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NASA Aerospace Flight Battery Program: Wet Life of Nickel-Hydrogen (Ni-H2) Batteries: Appendices - Volume 2, Part 3

This NASA Aerospace Flight Battery Systems Working Group was chartered within the NASA Engineering and Safety Center (NESC). The Battery Working Group was tasked to complete tasks and to propose proactive work to address battery related, agency-wide issues on an annual basis. In its first year of operation, this proactive program addressed various aspects of the validation and verification of aerospace battery systems for NASA missions. Studies were performed, issues were discussed and in many cases, test programs were executed to generate recommendations and guidelines to reduce risk associated with various aspects of implementing battery technology in the aerospace industry. This document contains Part 3 - Volume II Appendices to Part 3 - Volume I.

Jung, David S,↗

Space Shuttle Program (SSP) Orbiter Main Propulsion System (MPS) Gaseous Hydrogen (GH2) Flow Control Valve (FCV) Poppet Eddy Current (EC) Inspection Probability of Detection (POD) Study

The Director of the NASA Engineering and Safety Center (NESC), requested an independent assessment of the anomalous gaseous hydrogen (GH2) flow incident on the Space Shuttle Program (SSP) Orbiter Vehicle (OV)-105 during the Space Transportation System (STS)-126 mission. The main propulsion system (MPS) engine #2 GH2 flow control valve (FCV) LV-57 transition from low towards high flow position without being commanded. Post-flight examination revealed that the FCV LV-57 poppet had experienced a fatigue failure that liberated a section of the poppet flange. The NESC assessment provided a peer review of the computational fluid dynamics (CFD), stress analysis, and impact testing. A probability of detection (POD) study was requested by the SSP Orbiter Project for the eddy current (EC) nondestructive evaluation (NDE) techniques that were developed to inspect the flight FCV poppets. This report contains the findings and recommendations from the NESC assessment.

Piascik, Robert S.↗

Space Shuttle Program (SSP) Orbiter Main Propulsion System (MPS) Gaseous Hydrogen (GH2) Flow Control Valve (FCV) Poppet Eddy Current (EC) Inspection Probability of Detection (POD) Study: Appendices - Volume 2

The Director of the NASA Engineering and Safety Center (NESC), requested an independent assessment of the anomalous gaseous hydrogen (GH2) flow incident on the Space Shuttle Program (SSP) Orbiter Vehicle (OV)-105 during the Space Transportation System (STS)-126 mission. The main propulsion system (MPS) engine #2 GH2 flow control valve (FCV) LV-57 transition from low towards high flow position without being commanded. Post-flight examination revealed that the FCV LV-57 poppet had experienced a fatigue failure that liberated a section of the poppet flange. The NESC assessment provided a peer review of the computational fluid dynamics (CFD), stress analysis, and impact testing. A probability of detection (POD) study was requested by the SSP Orbiter Project for the eddy current (EC) nondestructive evaluation (NDE) techniques that were developed to inspect the flight FCV poppets. This report contains the Appendices to the main report.

Piascik, Robert S.↗

Hydrogen Learning for Local Leaders – H2L3

The Hydrogen Learning for Local Leaders program, H2L3, elevates the knowledge about hydrogen by local government officials across the United States. The program reaches local leaders directly through “Hydrogen 101” workshops and webinar sessions; the creation and dissemination of a unique report on the hydrogen and fuel cell market in the US, covering 57 different sectors; and support of the Hydrogen Student Design Contest, a competition for interdisciplinary teams of university students to design hydrogen and fuel cell systems based on technology that’s currently commercially available.

08 HYDROGEN↗

Progress and Accomplishments in Hydrogen and Fuel Cells (Fuel Cells Technologies Program Factsheet)

The U.S. Department of Energy’s (DOE’s) efforts have greatly advanced the state of the art of hydrogen and fuel cell technologies —making significant progress toward overcoming many of the key challenges to widespread commercialization. DOE has also made major advances by demonstrating and validating the technologies under real-world conditions, supporting early markets through Recovery Act deployments, and leveraging domestic and international partnerships to advance the pace of commercialization.

fact sheet↗

Final Report for Project DE-FG02-05ER15718 Fluoropolymers, Electrolytes, Composites and Electrodes

