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DOE OSTI2025

Renewable Hydrogen to Vehicle (RH2V) – Operation Verification and Risk Mitigation Studies: Original Agreement (Modification 0) (CRADA Final Report)

Toyota has announced plans for commercial fuel cell vehicle deployment in 2015. To fully realize the benefits of fuel cell vehicles (zero emission with no performance loss in terms of vehicle range and capability), hydrogen produced efficiently from renewable sources is necessary. Most of the hydrogen fueling stations today utilize hydrogen reformed from natural gas (produced onsite or delivered). This enables more stations to be deployed cost-effectively within a network. Producing and using cost-effective renewable hydrogen in fuel cell vehicles will enable realization of the full potential. A viable option of green hydrogen that reliably delivers on the full suite of benefits for Toyota fuel cell vehicle drivers is needed. NREL is in a unique position to analyze and optimize renewable hydrogen production scenarios using the Energy Systems Integration Facility (ESIF), a facility that is specifically designed to evaluate renewable energy integration technologies. As the U.S. Department of Energy's (DOE) primary national laboratory for renewable energy and energy efficiency research and development, NREL has extensive knowledge of photovoltaic systems as well as alternative renewable technologies for efficient and reliable production of green hydrogen.

08 HYDROGEN↗

DOE OSTI2025

Efficient, reliable and cost-effective reversible solid oxide cell technology for hydrogen and electricity production

This report summarizes the work performed by University of California San Diego (UCSD) – OxEon Energy LLC (OxEon) for the U. S. Department of Energy/National Energy Technology Laboratory (DOE/NETL) under Cooperative Agreement DE-FE0031940 entitled “Efficient, Reliable and Cost Effective Reversible Solid Oxide Cell Technology for Hydrogen and Electricity Production”. This reversible solid oxide cell (RSOC) technology has two main novel elements: (i) a compact and low-cost stack architecture that consists of multi-cell cell modules in electrical parallel and series connections and (ii) high performance and fuel-flexible reversible cells with electrodes or all components made by sputtering deposition process for efficient operation in both fuel cell (power generation) and electrolysis (hydrogen production) modes.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2023

Estimating the Value of Nuclear Integrated Hydrogen Production and the Dependency of Electricity and Hydrogen Markets on Natural Gas

Producing low carbon Hydrogen at a competitive price is one of the challenges to hydrogen being part of the solution to reach net-zero emission targets set by the U.S. DOE by 2050. With projected near-term improvements in technology, hydrogen production via solid oxide electrolysis cell (SOEC) / high-temperature steam electrolysis (HTSE) integrated with existing light water reactor (LWR) Nuclear Power Plants (NPP-HTSE) can produce carbon-free hydrogen competitively. In the near term, a 10-year production tax credit (PTC) found in the Inflation Reduction Act (IRA) has been passed, which will catalyze the development and improvement of hydrogen production technology to be competitive. The “1-1-1” target set by the U.S. DOE is to reduce the cost of carbon-free hydrogen by 80% to $1 per kilogram in 1 decade. Several models are available to analyze the profitability, opportunity, and technical capability of NPP-HTSE systems. In order of complexity from most complex to least complex some of these models include: RAVEN/HERON, process models using Aspen HYSYS and capital expense estimations using Aspen Process Economic Analyzer (APEA) and levelized cost of hydrogen (LCOH) calculation using the H2A model (Hydrogen Analysis Model), and custom spread sheets built by the interested party. Though some of the more advanced existing models provide detailed analysis to complex grid integrated problems, they also can take considerable time to setup and run. These advanced models are well suited to complex grid integrated analysis and the consideration of flexibility and variability of regulated and de-regulated electricity price and advanced estimation of capital and operating expenses and heat and material balances.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Economically Viable Intermediate to Long Duration Hydrogen Energy Storage Solutions for Fossil Fueled Assets

