SEARCH · Engineering Papers
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.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
The mission of the Hydrogen Delivery Technical Team (HDTT) is to enable the development of hydrogen delivery technologies, which will allow for fuel cell competitiveness with gasoline and hybrid technologies by achieving an as-produced, delivered, and dispensed hydrogen cost of $2-$4 per gallon of gasoline equivalent of hydrogen.
High pressure hydrogen gas is known to adversely affect metallic components of compressors, valves, hoses, and actuators. However, relatively little is known about the effects of high pressure hydrogen on the polymer sealing and barrier materials also found within these components. More study is required in order to determine the compatibility of common polymer materials found in the components of the hydrogen fuel delivery infrastructure with high pressure hydrogen. As a result, it is important to consider the changes in physical properties such as friction and wear in situ while the polymer is exposed to high pressure hydrogen. In this protocol, we present a method for testing the friction and wear properties of ethylene propylene diene monomer (EPDM) elastomer samples in a 28 MPa high pressure hydrogen environment using a custom-built in situ pin-on-flat linear reciprocating tribometer. Representative results from this testing are presented which indicate that the coefficient of friction between the EPDM sample coupon and steel counter surface is increased in high pressure hydrogen as compared to the coefficient of friction similarly measured in ambient air.
Metal hydride hydrogen compression utilizes a reversible heat-driven interaction of a hydride-forming metal alloy with hydrogen gas. This paper reports on the development of a laboratory scale two-stage Metal Hydride Compressor (MHC) system with a feed pressure of 150 bar delivering high purity H2 gas at outlet pressures up to 875 bar. Stage 1 and stage 2 AB 2 metal hydrides are identified based on experimental characterization of the pressure-composition-temperature (PCT) behavior of candidate materials. The selected metal hydrides are each combined with expanded natural graphite, increasing the thermal conductivity of the composites by an order of magnitude. These composites are integrated in two compressor beds with internal heat exchangers that alternate between hydrogenation and dehydrogenation cycles by thermally cycling between 20 °C and 150 °C. The prototype compressor achieved compression of hydrogen from 150 bar to 700 bar with an average flow rate of 33.6 g/hr.
The cost of hydrogen delivery for transportation accounts for most of the current H 2 selling price; delivery also requires substantial amounts of energy. In this work, we developed harmonized techno-economic and life-cycle emissions models of current and future H 2 production and delivery pathways. Our techno-economic analysis of dispensed H 2 costs guided our selection of pathways for the life-cycle analysis. In this paper, we present the results of market expansion scenarios using existing capabilities (for example, those that use H 2 from steam methane reforming, chlor-alkali, and natural gas liquid cracker plants), as well as results for future electrolysis plants that use nuclear, solar, and hydroelectric power. Reductions in greenhouse gas emissions for fuel cell electric vehicles compared to conventional gasoline pathways vary from 40% reduction for fossil-derived H 2 to 20-fold for clean H 2 . Supplemental tables with greenhouse gas emissions data for each step in the H 2 pathways enable readers to evaluate additional scenarios.
In view of the very expensive and wasteful nature of today's approaches to H 2 delivery, in this work we explore the possibility of transporting cold (200 K) high pressure (875 bar) H 2 in thermally insulated trailers and dispensing H 2 directly from the trailer, with the potential to eliminate station compressor, cascade, and refrigerator, leading to major reductions in station complexity, maintenance, electricity consumption, and cost, while improving functionality by enabling essentially unlimited back to back refuels, and improving safety due to reduced H 2 expansion energy at low temperature. Detailed techno-economic analysis shows promise for substantial delivery cost reductions through cold high pressure H 2 dispensed directly from the trailer. Results indicate that: (1) Terminal operations for cold high pressure H 2 delivery are $\$$0.32/kg H 2 more expensive than for 350 bar compressed gas delivery (today's lowest cost H 2 delivery technology) due to higher level of pressurization (to 1000 bar) and chilling needs (to 165 K). (2) Trailer cost drops slightly ($\$$0.73 vs. $\$$0.81/kg H 2 for a 350 bar trailer) due to increased capacity (1035 kg H 2 delivered vs. 700 kg) compensating for increased capital cost ($\$$906,900 for cold high pressure H 2 vs. $\$$634,000 for 350 bar trailer). (3) Cold hydrogen delivery presents major advantages in fueling station cost, reduced from $\$$1.27 to $\$$0.46/kg H 2 due to elimination of major system components: compressor, cascade, and chiller. (4) Total compression cost (terminal + station) drops from $\$$0.92/kg H 2 ($\$$0.32 terminal and $\$$0.60 station) for 350 bar trailers to $\$$0.55/kg H 2 (all at the terminal) for cold high pressure H 2 . (5) Elimination of small-scale station compressors is the main contributor to reduced delivery cost due to their inefficiency, capital expense, and maintenance needs. In summary, total delivery cost reduction vs. 350 bar trailer equals $\$$0.58/kg H 2 (from $\$$2.96 to 2.38/kg H 2 ), equivalent to 24% of the total delivery cost. This large cost advantage will improve the economics of H 2 vehicles facilitating the transition to a future of zero emission transportation.