This report is for a project that was initiated under the title “New Proton-Conducting Fluoropolymer Electrolytes for PEM Fuel Cells”, as part of the DOE program titled “Basic Research for the Hydrogen Fuel Cell Initiative”, Program Notice DE-FG01-04ER04-20. The project received 750,000 dollars in initial funding for a three-year term with a start date of August 15, 2005. Creager was PI and co-PIs were DesMarteau and Smith, all from Clemson. The project was renewed for a second three-year term with a start date of June 15 2008, again for 750,000 dollars, with the new title, “Fluoropolymers, Electrolytes, Composites and Electrodes”. Shortly after the renewal was put in place, co-PI Smith left Clemson to accept a position at the University of Texas at Dallas. After a period of no-cost extension the project was renewed on January 1 2013 for another three-year term, this time for a smaller amount ($525,000) and with Thrasher, a new senior hire at Clemson, as co-PI in place of Smith. DesMarteau had retired from Clemson by this time but was retained as a project advisor. After a final one-year no-cost extension for calendar year 2016, the project ended on December 31, 2016, giving it an active period of eleven and one-half years, from August 15 2005 to December 31 2016. The overall objective of this research project has been to create and understand the behavior of new fluoropolymer-based electrolytes and electrodes suitable for use in electrochemical energy storage and conversion devices. The objective was pursued via research on new fluorinated monomers, new polymers and polyelectrolytes (also known as ionomers), and new electrocatalyst supports that in some cases include chemically grafted electrolytes to promote rapid ion transport to electrocatalytically active sites (usually platinum nanoparticles) on the support. The research involved synthesis and characterization of new materials, and creation and use of new measurement techniques that address key properties of the materials, e.g. mixed electronic / ionic conduction in the absence of liquid electrolyte, that are relevant to their use in energy conversion and storage.

30 DIRECT ENERGY CONVERSION↗

Shuttle Gaseous Hydrogen Venting Risk from Flow Control Valve Failure

This paper describes a series of studies to assess the potential risk associated with the failure of one of three gaseous hydrogen flow control valves in the orbiter's main propulsion system during the launch of Shuttle Endeavour (STS-126) in November 2008. The studies focused on critical issues associated with the possibility of combustion resulting from release of gaseous hydrogen from the external tank into the atmosphere during assent. The Shuttle Program currently assumes hydrogen venting from the external tank will result in a critical failure. The current effort was conducted to increase understanding of the risk associated with venting hydrogen given the flow control valve failure scenarios being considered in the Integrated In-Flight Anomaly Investigation being conducted by NASA.

Drummond, J. Philip↗

Florida Hydrogen Initiative (FHI) (Final Report)

The Florida Hydrogen Initiative (FHI) was a research, development and demonstration (RD&D) hydrogen and fuel cell program funded by U.S. Department of Energy (DOE). The FHI program objectives were to develop Florida’s hydrogen and fuel cell infrastructure and to assist DOE in its hydrogen and fuel cell activities by creating partnerships for demonstration projects, sponsoring research and development programs, facilitating technology transfer between the public and private sectors, developing industry support and establishing unique hydrogen/fuel cell university-level education programs. The FHI program funded 12 RD&D projects. Each project was issued a sub-contract with specific tasks, deliverables and budget. The results of these projects are presented in this final report. In this Executive Summary, a one paragraph description is given for each of the 12 projects conducted with FHI support. The 12 projects are presented in numerical order by task (Task 1 to Task 14). These include five projects (Tasks 1, 5, 7, 10 and 13) in the hydrogen technology areas, five (Tasks 2, 8, 9, 11 and 14) fuel cell related activities and two covering education and public understanding and information exchange (Task 3 and 12). Note that Tasks 4 and 6 were administrative tasks.

08 HYDROGEN↗

Coal Ash Behavior in Reducing Environments (CABRE) III: Year 6 - Activity 1.10 - Development of a National Center for Hydrogen

The Energy & Environmental Research Center (EERC) has been conducting research on gasification for six decades. One of the objectives of this gasification research has been to maximize carbon conversion and the water–gas shift process for optimal hydrogen production and syngas quality. This research focus and experience were a perfect fit for the National Center for Hydrogen Technology ® (NCHT®) Program at the EERC for improving all aspects of coal gasification, which ultimately aids in the production and purification of hydrogen. A consortia project was developed under the NCHT Program to develop an improved predictive model for ash formation and deposition under the project entitled “Coal Ash Behavior in Reducing Environments (CABRE) III: Development of the CABRE III Model.” The computer-based program is now applicable to the modeling of coal and ash behavior in both entrained-flow and fluidized-bed gasification systems to aid in overall gasification efficiency. This model represents a significant improvement over the CABRE II model and runs on a Microsoft Windows PC platform.

