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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Electrochemical Hydrogen Compression Cell Design (CRADA Final Report)

Electrochemical compression and purification is a high potential technology that is likely to outcompete mechanical compression for hydrogen end use applications. However, testing and understanding what is occurring within the cell is difficult as it is not readily accessible through experimentation. Thus, the main target is to increase performance and reduce cost of electrochemical hydrogen compression (EHC) and purification (EHP) cells and stacks using multiscale mathematical modeling informed by experiment. The models can provide physical insight into limiting processes and develop mitigation methods, which can be proven out through rapid sub-scale testing of the devices.

08 HYDROGEN↗
DOE OSTI2023

Concentration fluctuations and flammability of cryo-compressed hydrogen and methane jets

Compressed hydrogen stored at cryogenic temperatures has a much higher density than room-temperature storage, which enables large-scale hydrogen storage and transport. An understanding of the release of cryogenic hydrogen from pressurized vessels is needed to evaluate the risk and safety concerns with the use of this fuel. Here, the present work extends the analysis of previous experimental studies that measured the gas concentrations of cryo-compressed hydrogen jets and methane jets using a laser Raman scattering diagnostic system. Since the Raman signals are very small, a denoising algorithm was applied to significantly reduce the noise to enable statistical analysis of the data. The transient features of the turbulent jets were characterized by their concentration intermittencies and probability density functions (PDFs). A two-part PDF was developed to predict the bimodal features of the jet concentration distributions. Then, the flammability factors of the cryogenic jets were calculated based on the intermittency and the PDF.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

System and Machine Learning-Guided Materials Design for High-Pressure Hydrogen Compression

Cost-effective and reliable hydrogen compression remains a challenging barrier in the widespread adoption of hydrogen as an energy carrier. The prevailing technology of mechanical compression suffers from several drawbacks, some of which can be addressed by nonmechanical compression strategies (e.g., electrochemical or metal hydride-based thermal compression). Thermally driven metal hydride compression strategies typically rely on multistage metal hydride-based compressors; however, discovering or optimizing low-stability metal hydrides that can pressurize hydrogen upward of 1000 bar is difficult, both with respect to computational predictions and experimental validation. Here, in this study, we (1) demonstrate that simple machine learning-derived design rules can inform the rational design of alloying strategies yielding low-stability hydrides, (2) validate their experimental pressure–composition–temperature (PCT) isotherms up to 875 bar, and (3) utilize a dynamic system-level model of a metal hydride compressor design to evaluate their performance under realistic operating conditions. Importantly, this analysis yields predicted operational efficiencies of both 2-stage (90–875 bar) and 3-stage (20–875 bar) metal hydride compressors to enable further evaluation of this technology and its techno-economic outlook.

alloy optimization↗
DOE OSTI2022

Research and development of hydrogen carrier based solutions for hydrogen compression and storage

Industrial and public interest in hydrogen technologies has risen strongly recently, as hydrogen is the ideal means for medium to long term energy storage, transport and usage in combination with renewable and green energy supply. In a future energy system, the production, storage and usage of green hydrogen is a key technology. Hydrogen is and will in future be even more used for industrial production processes as a reduction agent or for the production of synthetic hydrocarbons, especially in the chemical industry and in refineries. Under certain conditions material based systems for hydrogen storage and compression offer advantages over the classical systems based on gaseous or liquid hydrogen. This includes in particular lower maintenance costs, higher reliability and safety. Hydrogen storage is possible at pressures and temperatures much closer to ambient conditions. Hydrogen compression is possible without any moving parts and only by using waste heat. In this paper, we summarize the newest developments of hydrogen carriers for storage and compression and in addition, give an overview of the different research activities in this field.

