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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 OSTI2021

Hydrogen Component Leak Rate Quantification for System Risk and Reliability Assessment through QRA and PHM Frameworks: Preprint

The National Renewable Energy Laboratory's (NREL) Hydrogen Safety Research and Development (HSR&D) program in collaboration with the University of Maryland's Systems Risk and Reliability Analysis Laboratory (SyRRA) are working to improve reliability and reduce risk in hydrogen systems. This approach strives to use quantitative data on component leaks and failures, together with Prognosis and Health Management (PHM), and Quantitative Risk Assessment (QRA) to identify at-risk components, reduce component failures and downtime, and predict when components require maintenance. Hydrogen component failures increase facility maintenance cost, facility downtime, and reduce public acceptance of hydrogen technologies, ultimately increasing facility size and cost because of potentially overly conservative requirements. Leaks are a predominant failure mode for hydrogen components. However, uncertainties in the amount of hydrogen emitted from leaking components and the frequency of those failure events limit the understanding of the risks that they present under real-world operational conditions. NREL has deployed a test fixture, the Leak Rate Quantification Apparatus (LRQA), to quantify the mass flow rate of leaking gases from medium and high-pressure components that have failed while in service. Quantitative hydrogen leak rate data from this system could ultimately be used to better inform risk assessment and Regulation Codes and Standards (RCS). Parallel activity explores the use of PHM and QRA techniques to assess and reduce risk, thereby improving safety and reliability of hydrogen systems. The results of QRAs could further provide a systematic and science-based foundation for the design and implementation of RCS, as in the latest versions of the NFPA 2 code for gaseous hydrogen stations. Alternatively, data-driven techniques of PHM could provide new damage diagnosis and health-state prognosis tools. This research will help end users, station owners and operators, and regulatory bodies move towards risk-informed preventative maintenance versus emergency corrective maintenance, reducing cost and improving reliability. Predictive modelling of failures could improve safety and affect RCS requirements such as setback distances at liquid refuelling sites. The combination of leak rate quantification research, PHM, and QRA can lead to better informed models enabling data-based decision to be made for hydrogen system safety improvements.

codes and standards↗
DOE OSTI2019

Integrated Regional Technical Exchange Centers

The Ohio Fuel Cell Coalition (OFCC) with an award from the Department of Energy Fuel Cell Fuel Cell Technologies Office (FCTO), Award No. DE-EE0006931, conducted a project to facilitate the development of a robust supply chain for fuel cell and hydrogen systems that would accelerate mass production, reduced cost, and improve performance and durability of Proton Exchange Membrane (PEM) fuel cell systems.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

HYPSTAT (Hydrogen Production, Storage, and Transmission Analysis Tool) [SWR-23-04]

The Hydrogen Production, Storage, and Transmission Analysis Tool (HYPSTAT) is a modeling framework developed by the National Renewable Energy Laboratory (NREL) to support the analysis of hydrogen systems. HYPSTAT focuses on key components of hydrogen infrastructure, particularly electrolytic hydrogen production, hydrogen storage, and hydrogen transmission, as part of the transition to decarbonized energy systems HYPSTAT operates as a supply-to-demand model, taking a fixed exogenous demand as input and optimizing the design and operation of the hydrogen system to meet that demand. It determines cost-optimal configurations based on specified technology options and system constraints.

Brauch, Joseph [National Renewable Energy Laborato↗
DOE OSTI2022

Design Tool for Estimating Adsorbent Hydrogen Storage System Characteristics for Light-Duty Fuel Cell Vehicles

This work combines materials development with hydrogen storage technology advancements to address onboard hydrogen storage challenges in light-duty vehicle applications. These systems are comprised of the vehicle requirements design space, balance of plant requirements, storage system components, and materials engineering culminating in the development of an Adsorbent System Design Tool that serves as a preprocessor to the storage system and vehicle-level models created within the Hydrogen Storage Engineering Center of Excellence. Computational and experimental efforts were integrated to evaluate, design, analyze, and scale potential hydrogen storage systems and their supporting components against the Department of Energy 2020 and Ultimate Technical Targets for Hydrogen Storage Systems for Light Duty Vehicles. Ultimately, the Adsorbent System Design Tool was created to assist material developers in assessing initial design parameters that would be required to estimate the performance of the hydrogen storage system once integrated with the full fuel cell system.