01 COAL, LIGNITE, AND PEAT↗

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↗

Vehicle Technologies and Hydrogen and Fuel Cell Technologies Research and Development Programs Benefits Assessment Report for 2020

The U.S. Department of Energy’s Vehicle Technologies and Hydrogen and Fuel Cell Technologies Offices (VTO and HFTO) support research and development of efficient and sustainable transportation technologies that will improve energy efficiency, minimize emissions, and enable America to use less petroleum. VTO and HFTO regularly revisit and update relevant research and development goals and areas of emphasis in response to the latest technological advancements and in alignment with current national priorities. As such, analyses of expected benefits resulting from VTO and HFTO investments and anticipated goal achievements are updated periodically and will be again for 2021 in the context of the latest national-level transportation decarbonization goals. The analysis in the present report is based on technical progress goals established in VTO and HFTO in the years immediately prior to and including 2020, and it summarizes the estimated energy and emissions benefits corresponding to achievement of those goals. The goals span research activities on batteries, electric drive technologies (EDT), combustion, lightweight materials, fuel cells, and hydrogen storage. The evaluation includes detailed analyses into the benefits of technology improvements on the U.S. light-duty (LD) vehicle fleet and separately on the U.S. medium- and heavy-duty (MDHD) vehicle fleet. This report summarizes the outcomes from each of these analyses both independently and in combination.

08 HYDROGEN↗

Numerical investigation of the perpendicular injector flow field in a hydrogen fueled scramjet

A computer program has been developed which numerically solves the full (elliptic) two-dimensional Navier-Stokes and specie equations near a slotted perpendicular hydrogen fuel injector in a scramjet engine. The program currently predicts the turbulent mixing of injected hydrogen fuel and air without reaction, and allows the study of separated regions of flow immediately preceding and following the injector as well as the complex shock-expansion structure produced by the injector in this region of the engine. Results are presented that describe the size of the separated regions near the injector as well as locations where ignition is likely to occur.

Drummond, J. P.↗

Final Technical Report for GO17004 Regulatory Logic: Codes and Standards for the Hydrogen Economy

The objectives of this project are to: develop a robust supporting research and development program to provide critical hydrogen behavior data and a detailed understanding of hydrogen combustion and safety across a range of scenarios, needed to establish setback distances in building codes and minimize the overall data gaps in code development; support and facilitate the completion of technical specifications by the International Organization for Standardization (ISO) for gaseous hydrogen refueling (TS 20012) and standards for on-board liquid (ISO 13985) and gaseous or gaseous blend (ISO 15869) hydrogen storage by 2007; support and facilitate the effort, led by the NFPA, to complete the draft Hydrogen Technologies Code (NFPA 2) by 2008; with experimental data and input from Technology Validation Program element activities, support and facilitate the completion of standards for bulk hydrogen storage (e.g., NFPA 55) by 2008; facilitate the adoption of the most recently available model codes (e.g., from the International Code Council [ICC]) in key regions; complete preliminary research and development on hydrogen release scenarios to support the establishment of setback distances in building codes and provide a sound basis for model code development and adoption; support and facilitate the development of Global Technical Regulations (GTRs) by 2010 for hydrogen vehicle systems under the United Nations Economic Commission for Europe, World Forum for Harmonization of Vehicle Regulations and Working Party on Pollution and Energy Program (ECE-WP29/GRPE); and to Support and facilitate the completion by 2012 of necessary codes and standards needed for the early commercialization and market entry of hydrogen energy technologies.

08 HYDROGEN↗

Effect of Pt promotion on Ni/Al{sub 2}O{sub 3} for the selective catalytic reduction of NO with hydrogen

Ni/Al{sub 2}O{sub 3} (10 wt.% Ni) and Ni-Pt/Al{sub 2}O{sub 3} (10 wt.% Ni, 0.5 wt.% Pt) were comparatively tested in the hydrogen selective catalytic reduction process (H{sub 2}-SCR), at reaction temperatures below 350°C. Catalytic activity tests consisted in temperature programmed reactions (TPRea) under plug flow conditions from 50 to 350°C, with a temperature rate of 5°C/min, using a feed stream with a reactant ratio NO:H{sub 2} = 1:1.3 and a GHSV of 4500 h{sup −1}. Promotion with Pt increases the catalytic performances of the Ni based catalyst, in respect to NO conversion, N{sub 2} selectivity and N{sub 2} yield. The reaction temperatures for NO conversion above 95% decrease significantly due to Pt addition, from 250°C for Ni/Al{sub 2}O{sub 3} to 125°C for Ni-Pt/Al{sub 2}O{sub 3}. Characterization of catalysts was performed by: X ray powder diffraction (XRD) for the estimation of Ni crystallite size, temperature programmed reduction (TPR) for the catalyst reducibility, temperature programmed desorption of hydrogen (H{sub 2}-TPD) for the investigation of active sites and metal dispersion on the support, N{sub 2} adsorption-desorption isotherms at −196°C for the determination of total specific surface area and pore size distribution, and H/D isotopic exchange on the catalyst surface.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