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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 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

H2Fills™ [SWR-19-67]

H2FillS: Hydrogen Filling Simulation The Hydrogen Filling Simulation (H2FillS) software is a thermodynamic model designed to track and report on the transient change in hydrogen temperature, pressure, and mass flow when filling a fuel cell electric vehicle (FCEV). H2FillS simulates gas flow from the hydrogen station to the FCEV storage system. Using empirical fueling data sets, the model has been validated over a range of fueling conditions to match common light-duty FCEV fill profiles. Overall, it provides significant benefits to the light-duty fueling market and fill knowledge gaps of the interaction between a hydrogen station and an FCEV. Capabilities Use the comprehensive H2FillS model to: Safely design and operate a hydrogen fueling station Support code refinement with readily available data Develop system and operational improvements to reduce capital or operating costs at hydrogen stations or on-board FCEVs. How It Works H2FillS uses a "drag-and-drop" graphical user interface to simulate station and vehicle systems with preset parameters for common hydrogen station components as default values. When needed, users can define their own parameters to create their own station or vehicle components. Download H2FillS in Two Steps Read the terms of the end user software license agreement. Register to download the software. There are two versions of the model: A full-station model starts the simulation at high-pressure ground storage, runs through a dispenser, and ends at a vehicle storage system. A partial-station model starts at the dispenser breakaway and consists solely of the dispenser components and the vehicle storage system. H2FillS will automatically output fill performance data from the vehicle by tracking pressure and temperature throughout the fill. Users can input their own fill profiles into the model to run a variety of simulations.

Peters, Michael↗
DOE OSTI2024

Nuclear Integrated Hydrogen Production Analysis Tool

This is an Excel-based time-independent discount cash flow calculator for LWR-HTSE systems. The tool incorporates (1) discounted cash flow and levelized cost of hydrogen (LCOH) analysis, (2) sensitivity analysis with respect to select financial performance metrics with output ‘tornado’ charts, (3) profitability analysis represented by heat maps using the two most sensitive parameters, (4) electricity versus hydrogen production preference analysis by comparing change in net present value (?NPV) between NPP-HTSE and business-as-usual electricity production for the grid, and (5) competitiveness analysis by comparing the calculated LCOH for NPP-HTSE with that of steam methane reforming, which is the conventional process to produce hydrogen.

Cheng, WenChi [Idaho National Laboratory (INL), Id↗
DOE OSTI2024

Electrolyzer Integrated Modular Nano-Array Monolithic Catalytic Reactors

The project objective is to design and develop a new class of electrolyzer-integrated, modular, nanostructure array (nano-array) monolithic catalytic reactors for high-flux, robust and selective methanol synthesis. The modular reactor features metal oxide nano-array grown on an additively-manufactured channeled honeycomb monolith made of ceramic or metals; this low-pressure carbon dioxide hydrogenation reactor is fueled with hydrogen from a low-temperature water electrolyzer having reduced platinum group metal (PGM) content. Through these nanostructured monolithic reactors, methanol synthesis is enabled with cost-effective hydrogenation reactions under low-temperature (<200°C) and low-pressure (<10 atm) conditions, thus significantly reducing the energy demand of the entire process.

08 HYDROGEN↗
DOE OSTI2023

Editorial: Advanced water splitting technologies development: Best practices and protocols