This MP3 provides an overview of how hydrogen is delivered from the point of production to where it is used.
Thin-lined, high fiber fraction vessels have been designed, built and tested for producing cryogenic pressurized hydrogen storage with weight (9+% hydrogen weight fraction) and volume ( 50+ grams of hydrogen per liter of system volume) onboard storage performance. Long-term vessel durability was tested and partially demonstrated to 456 cycles. Other accomplishments included cycle testing a vessel provided by BMW 1000 times to demonstrate durability; and building and testing a facility for efficient testing of vessels and hydrogen components.
The main objective of the study is as follows: Identify steel compositions/microstructures suitable for construction of new pipeline infrastructure and evaluate the potential use of the existing steel pipeline infrastructure in high pressure gaseous hydrogen applications. The microstructures of four pipeline steels were characterized and tensile testing was conducted in gaseous hydrogen and helium at pressures of 5.5 MPa (800 psi), 11 MPa (1600 psi) and 20.7 MPa (3000 psi). Based on reduction of area, two of the four steels that performed the best across the pressure range were selected for evaluation of fracture and fatigue performance in gaseous hydrogen at 5.5 MPa (800 psi) and 20.7 MPa (3000 psi). The basic format for this phase of the study is as follows: Microstructural characterization of volume fraction of phases in each alloy; Tensile testing of all four alloys in He and H 2 at 5.5 MPa (800 psi), 11 MPa (1600 psi), and 20.7 MPa (3000 psi). RA performance was used to choose the two best performers for further mechanical property evaluation; Fracture testing (ASTM E1820) of two best tensile test performers in H 2 at 5.5 MPa (800 psi) and 20.7 MPa (3000 psi); Fatigue testing (ASTM E647) of two best tensile test performers in H2 at 5.5 MPa (800 psi) and 20.7 MPa (3000 psi) with frequency =1.0 Hz and R-ratio=0.5 and 0.1.
The efficient delivery of electrochemically in situ produced H 2 can be a key advantage of microbial electrosynthesis over traditional gas fermentation. However, the technical details of how to supply large amounts of electric current per volume in a biocompatible manner remain unresolved. Here, we explored for the first time the flexibility of complex 3D-printed custom electrodes to fine tune H 2 delivery during microbial electrosynthesis. Using a model system for H 2 -mediated electromethanogenesis comprised of 3D fabricated carbon aerogel cathodes plated with nickel-molybdenum and Methanococcus maripaludis, we showed that novel 3D-printed cathodes facilitated sustained and efficient electromethanogenesis from electricity and CO 2 at an unprecedented volumetric production rate of 2.2 L CH4 /L catholyte /day and at a coulombic efficiency of 99%. Importantly, our experiments revealed that the efficiency of this process strongly depends on the current density. At identical total current supplied, larger surface area cathodes enabled higher methane production and minimized escape of H 2 . Specifically, low current density (<1 mA/cm 2 ) enabled by high surface area cathodes was found to be critical for fast start-up times of the microbial culture, stable steady state performance, and high coulombic efficiencies. Our data demonstrate that 3D-printing of electrodes presents a promising design tool to mitigate effects of bubble formation and local pH gradients within the boundary layer and, thus, resolve key critical limitations for in situ electron delivery in microbial electrosynthesis.
This project will explicitly investigate and demonstrate on a laboratory scale a two-stage Metal Hydride Compressor (MHC) system with a feed pressure of approximately 100 bar delivering highpurity H 2 gas at outlet pressures ≥ 875 bar capable of an energy efficiency of ≤ 4.0 kWh/kg relying on an innovative heat pump configuration at a refueling station.
The 2015 Annual Progress Report summarizes fiscal year 2015 activities and accomplishments by projects funded by the DOE Hydrogen and Fuel Cells Program. It covers the program areas of hydrogen production; hydrogen delivery; hydrogen storage; fuel cells; manufacturing R&D; technology validation; safety, codes and standards; systems analysis; and market transformation.
The 2016 Annual Progress Report summarizes fiscal year 2016 activities and accomplishments by projects funded by the DOE Hydrogen and Fuel Cells Program. It covers the program areas of hydrogen production; hydrogen delivery; hydrogen storage; fuel cells; manufacturing R&D; technology validation; safety, codes and standards; systems analysis; market transformation; and Small Business Innovation Research projects.
Degradation of material properties by high-pressure hydrogen is an important factor in determining the safety and reliability of materials used in high-pressure hydrogen storage and delivery. Hydrogen damage mechanisms have a time dependence that is linked to hydrogen outgassing after exposure to the hydrogen atmosphere that makes ex situ measurements of mechanical properties problematic. Designing in situ measurement instruments for high-pressure hydrogen is challenging due to known hydrogen incompatibility with many metals and standard high-power motor materials like Nd. Here we detail the design and operation of a solenoid based in situ tensile tester under high-pressure hydrogen environments up to 5,000 psi. Here, modulus data from high-density polyethylene (HDPE) samples tested under high-pressure hydrogen are also reported as compared to baseline measurements taken in air.