08 HYDROGEN↗
DOE OSTI2021

Refueling Infrastructure Scoping and Feasibility Assessment for Hydrogen Rail Applications

The feasibility and component cost of hydrogen rail refueling infrastructure is examined. Example reference stations can inform future studies on components and systems specifically for hydrogen rail refueling facilities. All of the 5 designs considered assumed the bulk storage of liquid hydrogen on-site, from which either gaseous or liquid hydrogen would be dispensed. The first design was estimated to refuel 10 multiple unit trains per day, each train containing 260 kg of gaseous hydrogen at 350 bar on-board. The second base design targeted the refueling of 50 passenger locomotives, each with 400 kg of gaseous hydrogen on-board at 350 bar. Variations from this basic design were made to consider the effect of two different filling times, two different hydrogen compression methods, and two different station design approaches. For each design variation, components were sized, approximate costs were estimated for major components, and physical layouts were created. For both gaseous hydrogen-dispensing base designs, the design of direct-fill using a cryopump design was the lowest cost due to the high cost of the cascade storage system and gas compressor. The last three base designs all assumed that liquid hydrogen was dispensed into tender cars for freight locomotives that required 7,500 kg of liquid hydrogen, and the three different designs assumed that 5, 50, or 200 tender cars were refueled every day. The total component costs are very different for each design, because each design has a very different dispensing capacity. The total component cost for these three designs are driven by the cost of the liquid hydrogen tank; additionally, delivering that much liquid hydrogen to the refueling facility may not be practical. Many of the designs needed the use of multiple evaporators, compressors, and cryopumps operating in parallel to meet required flow rates. In the future, the components identified here can be improved and scaled-up to better fit the needs of heavy-duty refueling facilities. This study provides basic feasibility and first-order design guidance for hydrogen refueling facilities serving emerging rail applications.

08 HYDROGEN↗
DOE OSTI2021

H 2 Production Pathways Cost Analysis (2016 - 2021) (Final Report)

This final report documents cost analysis conducted for the Department of Energy over a five year period (2016 to 2021) pertaining to hydrogen production and delivery system components, focusing on the key remaining challenges of the technology pathways within the Hydrogen Production and Delivery sub-program portfolio. A particular focus was placed on electrolysis for the generation of hydrogen. The effort primarily used the H2A discounted cash flow computational model as a tool to project hydrogen cost ($/kgH 2 ) and determine status improvements resulting from technology advancements. The effort also considered cost as a function of production volume, employed error bars to illustrate uncertainties in the cost estimates, and utilized sensitivity analyses to show the potential for cost reductions. The project examined a range of hydrogen production and delivery related systems. These included WireTough wire-wrapped pressure vessels for hydrogen storage, proton exchange membrane (PEM) electrolysis, solid oxide electrolysis (SOE), anion exchange membrane (AEM) electrolysis, photoelectrochemical (PEC) electrolysis, solar thermochemical hydrogen (STCH) production, the cost of energy transmission, and a study on the necessary price of hydrogen to produce competitively-priced electricity via fuel cell conversion.

08 HYDROGEN↗
DOE OSTI2026

Review of Shock, Vibration, and Other Tests for Type IV Hydrogen Composite Pressure Vessels for Rail Use

Requirements specific to hydrogen rail transportation and its unique components are currently not well represented in safety codes and standards. Notably, one of the most important components of the system, the hydrogen storage vessel, may be subject to entirely different shock and vibration conditions compared to hydrogen tanks on road vehicles. This report focuses on how composite hydrogen tanks are tested for performance and how this may relate to these tanks being used on rail systems. The shock and vibration testing procedures that are relevant for hydrogen composite tanks used for rail applications have been identified, as well as some general testing requirements for hydrogen tanks and composite tanks.