As the level of deployment and utilization of renewable energy sources, including wind and solar, continues to rise, large-scale, long-term energy storage technologies that could accommodate weekly and seasonal energy fluctuations will play a significant role in the overall deployment of renewable energies in the future. Harnessing and storing renewable energy resources via electrochemical, photoelectrochemical, or thermochemical processes by converting renewable energy into sustainable (energy storage) fuels have the potential to meet the long-term, terawatt scale energy storage challenge. Renewable hydrogen production is the cornerstone for sustainable fuel production and deep decarbonization of multiple sectors in our society. Cost-competitive clean hydrogen provides value to applications, such as 1) in the transportation sector for fuel cell vehicles, 2) in the electric grid sector for system stability and load balancing, and 3) in the industrial sector with metal refineries, cement production, and biomass upgrading (carbon-free fertilizer production). In addition, coupling clean renewable hydrogen with the carbon and nitrogen cycles enables known and well-established thermal-chemical processes to generate renewable hydrocarbon fuels and ammonia. The Advanced Water Splitting Technologies (AWST): low temperature electrolysis (LTE), high temperature electrolysis (HTE), photoelectrochemical (PEC) and solar thermo-chemical hydrogen (STCH) provide four unique and parallel approaches to produce low cost, low greenhouse gas (GHG) emission hydrogen at scale (Figure 1). Cost competitive clean hydrogen production using these four technologies is a current high priority focus for governments and industry. In June of 2022, the U.S. Department of Energy (DOE) launched the first in a series of Earthshot Initiatives. The Hydrogen Shot, “1 1 1” aims to reduce the cost of clean hydrogen by more than 80% to one dollar per one kilogram in 1 decade ($\$$1/kg H 2 ). The European Green Deal and the International Energy Agency (IEA) have implemented a strong focus on green hydrogen production for a clean and secure energy future.

benchmarking, low temperature electrolysis↗
DOE OSTI2023

Renewable Electrolysis System Development (Final Report)

Renewable hydrogen is becoming globally recognized as a key component required for de-carbonization of our energy system, both as a medium for capture of excess renewable energy sources, vehicle refueling, and as an intermediate for multiple industrial processes. Hydrogen production, via low-temperature electrolysis, is a flexible grid-friendly, clean energy carrying intermediate that enables fast ramp and de-ramp rates as naturally varying solar, wind, and storage systems become a larger percentage of the electricity mix. Analysis shows that by 2050, employing renewable hydrogen at scale can decrease total U.S. CO 2 emissions by about half relative to business as usual, critical to achieving >80% greenhouse gas reduction targets. Energy storage systems help commercial customers reduce their electric bills by storing energy from the grid or from renewable electricity sources when energy is inexpensive, then using that stored energy when demand and prices are high. Proton exchange membrane (PEM) electrolysis is one of the few technologies that can produce hydrogen with zero carbon emissions at relevant scale (hundreds of MWs) in the near term. NREL's research has shown that electrolyzers are fast and flexible enough to participate in energy and ancillary service markets that can help stabilize the grid. In 2015, Proton OnSite (now NEL Hydrogen) introduced the M-series electrolyzer platform, the world's first megawatt PEM electrolyzer for the global energy storage market, offering a carbon-free source of hydrogen fuel or process gas. In addition, the ability to sell the hydrogen into a high value application like vehicle (e.g., light- and heavy-duty and material handling) fueling allows for a layering of revenue streams that creates better business cases for hydrogen energy storage systems (HES). The ability to provide multiple value streams from the fast-responding controllable electrolyzer will have a direct impact on the net cost of hydrogen.

08 HYDROGEN↗
DOE OSTI2025

Preliminary Techno-Economic Assessment of Gas Switching Reforming (GSR) of Natural Gas for Pure Hydrogen Production and Power Generation with Integrated CO2 Capture