08 HYDROGEN↗
DOE OSTI2022

Pressurized formic acid dehydrogenation: an entropic spring replaces hydrogen compression cost

Formic acid is unique among liquid organic hydrogen carriers (LOHCs), because its dehydrogenation is highly entropically driven. This enables the evolution of high-pressure hydrogen at mild temperatures that is difficult to achieve with other LOHCs, conceptually by releasing the “spring” of energy stored entropically in the liquid carrier. Applications calling for hydrogen-on-demand, such as vehicle filling, require pressurized H 2 . Hydrogen compression dominates the cost for such applications, yet there are very few reports of selective, catalytic dehydrogenation of formic acid at elevated pressure. Herein, we show that homogenous catalysts with various ligand frameworks, including Noyori-type tridentate (PNP, SNS, SNP, SNPO), bidentate chelates (pyridyl)NHC, (pyridyl)phosphine, (pyridyl)sulfonamide, and their metallic precursors, are suitable catalysts for the dehydrogenation of neat formic acid under self-pressurizing conditions. Quite surprisingly, we discovered that their structural differences can be related to performance differences in their respective structural families, with some tolerant or intolerant of pressure and others that are significantly advantaged by pressurized conditions. Here, we further find important roles for H 2 and CO in catalyst activation and speciation. In fact, for certain systems, CO behaves as a healing reagent when trapped in a pressurizing reactor system, enabling extended life from systems that would be otherwise deactivated.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Foam-insulated cryo-compressed hydrogen storage vessels for buses

Here, large reductions (40 % vs. compressed gaseous hydrogen vessels and 17 % vs. vacuum insulated cryo-compressed vessels) in hydrogen storage system cost are possible by operating buses with foam-insulated cryo-compressed hydrogen (CcH 2 ) vessels. Detailed thermodynamic analysis reveals that large size and rapid H 2 consumption in buses compensate for the poor performance of foam insulation (∼100 times more conductive than vacuum multilayer insulation), resulting in compact and inexpensive H 2 storage systems with sufficient H 2 capacity for the longest routes (500 km) while maintaining previously identified advantages of CcH 2 systems: increased autonomy, rapid high density refueling, and improved safety, while simultaneously avoiding vacuum insulation stability problems resulting from composite resin outgassing.

Cryo-compressed↗
DOE OSTI2020

Modeling The Effects of Loading Scenario and Thermal Expansion Coefficient on Potential Failure of Cryo-compressed Hydrogen Vessels

A multiscale thermomechanical model for a simplified Type-3 cryogenic compressed hydrogen (H2) storage vessel is developed in this paper. The model accounts for the temperature-dependent elastic-plastic behavior of the vessel carbon/epoxy composite overwrap and aluminum alloy liner. The homogenized thermo-elastic-plastic behavior for the individual laminas of the vessel layup is obtained by an incremental Eshelby-Mori-Tanka approach associated with a micromechanical failure criterion to predict lamina failure while a standard elastic-plastic constitutive model is used to describe the behavior of a typical aluminum alloy assumed for the liner. The vessel response to external loadings is achieved by a finite element method. Four loading scenarios representing four thermomechanical cycles applied to the vessel are analyzed to evaluate constituent and lamina stresses as well as the associate failure criterion during the cycle according to these scenarios. The model can provide helpful guidance to mitigate thermal stresses by an adequate selection of loading scenario, optimizing the layup and by tailoring thermomechanical properties of the resin matrix.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Continuous caustic aqueous phase electrochemical reforming (CAPER) of ethanol for producing compressed hydrogen

Caustic Aqueous Phase Electrochemical Reforming (CAPER) of ethanol produces pure compressed H 2 at lower voltages, temperatures, and energy requirements than conventional electrolysis, while capturing carbonaceous products. The CAPER flow reactor consists of stainless steel endplates, stainless steel current collectors, and a Teflon flow field. The electrodes are prepared using commercial palladium nanoparticles on carbon support for the anode and platinum nanoparticles on carbon support for the cathode. The catalyst metal loading was 1 mgcm –2 on a 10cm 2 carbon cloth for both electrodes. Our CAPER reactor produces pure H 2 at 80bar and 80°C applying voltages at ≤0.5V. The only gas-phase product detected was H 2 and any carbonaceous products were contained in the liquid phase. The H 2 was produced with 97±4% faradaic efficiency. Further, operating at smaller electrode separation distances (4mm) and 80°C increased the current density. The highest lower heating value efficiency achieved was 28% at a flow rate of 0.05mLmin –1 and an applied voltage of 0.5V. The compressed H 2 was produced at ≤20 kWh kg –1 , which is much lower than electrolysis systems that require upwards of 50 kWh kg –1 .