42 ENGINEERING↗
DOE OSTI2021

H2@Scale 2.0: Realizing the Benefits of a Hydrogen-Based Energy System

Throughout the world, hydrogen is increasingly recognized as the critical, central component for a clean, sustainable, efficient, and economic energy system. Hydrogen is remarkable for its ability to carry, store, and interconvert energy - its chemical energy can be used for clean and efficient chemical conversions to products and fuels; electricity generation; and heat generation. Hydrogen can be used as a storage medium, even for seasonal storage, to enable larger-scale deployment and use of renewable electricity. As an energy carrier, hydrogen is central to cross-sector coupling and clean, efficient transportation fuels and industrial processes, enabling decarbonization of products and services while meeting customer expectations.

chemical conversions↗
DOE OSTI2023

Low temperature hydrogen plasma permeation in palladium and its alloys for fuel recycling in fusion systems

Superpermeation of hydrogen isotopes through metal foils is a critical component for efficient fuel recycling in fusion power systems. In that context hydrogen permeation through foils of palladium and its alloys with silver and copper was studied at low temperature (60 - 200°C) under plasma exposure. These alloys differ significantly in both bulk and surface properties, and comparisons can provide mechanistic insights. Here, permeation was observed only during plasma operation, confirming the negligible contribution of molecular hydrogen to the observed flux. As-received foils required surface treatment to achieve top performance. For Pd and Pd75Ag25 an oxidation treatment increased permeation an order of magnitude, but proved unstable as this desirable surface was reduced under hydrogen plasma exposure. In contrast, an Ar plasma cleaning step provided both high and stable flux. As-received FCC phase Pd60Cu40 foils required annealing to transform it into the high permeability BCC phase that delivered top performance. All foils displayed similar temperature dependence with flux declining with temperature, suggesting that the primary rate-limiting step is absorption of superthermal hydrogen. Among these foils the hydrogen flux through PdCu was 3 - 5X greater than that of Pd or PdAg, which were similar. The superiority of BCC PdCu is attributed to its superior hydrogen desorption kinetics. Using PdCu 100% permeation of supplied hydrogen was achieved, and the flux saturated with increasing plasma power at values >10 –2 mol H•m –2 •s– 1 , and under these conditions permeation rates are equivalent with or without the membrane present. The fluxes achieved are the highest reported to date at these conditions, and the results highlight the important roles of both surface and bulk properties.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Hydrogen Equipment Enclosure Risk Reduction through Earlier Detection of Component Failures

Hydrogen component reliability and the hazard associated with failure rates is a critical area of research for the successful implementation and growth of hydrogen technology across the globe. The research team has partnered to quantify system risk reduction through earlier detection of hydrogen component failures. A model of hydrogen dispersion in a hydrogen equipment enclosure has been developed utilizing experimentally quantified hydrogen component leak rates as inputs. This model provides insight into the impact of hydrogen safety sensors and ventilation on the flammable mass within a hydrogen equipment enclosure. This model also demonstrates the change in safety sensor response time due to detector placement under various leak scenarios. The team looks to improve overall hydrogen system safety through an improved understanding of hydrogen component reliability and risk mitigation methods. This collaboration fits under the work program of IEA Hydrogen Task 43 Subtask E Hydrogen System Safety.