The increasing demand for hydrogen and the CO2 intensity of natural gas (NG) reforming motivate the development of low-carbon-emission hydrogen production technologies. Gas Switching Reforming (GSR) is an advanced auto-thermal reforming technology that produces hydrogen or syngas from natural gas. It integrates inherent CO2 capture by utilizing a specialized oxygen carrier in a single fluidized bed reactor, eliminating the need for complex, energy-intensive post-combustion separation. GSR technology builds upon Chemical Looping Reforming (CLR), an experimentally proven technology with strong potential for scaling up. In this study, select oxygen carriers (OC) (NiO/Al2O3, Fe2O3-CeO2/Al2O3, and magnetite) were tested in methane steam reforming in a fixed bed reactor to determine their relative reactivities under relevant conditions for GSR (800 °C, 7 bar total pressure). Process models were then developed to perform techno-economic analysis (TEA) of GSR for hydrogen production (GSR-H₂) and a combined cycle (GSR-CC) in which high-purity H₂ is fired in a gas turbine to produce electricity. Operating at 10 bar and 1100 °C and with the additional recovery steps implemented increased H₂ production by ~30% and improved efficiency relative to prior studies. For GSR-H₂, the levelized cost of hydrogen (LCOH) is 1.61–1.64 $/kg-H₂, competitive with a reference SMR case, though operating and maintenance costs are higher due to increased electricity demand. GSR-CC has a significantly higher levelized cost of electricity (LCOE) than its reference NGCC (natural gas combined cycle) plant, suggesting it is less competitive; however, increasing production scale could make it more attractive. Life-cycle results for GSR-H2 indicate NG consumption drives ~75% of total global warming impacts (~2.3 kg CO2 eq/kg H2). An environmental, health, and safety screening suggests iron-based carriers are comparatively safer, whereas NiO may pose greater risks. Overall, GSR-H2 is a scalable, competitive option for hydrogen production using nickel and non-nickel OC.

03 NATURAL GAS↗
DOE OSTI2025

Preliminary techno-economic assessment of gas switching reforming (GSR) of natural gas for pure hydrogen production and power generation with integrated CO2 capture

The increasing demand for hydrogen and the CO2 intensity of natural gas (NG) reforming motivate the development of low-carbon-emission hydrogen production technologies. Gas Switching Reforming (GSR) with integrated CO2 capture, a technology based on Chemical Looping Reforming (CLR), has been experimentally proven and shows potential for scale-up. In this study, select oxygen carriers (OC) (NiO/Al2O3, Fe2O3-CeO2/Al2O3, and magnetite) were tested in methane steam reforming in a fixed bed reactor to determine their relative reactivities under relevant conditions for GSR (800 °C, 7 bar total pressure). Process models were then developed to perform techno-economic analysis (TEA) of GSR for hydrogen production (GSR-H2) and a combined cycle (GSR-CC) in which high-purity H2 is fired in a gas turbine to produce electricity. Operating at 10 bar and 1100 °C and with the additional recovery steps implemented increased H2 production by ∼ 30% and improved efficiency relative to prior studies. For GSR-H2, the levelized cost of hydrogen (LCOH) is 1.61–1.64 $/kg-H2, competitive with a reference SMR case, though operating and maintenance costs are higher due to increased electricity demand. GSR-CC has a significantly higher levelized cost of electricity (LCOE) than its reference NGCC (natural gas combined cycle) plant, suggesting it is less competitive; however, increasing production scale could make it more attractive. Life-cycle results for GSR-H2 indicate NG consumption drives ∼ 75% of total global warming impacts (∼2.3 kg CO2 eq/kg H2). An environmental, health, and safety screening suggests iron-based carriers are comparatively safer, whereas NiO may pose greater risks. Overall, GSR-H2 is a scalable, competitive option for hydrogen production using nickel and non-nickel OC.

03 NATURAL GAS↗
DOE OSTI2026

Comparative assessment of new oxygen carrier materials for gas switching reforming of natural gas: Techno-economics assessment, life cycle analysis, and experimental insights