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Rational design of semi-interpenetrating network based on hyperbranched polyglycerol grafted MXene/polyurethane–epoxy for compressed hydrogen storage

Here, hydrogen (H 2 ) energy has emerged as a promising alternative in the automotive sector to replace fossil fuel; however, its storage with volumetric efficiency remains a challenge. The latest type IV storage vessel featuring a polymeric liner with composite overwrap incurs hydrogen saturation, which eventually causes failure. To prevent the H 2 dissolution in the liner, we have developed a barrier coating comprised of polyurethane/epoxy semi-interpenetrating network (S-IPN) combined with hyperbranched polyglycerol grafted MXene (h-MXene). The hyperbranched structure facilitated the dispersion of MXene in the coating solution by enhancing the exfoliation and improved the polymer filler interaction by forming covalent and H-bonding through end-terminal hydroxyl groups. Leveraging the dense network of S-IPN combined with the dispersed layer structured h-MXene significantly increased the tortuosity of the spray-coated barrier film applied to the nylon 6 liner. The coating exhibited a 90 % reduction in the H 2 gas permeability at only 2 wt% h-MXene concentration, which further improved to above 98 % at 10 wt% loading. Additionally, the h-MXene considerably improved the adhesion with the liner even in a highly stretched condition, signifying the durability of the coating under cyclic pressurization and depressurization of the storage vessel.

08 HYDROGEN↗
DOE OSTI2021

Energy Arbitrage: Comparison of Options for use with LWR Nuclear Power Plants

Arbitrage is the opportunistic buying and selling of a commodity during local pricing valleys and peaks respectively to maximize economic value. This report evaluates options for energy arbitrage integrated with existing light water reactor (LWR) nuclear power plants (NPPs) where nuclear energy could be stored in a variety of forms and later recovered to generate electrical power during periods when grid electricity demand and pricing are high. The forms of energy storage examined in this report include the potential value of batteries, hydrogen, and thermal energy storage for coupling with nuclear power. Various large demand response options are also analyzed, including the production of liquid nitrogen via air separation and liquefaction, liquefaction of hydrogen, compressed hydrogen, and the cryogenic capture of CO2. Demand response refers to dispatchable loads that can cycle up or down depending on-grid electricity demand to aid in balancing the grid. Large demand response options could dispatch to aid nuclear power stations in avoiding power turndowns by providing an alternate disposition for electrical energy by producing marketable products (e.g., liquid nitrogen, hydrogen, or captured CO2). Static conditions were chosen and analyzed in this report for each option. Dynamic operation or optimization of energy arbitrage or demand response are out of scope for this report. The analysis is based on storage systems with discharge capacities of 500 MW for which various durations of storage and costs of charging (electricity cost) are examined. While the value of thermal energy to an industrial user for flexible plant operations has been previously proven as a business case, this report evaluates costs of hydrogen energy storage and leading thermal energy storage options, and large demand response loads that could be integrated with LWRs in comparison to utility-scale battery storage for use of off-peak nuclear energy. Compilation of this information will be used by the Idaho National Laboratory (INL) RAVEN/HERON systems integration and economics tool to evaluate thermal energy dispatch to industrial users. Relative ranking of energy storage options was done using a levelized cost of storage (LCOS) metric which calculates a rough breakeven cost for the system, taking into account the capital and operating costs as well as the revenue from arbitrage. Table ES1 below shows the LCOS for each of the energy storage options considered. First, in the table, lithium iron (Fe) phosphate batteries are listed as the base case for comparison against the other options. Next is hydrogen storage where most of the hydrogen analyses assumed the hydrogen to be produced using solid oxide electrolytic cell (SOEC) high temperature steam electrolysis (HTSE). The others used existing models of polymer electrolyte membrane (PEM) low temperature electrolysis to produce hydrogen. HTSE performance parameters and costs were taken from existing INL models. Various means were assumed to convert the hydrogen to electricity, including PEM fuel cells (FCs) and a gas turbine mixed in a 30 vol% mixture with natural gas. Physical storage (pressure vessels) and geological storage (natural underground features) were used to store the hydrogen as noted. Geological storage is more economical, but the locations are limited because of the requirement for pre-existing geological formations that will support storage. Thermal energy storage (TES) options were also analyzed including electro-thermal energy storage (ETES) and four different liquid sensible heat TES storage media as noted (Hitec, Hitec XL, Therminol-66, and Dowtherm A). The ETES process considered was modified using existing public documentation on an Echogen process and uses a separate supercritical CO2 charge and discharge cycle with sand as the heat storage media.