CFD↗
DOE OSTI2024

Computational design of high entropy alloy coating for hydrogen turbine applications

This project aims to develop novel high entropy alloy (HEA)-based coatings to protect critical components in hydrogen-fueled turbine power system. The HEA-coatings will demonstrate superior performance in hydrogen combustion environment to commercial NiCoCrAlY coating in current natural gas turbine system. The HEA coating facilitates the formation of a protective scale of alpha-alumina to slow down the inward diffusion of oxidizing species and the outward diffusion of metal elements, and possesses ultrahigh corrosion and spallation resistance to prolong the service lifetime of critical components in hydrogen turbine power system. Aimed to accelerate the discovery of novel HEA coating compositions, high throughput computational modeling including CALPHAD and density functional theory and machine learning are performed to predict phase stability, oxygen permeability, oxidation rate constant, coefficient of thermal expansion, and mechanical properties. Based on the modeling and machine learning prediction, experimental validation is performed. Preliminary results will be presented and approaches to minimize oxidation will be discussed.

alloy design↗
DOE OSTI2023

Molten Salt Tritium Transport Experiment: A Versatile Fluoride Salt Loop for Validation of Tritium Transport Phenomena

Tritium is generated in Molten Salt Reactors (MSRs) from neutron capture by lithium and other constituents of the molten salt FLiBe. Tritium is a unique radionuclide as it readily permeates through hot structural materials. Thus, any material in contact with tritium laden molten salt is a potential pathway for release. Understanding tritium transport and devising adequate control strategies is necessary for the safe operation of MSRs. The Molten Salt Tritium Transport Experiment (MSTTE) is a forced-convection fluoride salt loop with the capability to inject hydrogen isotopes into flowing molten salt and to measure transport phenomena such as permeation through metals and evolution from free-surfaces. MSTTE is designed to be versatile to test potential control technology in future campaigns. This report focuses on the current design and analysis of MSTTE. Custom designed and fabricated experiment components such as the hydrogen injection system, permeation test section, diagnostics, and gas distribution system are discussed in detail. System-level tritium transport modeling using the System Analysis Module investigates experiment parameters such as hydrogen source terms, salt flow rate, and salt temperature. Computational fluid dynamics of the salt flow in the permeation test section informs design choices to establish fully developed flow in the measured permeation zone.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2026

Organic superbases in Lewis pair catalyzed hydrogenations of imines

Organic superbases have recently emerged as powerful components in metal-free catalytic systems, yet their role in frustrated Lewis pair (FLP) catalyzed hydrogenation reactions remain underexplored. In this article, we investigate the diphosphazene superbases P 2 - t Bu (1) and P 2 -Et (2) as base components combined with electronically tunable boranes of formula 9-(X n -C 6 H 5-n )BBN, where X n = 4-NMe₂, 4-OMe, 4-Me, 4-H, 4-F, 4-OCF 3 , 4-CF 3 , 3,5-(CF3), in FLP-catalyzed hydrogenations of imines. While the more sterically encumbered base 1 forms persistent FLPs whose activity correlates with the hydride affinity of the borane, less hindered base 2 generates Lewis acid–base adducts and displays superior catalytic performance, especially with boranes of lower hydride affinity. A systematic screening identified the adduct 2/9-(4-MeO-C 6 H 4 )BBN as the most active catalytic system, achieving quantitative hydrogenation of N-benzylidene aniline at 80 °C and H 2 pressures as low as 40 bar in THF. Multinuclear NMR spectroscopic studies and DFT calculations support a mechanistic scenario in which reversible adduct formation and subsequent dissociation to the free acid–base pair precede heterolytic H₂ cleavage, with adduct stability and borane electrophilicity concurrently dictating catalytic activity. Under optimized conditions, the most active catalyst system, 2/9-(4-MeO-C 6 H 4 )BBN, hydrogenates a broad range of aldimines, including electron-rich 4-NMe₂ and push-pull substrates, mono- and bis-ortho-substituted imines, and selected heteroaryl imines, with excellent yields and selectivity. Collectively, these findings establish design principles for tuning BBN-derived FLP systems and expand the scope of metal-free hydrogenation catalysis.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