This report describes a life-cycle assessment conducted by the National Renewable Energy Laboratory (NREL) of 10 hydrogen production, delivery, dispensing, and use pathways that were evaluated for cost, energy use, and greenhouse gas (GHG) emissions. This evaluation updates and expands on a previous assessment of seven pathways conducted in 2009. This study summarizes key results, parameters, and sensitivities to those parameters for the 10 hydrogen pathways, reporting on the levelized cost of hydrogen in 2007 U.S. dollars as well as life-cycle well-to-wheels energy use and GHG emissions associated with the pathways.
To make the hydrogen economy realistic at a large scale, one of the main technical issues to be overcome is relative to the high-pressure hydrogen delivery. Traditional hydrogen compressors suffer from high operating and maintenance costs and high capital investment. Metal hydride based compressors represent a realistic alternative that can potentially overcome all of the technical hurdles of the traditional mechanical systems. However, to date, the metal hydrides, available for this type of application (e.g. rare earth based materials), are generally based on expensive compounds and elements. A novel materials-genome based high throughput technique was established to define and develop a new class of materials for hydrogen compression. Specific material properties, required to meet the techno-economic targets for hydrogen compression systems, were identified. After validation of the high throughput methodology by comparing the results with the available material data, the technique was applied to identify preliminary new material formulations that meet the targets. A novel techno-economic analysis constrained machine learning system was developed and applied to identify the new set of metal hydride materials.
It is commonly accepted that the introduction of hydrogen as an energy carrier for light-duty vehicles involves concomitant technological development of infrastructure elements, such as production, delivery, and consumption, all associated with certain emission levels. To analyze these at a system level, the suite of corresponding models developed by the United States Department of Energy andinvolving several national laboratories is combined in one macro-system model (MSM). The macro-system model is being developed as a cross-cutting analysis tool that combines a set of hydrogen technology analysis models. Within the MSM, a federated simulation framework is used for consistent data transfer between the component models. The framework is built to suit cross-model as well ascross-platform data exchange and involves features of 'over-the-net' computation.
The objective of this three-year project was to develop a pipe coupler for high-pressure (100bar service, 350bar burst) composite hydrogen pipelines, without the use of elastomeric sealing mechanisms (e.g. o-rings), thereby avoiding seal maintenance costs and effort associated with digging up subterranean lines over a pipe’s lifetime of up to 50 years. The project aimed to build on past designs at (TRL 3), to adapt their use to hydrogen delivery and test in a relevant environment (TRL 5). This work is toward the DOE’s objective to reduce the technical barrier of high as-installed cost of pipelines, by utilizing fiber reinforced plastic (FRP) pipe. Further DOE targets include those from the Fuel Cell Technologies Office Multi-Year Research, Development, and Demonstration Plan: Milestone 1.5: Coordinating with the H2 Production and Storage sub-programs, identify optimized delivery pathways that meet a H2 delivery and dispensing cost of <\$ 2/gge for use in consumer vehicles. (4Q, 2020) Milestone 6.3: By 2020, reduce the cost of hydrogen delivery from the point of production to the point of use in consumer vehicles to <\$ 2/gge of hydrogen for the gaseous delivery pathway (4Q, 2020). This project headed by Automated Dynamics (now Trelleborg) with partners Savanah River National Laboratory, and NOV Fiber Glass Systems, emerged due to a similar previous project with the DOE, completed by SNRL and NOV Fiber Glass Systems (formerly Fiberspar) in 2014, that evaluated the mechanical suitability of FRP (composite) lines for these same high pressures. That projected concluded with a favorable outlook on using composite lines and required a suitable pipe coupler. The resulting coupler design from this current project employs electrofusion due to its proven use on low pressure unreinforced lines and for its simplicity in the field. This electrofusion coupler design utilizes established concepts for pipe couplers and combines them in a new and unique method. Existing pipe couplers are employed on thermoset pipes in high pressure, with elastomeric seals as the sealing mechanism, and on thermoplastic low-pressure pipes by way of electrofusion. However, no EF coupler is available for composite pipelines for 350bar hydrogen containment.
The Energy & Environmental Research Center (EERC) has developed a high-pressure hydrogen production system that reforms a liquid organic feedstock and water at operating pressures up to 800 bar (~12,000 psig). The advantages of this system include the elimination of energy-intensive hydrogen compression, a smaller process footprint, and the elimination of gaseous or liquid hydrogen transport. This system could also potentially enable distributed hydrogen production from centralized coal. Processes have been investigated to gasify coal and then convert the syngas into alcohol or alkanes. These alcohols and alkanes could then be easily transported in bulk to distributed high-pressure water-reforming (HPWR)-based systems to deliver hydrogen economically. The intent of this activity was to utilize the EERC’s existing HPWR hydrogen production process, previously designed and constructed in a prior project phase, as a basis to improve operational and production performance of an existing demonstration unit. Parameters to be pursued included higher hydrogen delivery pressure, higher hydrogen production rates, and the ability to refill within a 5-minute time frame.