The increasing demand for hydrogen and the CO 2 intensity of natural gas (NG) reforming motivate the development of low-carbon-emission hydrogen production technologies. Gas Switching Reforming (GSR) with integrated CO 2 capture, a technology based on Chemical Looping Reforming (CLR), has been experimentally proven and shows potential for scale-up. In this study, select oxygen carriers (OC) (NiO/Al 2 O 3 , Fe 2 O 3 -CeO 2 /Al 2 O 3 , and magnetite) were tested in methane steam reforming in a fixed bed reactor to determine their relative reactivities under relevant conditions for GSR (800 °C, 7 bar total pressure). Process models were then developed to perform techno-economic analysis (TEA) of GSR for hydrogen production (GSR-H 2 ) and a combined cycle (GSR-CC) in which high-purity H 2 is fired in a gas turbine to produce electricity. Operating at 10 bar and 1100 °C and with the additional recovery steps implemented increased H 2 production by ∼ 30% and improved efficiency relative to prior studies. For GSR-H 2 , the levelized cost of hydrogen (LCOH) is 1.61–1.64 $/kg-H 2 , competitive with a reference SMR case, though operating and maintenance costs are higher due to increased electricity demand. GSR-CC has a significantly higher levelized cost of electricity (LCOE) than its reference NGCC (natural gas combined cycle) plant, suggesting it is less competitive; however, increasing production scale could make it more attractive. Life-cycle results for GSR-H 2 indicate NG consumption drives ∼ 75% of total global warming impacts (∼2.3 kg CO 2 eq/kg H 2 ). An environmental, health, and safety screening suggests iron-based carriers are comparatively safer, whereas NiO may pose greater risks. Overall, GSR-H 2 is a scalable, competitive option for hydrogen production using nickel and non-nickel OC.

03 NATURAL GAS↗
DOE OSTI2020

Next Generation Hydrogen Station Composite Data Products: Retail Stations (Data through Quarter 3 of 2019)

This publication includes 98 composite data products (CDPs) produced for next generation hydrogen stations, with data through the third quarter of 2019. These CDPs include data from retail stations only and represent the following analysis categories: deployment, safety, maintenance and reliability, performance, cost, utilization, hydrogen quality, and component energy.

08 HYDROGEN↗
NASA NTRS2000

Design Study for A Low-Cost LH2 Turbopump

A preliminary design study, focusing on potential component selections and design for manufacturing and assembly (DFMAR1) analysis, is presented in this study. The investigation focused on a nominal cost liquid hydrogen turbopump suitable for a private launch class vehicle. Utilizing a "turbocharger-like" design philosophy, preliminary feasibility studies of the basic pump design class, the rotordynamic design class, and the turbine design class were conducted with associated DFMA evaluations. Reasonable cost levels and sensible levels of product assurance have been established.

Japikse, David↗
DOE OSTI2021

Economic Dispatch Model of Nuclear High-Temperature Reactor with Hydrogen Cogeneration in Electricity Market

Hydrogen produced without carbon emissions could be a useful fuel as nations look to decarbonize their electricity, transport, and industry sectors. Using the iodine–sulfur (IS) cycle coupled with a nuclear heat source is one method for producing hydrogen without the use of fossil fuels. An economic dispatch model was developed for a nuclear-driven IS system to determine hydrogen sale prices that would make such a system profitable. The system studied is the HTTR-GT/H2, a design for power and hydrogen cogeneration at the Japan Atomic Energy Agency’s High Temperature Engineering Test Reactor. This study focuses on the development of the economic model and the role that input data plays in the final calculated values. Using a historical price duration curve shows that the levelized cost of hydrogen (LCOH) or breakeven sale price of hydrogen would need to be 98.1 JPY/m3 or greater. Synthetic time histories were also used and found the LCOH to be 67.5 JPY/m3. The price duration input was found to have a significant effect on the LCOH. As such, great care should be used in these economic dispatch analyses to select reasonable input assumptions.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Front End Engineering Design Study on Gasification of Coal and Biomass to Generate Carbon- Free Electric Power and Hydrogen

