, air, and maritime transportation, the feasibility of increased PV use varies in the near term; opportunities for synergies with solar include the electrification of rail, increased reliability from airport microgrids, and switching from heavy fuel oil to clean maritime electrofuels made from PV-based hydrogen. Over the longer term, battery swap stations for electric airplanes and the co-location of solar with hydrogen fueling stations at shipping ports may enable greater synergies between PV and transportation.
A test of the second postulate of special relativity, the universality of the speed of light, using the ExTRAS (Experiment on Timing Ranging and Atmospheric Sounding) payload to be flown on board a Russian Meteor-3M satellite (launch date January 1997) is proposed. The propagation time of a light signal transmitted from one point to another without reflection would be measured directly by comparing the phases of two hydrogen maser clocks, one on board and one on the ground, using laser or microwave time transfer systems. An estimated uncertainty budget of the proposed measurements is given, resulting in an expected sensitivity of the experiment of delta c/c is less than 8xl0(exp -10) which would be an improvement by a factor of approximately 430 over previous direct measurements and by a factor of approximately 4 over the best indirect measurement. The proposed test would require no equipment additional to what is already planned and so is of inherently low-cost. It could be carried out by anyone having access to a laser or microwave ground station and a hydrogen maser.
Modular chemical process intensification (MCPI) is an emerging field where chemical processing is performed using small-scale modular equipment instead of conventional large centralized chemical plants. Conventional chemical plants benefit from economies of scale that encourage scale-up to ever larger plants. A goal of MCPI is to develop technology that intensifies processing so that equipment can be dramatically smaller and integrated into modular systems. Scale-up occurs by adding more modules in parallel rather than making the equipment larger. A key concept is that equipment and modules can ultimately be cheaper by leveraging economies of mass production, analogous to the automotive industry, in manufacturing the equipment. This project made significant progress toward this outcome by meeting the RAPID institute metric to reduce equipment cost by 20% for each doubling in manufacturing volume. The MCPI application was thermochemical technology that is being commercialized by STARS Technology Corporation, one of the CRADA partners. The technology converts solar and renewable power to chemical energy to produce renewable hydrogen, fuels, and chemicals. The benefit to the public is reduction in greenhouse gases that are contributing to climate change. The project transitioned the steam methane reforming (SMR) reactor from conventional fabrication methods to additive manufacturing (AM) direct metal laser sintering (DMLS) process. This is projected to reduce the cost of making a reactor by 58% when producing 100 reactors per year. Innovations in the DMLS process produced a patented design that reduces reactor weight by 60%. Reductions in material costs and processing time extend the DMLS advantage to higher production volumes. The new design promises to be 38% cheaper than the conventional processes at 1000 units per year. The resulting 87% reduction in the steam methane reforming (SMR) module cost in scaling from current costs meets the RAPID metric. The project was successful in producing and testing the first ever additively manufactured SMR reactors. A reactor achieved over 82% efficiency in converting electric power to chemical energy, which is a world record for an inductively heated SMR. The project has contributed to the design and assembly of a first demonstration plant that is headed to a hydrogen bus filling station in Thousand Palms, CA.
Testing for the Space Station Freedom Nickel Hydrogen Cell Test Program began in 1990 at Crave Division, Naval Surface Warfare Center. The program has included receipt inspection, random vibration, acceptance, characterization, and life cycle testing of Ni-H2 cells in accordance with the NASA LeRC Interagency Order C-31001-J. A total of 400 Ni-H2 cells have been received at NAVSURFWARCENDIV Crane from three separate manufacturers; Yardney Technical Products (Yardney), Eagle Picher Industries (Eagle Picher), and Gates Energy Products (Gates). Of those, 308 cells distributed among 39 packs have undergone life cycle testing under a test regime simulating low earth orbit conditions. As of 30 September 1993, there are 252 cells assembled into 32 packs still on life cycle test. Since the beginning of the program, failed cells have been detected in all phases of testing. The failures include the following; seven 65 AmpHr and 81 AmpHr Yardney cells were found to be leaking KOH on receipt, one 65 AmpHr Eagle Picher cell failed the acceptance test, one 65 AmpHr Gates cell failed during the characterization test, and six 65 AmpHr Gates cells failed the random vibration test. Of the 39 life cycle packs, testing on seven packs, 56 cells, has been suspended because of low end of discharge voltages. All of the failed life cycle packs were cycled at 60% depth of discharge.
Hydrogen, particularly green hydrogen produced through electrolysis using renewable energy, is poised to play a critical role in decarbonizing the global economy. Its ability to address the intermittency of renewable energy sources and decarbonize hard-to-electrify sectors positions it as a vital component of a sustainable energy future. Interest in hydrogen as a clean energy carrier is in a decade of unprecedented growth, with dozens of countries having released national hydrogen strategies contributing to a global hydrogen economy. In 2021, the Department of Energy (DOE) announced the Hydrogen Shot, the first of the Energy Earthshot Initiatives, which aims to lower the cost of clean hydrogen to $\$$1/kg by 2031. This initiative was followed by a considerable increase in funding for hydrogen technologies through the Bipartisan Infrastructure Law (BIL), with $\$$18 billion recently announced for regional demonstration projects (Hydrogen Hubs) and another $\$$11.5 billion aimed at research and development of electrolyzers, fuel cells, manufacturing, and recycling. The 2023 U.S. National Clean Hydrogen Strategy and Roadmap identifies the cost of clean hydrogen as a critical challenge for achieving economic scale. This includes the cost of hydrogen production by electrolysis, delivery and dispensing, onboard storage, and end-use technologies like fuel cells. Fundamental research and development into catalysts, component architectures, and material durability are critical to lower the costs of these vital technologies aimed at achieving a net-zero carbon emission economy by 2050.