25 ENERGY STORAGE↗
DOE OSTI2025

Membrane Electrode Assembly Manufacturing Automation Technology for the Electrochemical Compression of Hydrogen: Cooperative Research and Development (Final Report)

Electrochemical compression has the possibility to outcompete mechanical compression for hydrogen end- use applications. While HyET has a compressor that can output JO kilograms (kg)/day (fully scalable from home-to-industrial application) at up to 700 bar, the energy demand and reliability require top-quality electrochemical hydrogen compression (EHC) membrane electrode assemblies (MEAs), preferably prepared by cost-effective high-capacity manufacturing. High pressure requires a special MEA design, deviating from typical proton exchange membrane fuel cell (PEMFC) MEAs with adapted catalyst layer substrates, asking for a modified coating process. The National Renewable Energy Laboratory (NREL) will help HyET by developing an automated catalyst coating process fit for EHC MEA manufacturing. In addition, inline quality inspection methods will be developed/selected to improve the MBA quality as it is used for EHC stack assembly. In a joint effort, NREL and HyET will even design an automated manufacturing process for the EHC MEA and approach potential United States (US) suppliers of manufacturing equipment.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2024

Method and system for electrochemically compressing gaseous hydrogen

Method and system for electrochemically compressing hydrogen. In one embodiment, the system includes a membrane electrode assembly (MEA) that includes a polymer electrolyte membrane (PEM), an anode, and a cathode. First and second gas diffusion media are positioned adjacent the cathode and anode, respectively. A humidifying membrane is positioned next to the second gas diffusion medium on a side opposite the anode. A water supply is connected to the humidifying membrane, and a hydrogen gas supply is connected to the second gas diffusion medium. A hydrogen gas collector including a back pressure regulator is connected to the first gas diffusion medium. Separators, positioned on opposite sides of the MEA, are connected to a power source. In use, hydrogen is electrochemically pumped across the MEA and collected in the hydrogen gas collector. The PEM is kept properly humidified by the humidifying membrane, which releases water into the second gas diffusion medium.

Hamdan, Monjid↗
NASA NTRS1979

Dedicated nuclear facilities for electrolytic hydrogen production

An advanced technology, fully dedicated nuclear-electrolytic hydrogen production facility is presented. This plant will produce hydrogen and oxygen only and no electrical power will be generated for off-plant use. The conceptual design was based on hydrogen production to fill a pipeline at 1000 psi and a 3000 MW nuclear base, and the base-line facility nuclear-to-shaftpower and shaftpower-to-electricity subsystems, the water treatment subsystem, electricity-to-hydrogen subsystem, hydrogen compression, efficiency, and hydrogen production cost are discussed. The final conceptual design integrates a 3000 MWth high-temperature gas-cooled reactor operating at 980 C helium reactor-out temperature, direct dc electricity generation via acyclic generators, and high-current density, high-pressure electrolyzers based on the solid polymer electrolyte approach. All subsystems are close-coupled and optimally interfaced and pipeline hydrogen is produced at 1000 psi. Hydrogen costs were about half of the conventional nuclear electrolysis process.

Foh, S. E.↗
DOE OSTI2022

Advanced Hydrogen Compressor for Hydrogen Storage Integrated with a Powerplant

This report summarizes work performed by Siemens Energy (SE) to design, build and test an advanced hydrogen compressor stage suitable for use in a hydrogen electrolysis system integrated with a powerplant to achieve energy storage in the form of compressed hydrogen. As hydrogen utilization increases to achieve energy storage and decarbonization of a variety of industries, the need is growing for improved and more cost-effective hydrogen compression technologies. The counter-rotating compression stage concept demonstrated under this contract and presented in this report offers a novel approach to achieve significantly more head rise per stage of compression, resulting in the potential for decreased capital cost and footprint compared to current state of the art centrifugal compression technologies. This report includes details of the design, testing, results, and subsequent validation of aerodynamic performance predictions.

08 HYDROGEN↗