A 2nd Phase Front End Engineering Design study of a gasification plant concept to co-produce electric power and hydrogen with net-negative CO2 emissions is being completed under the U.S. Department of Energy’s (DOE’s) 21st Century Power Plants initiative, whose goal is to advance innovative power plant concepts that are capable of flexible, net-zero carbon emission operations while producing cost-effective hydrogen to support economy-wide decarbonization goals. The proposed standalone plant would be constructed in Nebraska, USA. The specified design feedstock is a hybrid blend of Powder River Basin (PRB) subbituminous coal from Wyoming and local Nebraska biomass (corn stover), 50% each by weight (dry basis). Other potential feedstocks, including woody biomass (eastern red cedar) and waste plastic (auto shredder residue) were evaluated as alternates. The process block comprises a high-pressure, oxygen-blown fluidized bed gasifier coupled with water-gas shift, Selexol process for acid gas (H2S and CO2) removal, and pressure-swing adsorption (PSA) to yield 8,500 kg/h of high-purity hydrogen. Off-gas from the PSA unit is used in a gas turbine combined cycle plant (the power block) to supply 50 MWe net electric power to the grid. Overall thermal efficiency of the plant is 50% (HHV) with net atmospheric CO2 removal at a rate of 32 t/h. Design activities necessary to provide input to the current front-end engineering design (FEED) study, including, site selection, gasifier technology selection, investment case preparation, and the development of the Environmental Information Volume (EIV) for the host site, have been completed. These, as well as the current FEED activities, are described in this presentation.

gasification, biomass, coal, hydrogen, power gener↗
DOE OSTI2022

Developing novel electrodes with ultralow catalyst loading for high-efficiency hydrogen production in proton exchange membrane electrolyzer cells

Hydrogen plays more crucial roles for decarbonizing the planets and meeting the climate challenges because of its high energy density and zero-emission. It can be produced with proton exchange membrane electrolyzer cells (PEMECs) driven by sustainable and renewable energy resources. Although PEMECs have a number of advantages, including high purity production, quick response, and the ability to operate at high pressure facilitating the gas delivering, their performance and cost greatly hinder their commercial-scale applications. To achieve high-efficiency and cost-reduced hydrogen production in PEMECs, we proposed thin engineered liquid/gas diffusion layers (LGDLs) and associated electrodes, i.e., catalyst-coated LGDLs (CCLGDLs), over conventional porous transport layers (PTLs) and catalyst-coated membranes (CCMs). The research approaches in this project are based on material synthesis, in-situ and ex-situ characterizations, component design and treatment, numerical modeling, and cost analysis. The thin and tunable LGDLs (TT-LGDLs) and CCLGDLs were successfully developed with great performance improvement as demonstrated in lab-scale, bench-scale, and system-scale electrolyzer tests. The electrode thickness was reduced from 370 µm to less than 100 µm with simplified fabrication processes. With the catalytically enhanced Ir-based catalyst coating, the as-developed CCLGDLs with a catalyst loading of 0.34 mg Ir /cm 2 achieved a cell performance of 1.77 V at 2 A cm -2 , exhibiting the catalyst mass activity enhanced by >20 times with significant catalyst saving over conventional catalyst cell design. In-situ PEMEC characterizations, including the current distribution mapping and high-speed and multiscale visualizations, were conducted for a deeper understanding of mass transport and electrochemical reactions within an electrolyzer with LGDLs and CCLGDLs. A 2D cell model was developed and validated for the enhanced performance on TT-LGDL through reducing ohmic losses due to nonuniform hydration and water transport. Further, the cost analysis results have shown a path to move beyond equivalency and surpass costs associated with the project baseline. In this project, the design and fabrication of TT-LGDLs and CCLGDLs will contribute to the performance enhancement, manufacturing simplification, and cost reduction for PEMECs and other energy conversion devices, thus shortening their pathways towards commercialization. This project also provides a good foundation for furthering the in-situ reaction interface research.