BayoTech Risk and Modeling Support of NM Gas Site

The BayoTech hydrogen generation system has been evaluated in terms of safety considerations at the NM Gas site. The consequence of a leak in different components in the system was evaluated in terms of plume dispersion and overpressure. Additionally, the likelihood of a leak scenario for different hydrogen components was identified. The worst-case plume dispersion cases, full-bore leaks, resulted in relatively large plumes. However, these cases were noted to be far less likely than the partial break cases that were evaluated. The partial break cases resulted in nearly negligible plume lengths. Similarly, the overpressure analysis of the full-bore break scenarios resulted in much larger overpressures than the partial break cases (which resulted in negligible overpressure at the lot line). There were several cases evaluated in the analysis that represented leak scenarios from both hydrogen and natural gas sources. Generally, the natural gas leak scenarios resulted in a smaller horizontal impact than that of hydrogen leaks. The worst-case consequence from a hydrogen leak resulted from the compressors, storage pods, or dispensing system. To consider the safety features that may isolate the leak, the consequence was evaluated at different times after the leak event to show the reduction of pressure. After 2 seconds, the plume dispersion from this event is contained within the perimeter of the site. The worst-case consequences show that the plume may disperse to adjacent facilities and to the street. When considering both likelihood and consequence, the risk may be considered low because the maximum frequency of a full-bore leak from any component within the hydrogen compound is 8.2 E-5/yr. This means that a full-bore leak is expected to occur less than once every 10,000 years. The risk can be further reduced by implementing mitigative countermeasures, such as CMU walls along the sides of the equipment compound. This would reduce the overall consequence of the worst-case dispersion scenarios (horizontal impact of plume). In terms of siting and safety analysis, the NFPA 2 code was used to provide a high-level evaluation of the current site plan. The most limiting equipment in terms of set-back distance are the compressors/storage units because of the high-pressure hydrogen. The site layout was evaluated for an acceptable location for the compression/storage unit based on NFPA 2 set-back distances. It is important to note that the NFPA 2 set-back distances consider both likelihood and consequence. This is important because the worst-case results evaluated herein also represent the least likely leak scenario. Other site-specific considerations were evaluated, including the parking shade structure with photovoltaic cells and refueling vehicles. These issues were dispositioned and determined to not present a safety risk.

08 HYDROGEN↗
DOE OSTI2019

System and method for production of ultra-pure hydrogen from biomass

The disclosure provides a system and method for synthesizing ultra-pure hydrogen from biomass waste. The present invention comprises a gasifier, an oils and tars filter, a steam generator, a water gas shift reactor ("WGS"), a heat-exchange two-phase water separator, a scrubber, a hydrogen separator, and fluid conduits in fluid communication with the various system components, which together convert hydrocarbon-based biomass, e.g., woodchips, into ultra-pure hydrogen gas. Fluid conduits connect the gasifier and the steam generator, separately, to the WGS, the WGS to the two-phase separator, the two-phase separator to the scrubber, and the scrubber to the hydrogen separator, which further comprises an outlet port through which hydrogen gas may flow free of carbon monoxide. The hydrogen may flow to a device that utilizes hydrogen to generate energy, such as a hydrogen fuel cell or to an internal combustion engine.

Tawfik, Hazem↗
DOE OSTI2023

Hydroelectric Power and Hydrogen Production Integration

Hydropower-based hydrogen production could introduce opportunities for new revenue streams for hydropower plants, including from energy storage and regeneration as well as from sale of the hydrogen product to external markets. Hydrogen-based energy storage and regeneration could also help support Idaho Power’s decarbonization goals by decreasing dependence on fossil-based peaking power plants. Additionally, integration of hydrogen production with hydropower generation could help address the issue of low dissolved oxygen river water conditions that commonly accompany hydropower plant operations by utilizing the oxygen byproduct from an electrolytic hydrogen production process as a resource for mitigation of low dissolved oxygen water conditions. Comprehensive techno-economic analysis of the hybrid hydroelectric and hydrogen energy storage system has revealed critical insights into the pathways and considerations for optimizing the economic value and environmental benefits of such systems. Among the three identified pathways of natural gas blending, regeneration, and direct sale of hydrogen, the direct sale of hydrogen emerges as the most profitable, particularly given the current pricing dynamics of hydrogen and electricity. However, as we anticipate a future grid characterized by higher renewable energy penetration, the landscape may evolve, featuring lower average electricity prices, heightened fluctuations, and more significant seasonal variations. Consequently, the attractiveness of electricity regeneration through hydrogen and the benefits of long-duration hydrogen storage are expected to increase substantially in such a dynamic energy scenario. The careful selection of component sizes within the hybrid system proves to be paramount for ensuring cost-effectiveness. Notably, the size of the hydrogen market has emerged as a critical determinant for the optimal size of the electrolyzer. Hydrogen storage should be sized to meet energy shifting requirements. The appropriate size of the fuel cell/microturbine generator hinges on the shape of electricity prices and the available revenue streams derived from participating in grid services. Striking the right balance among these components is essential for maximizing the overall efficiency and profitability of the hydrogen facility. Furthermore, the by-product of electrolysis, namely oxygen, introduces an additional dimension to the system's functionality. The oxygen generated can be effectively utilized for dissolved oxygen (DO) mitigation, particularly with larger electrolyzer sizes capable of satisfying the complete oxygen demand for this purpose. While the economic benefits derived from saved oxygen purchase costs may be relatively modest compared to other revenue streams, the environmental advantages of repurposing oxygen for DO mitigation could help Idaho Power meet their environmental obligations. In addition to the identified factors shaping the viability of hybrid hydrogen production and hydroelectric generation, it is noteworthy that the integration of hydrogen energy storage offers a unique advantage during unusually wet years. In such periods of increased water inflow, the hydrogen storage capacity serves as a valuable supplement to the reservoir. By utilizing hydrogen energy storage as a complementary reservoir, the system gains flexibility in reservoir management when dealing with fluctuations in water availability.

08 HYDROGEN↗
DOE OSTI2022

Dynamic Frequency Regulation Improvement in Hydropower-Hybrid System using Variational Mode Decomposition

Providing frequency response, especially fast frequency response such as Red D in the Pennsylvania-New Jersey-Maryland Interconnection (PJM) market, is challenging for many generation plants to deliver on their own. If they have adequate flexibility, hydropower plants are typically able to provide slower regulation support (e.g., Reg A in PJM), but do not respond fast enough to provide Reg D. The ability to provide Reg D would improve their revenue because this service is typically more valuable. This work presents a control approach to use hydropower, battery, and ultracapacitor systems to provide fast regulation in a way that uses the response contribution of each asset. In particular, the proposed control architecture applies a variational mode decomposition (VMD) technique on the incoming Reg D signal to extract multiple dynamic-regulation components with non-overlapping frequencies. With the response-speed dependent alignment, these regulation components are fed to the hydrogenator and hybrid energy storage system (HESS). The paper evaluates the proposed approach on a direct-current (DC)-coupled active system by computing several performance measures and analyzing sensitivity based on HESS component proportional capacities. The results reveal that the proposed VMD-based signal conditioning performs well and that optimizing the sizing of the battery and ultracapacitor components further enhances performance.

13 HYDRO ENERGY↗
DOE OSTI2022

Component Reliability R&D

A review of the work done on the hydrogen Component Reliability R&D project in the last year. The National Renewable Energy Laboratory's (NREL) Hydrogen Safety Research and Development (HSR&D) program in collaboration with the University of Maryland's Systems Risk and Reliability Analysis Laboratory (SyRRA) are working to improve reliability and reduce risk in hydrogen systems through the use of use quantitative data on component leaks and failures, together with Prognosis and Health Management (PHM), and Quantitative Risk Assessment (QRA).

component↗