08 HYDROGEN↗
DOE OSTI2021

Hydrogen from Sunlight and Water: A Side-by-Side Comparison between Photoelectrochemical and Solar Thermochemical Water-Splitting

Photoelectrochemical (PEC) and solar thermochemical (STCH) water-splitting represent two promising pathways for direct solar hydrogen generation. PEC water-splitting integrates multiple functional materials and utilizes energetic electrons and holes generated from sunlight to produce hydrogen and oxygen in two half-reactions, while STCH water-splitting couples a series of consecutive chemical reactions and uses absorbed heat from sunlight to generate hydrogen and oxygen in two full reactions. In this Focus Review, the basic operating principles, sunlight utilization, device architecture, reactor design, instantaneous and annually averaged solar-to-hydrogen (STH) conversion efficiency, and the operating conditions and constraints of both pathways are compared. A side-by-side comparison addresses some common sources of confusion and misinterpretation, especially in the evaluation of STH conversion efficiencies, and reveals distinct features and challenges in both PEC and STCH technologies. Furthermore, this Focus Review also addresses materials and device challenges in PEC and STCH for cost-competitive hydrogen generation.

08 HYDROGEN↗
DOE OSTI2023

Polymeric Membranes for H2S and CO2 Removal from Natural Gas for Hydrogen Production: A Review

Natural gas, an important source of hydrogen, is expected to be crucial in the transition to a hydrogen-based economy. The landscape of the gas processing industry is set to change in the near future with the development of highly acidic sour gas wells. Natural gas purification constitutes a major share of the gas separation membrane market, and the shift to low-quality sour gas wells has been mirrored in the trends of membrane material research. Purification also constitutes the major portion of the cost of natural gas, posing implications for the cost of hydrogen production. This review provides an update on the current state of research regarding polymeric membranes for H2S removal, along with CO2 separation, from natural gas that is used for hydrogen production via steam methane reforming. The challenges of adapting polymeric membranes to ternary H2S/CO2/CH4 separations are discussed in detail. Key polymeric materials are highlighted, and the prospects for their application in H2S removal from natural gas are evaluated. Finally, the growing interest in H2 production from H2S is discussed. Advances in the membrane industry and the emergence of new membrane materials may significantly improve the commercial viability of such processes.

Rao, Shraavya↗
DOE OSTI2024

Economic Case for Replacing High-Emitting Peaker Plants with Fuel Cells for Automotive Applications

The identification of clean and cost-effective solutions to replace high-emitting peaker plants and support a just transition is a challenge faced by utilities across the US today. However, falling costs of hydrogen production as well as the widespread availability of fuel cells for automotive applications have made them an attractive option for a zero-emission peak power supply. This study evaluates the techno-economics, operation, and environmental justice impacts of siting a peaker plant based on fuel cells for automotive applications through the lens of the existing Intermountain Power Plant, in order to supply peak power to the Los Angeles basin. Compared to the fossil fuel-fired peakers in operation today, the fuel cell peaker would be lower-cost up to a 17% capacity factor with Inflation Reduction Act incentives while also reducing air pollution in environmental justice communities. With corresponding transmission upgrades, the Intermountain site could host up to a 5 GW fuel cell peaker in the future.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

On the design and performance of InGaN/Si double-junction photocathodes

Via a combined theoretical and experimental study, we have investigated the synthesis and performance characteristics of InGaN/Si double-junction photoelectrochemical (PEC) water splitting devices, which promise a theoretical solar-to-hydrogen conversion efficiency ~30% under AM 1.5G one-sun illumination. The double-junction photocathodes consist of a p + -InGaN top light absorber and a Si bottom p-n junction, which are connected through a nanowire tunnel junction. The effect of indium composition of the top light absorber as well as the impact of p-type Mg dopant incorporation on the PEC performance was studied. Experimentally, the sample with 32% indium composition showed a maximum photocurrent density of ~9 mA/cm 2 at 0.4 mV vs reverse hydrogen electrode (RHE) with applied bias photon-to-current efficiency (ABPE) of ~9.5%. An optimum p-type doping level ~1 × 10 17 cm -3 was also identified, which results in the best device performance as a result of optimum surface band bending as well as vertical charge carrier (hole) transport. These results also show a good agreement with our theoretical analysis. This work provides significant insights in advancing the design and development of high efficiency PEC devices for artificial photosynthesis using industry ready materials, e.g., Si and GaN, to achieve large-scale, low-cost onsite hydrogen fuel production.

42 ENGINEERING↗