This report was prepared as an account of work sponsored by the Office of Fossil Energy and Carbon Management of U.S. Department of Energy under Funding Opportunity Announcement Number DE-FOA-0002332 “Energy Storage for Fossil Power Generation”. The work aimed to explore and advance an innovative hydrogen energy storage system – the synergistically integrated hydrogen energy storage system (SIHES) – that has the following characteristics: • Compatible with existing or new coal and gas fuel electricity generation units, • best suited for intermediate to long duration energy storage, from 12 hours to weeks even months, and • capable of storing energy at the utility scale – hundreds of MWh to GWh energy storage with power output level in tens to hundreds of MW. Preliminary front-end engineering design (Pre-FEED) studies was carried out to develop and refine a site-specific SIHES as peaking power generation units (so named as HyPeaker) as the first market entry point, to demonstrate both the technical feasibility and the economic viability to integrate the HyPeaker “within the fence” of a fossil power plant. This specific site was TVA’s Johnsonville Combustion Turbine Plant. The HyPeaker was designed and engineered to integrate with a 60MW aeroderivative gas turbine unit already available at TVA’s Johnsonville site. This site-specific HyPeaker consists of an alkaline electrolyzer to produce hydrogen from CO 2 free electricity sources, an innovative low-cost high-pressure hydrogen storage system (Big-Ton) and the aero gas turbine to generate electricity using blend of hydrogen and natural gas. A holistic system level technoeconomic analysis tool specific to HyPeaker was developed to optimize the engineering design of the Johnsonville site-specific HyPeaker for cost and performance. The optimal design and specification of the Johnsonville site-specific HyPeaker are the following: • Alkaline electrolyzer: 3MW • Big-Ton storage vessel: 11,000kg H 2 at 3000psi. • 4-stage diaphragm hydrogen compressor: 55kg-H 2 /hr from 150psi to 3000psi. The HyPeaker is designed to provide sufficient hydrogen for 90% continuous operation of the HyPeaker. All major components have design life of 30 years. The capex of HyPeaker is estimated at $\$$7.1M. This included $\$$1.5M for the electrolyzer, $\$$5.6M for the storage vessel and compressor. The cost of aero gas turbine was included as it is already available at the site. Key findings are: • HyPeaker can be designed, manufactured, installed and integrated with the fossil power plants, with sub-systems and components commercially available on the market today, even when it is scaled up to an order of magnitude larger than the one at the Johnsonville site. HyPeaker is a technologically viable solution to cover a wide range of energy storage duration needs, from daily peaking operation to seasonal shifting for fossil fueled assets. • The cost advantage of SCCV based Big-Ton H 2 storage vessel made it possible to “oversize” the H 2 storage subsystem to achieve overall system level cost optimization. The benefits are two-fold. First, it allows to significantly reduce the capacity and cost of electrolyzer by spreading H 2 production over a much longer period of time when the fuel cost for electricity production is low. Second, it allows to balance the hydrogen production and usage shift over weeks to months to meet the peak demands. As such, the capital cost of HyPeaker system using the Big-Ton was less than half of the cost of a system with today’s steel tube based H 2 storage system. The HyPeaker has even better cost advantage Li-ion battery based energy storage system. The estimated capital cost of Li-Ion battery system would be at $\$$38M, under the same projected 20-year electricity generation profile of the Johnsonville site. This is over 5 times more expensive than the HyPeaker system. • Since industry scale energy storage systems do not have 100% energy conversion and storage efficiency, energy storage systems using fossil fuel generated electricity would increase the CO 2 emission. This is particularly the case for HyPeaker due to its low round trip efficiency. Therefore, a more sensible solution would be to the excessive or curtailed electricity from CO 2 emission free sources such as solar farms, wind farms or nuclear power plants, to produce hydrogen, and integrate them with the HyPeaker. Electricity from TVA’s nuclear power plants was used for the Johnsonville HyPeaker. • The economic viability of HyPeaker is expected to be further improved when global supply chains are taken into consideration. For the same Johnsonville site specific HyPeaker, the capex would be reduced to ~$\$$3.6M from ~$\$$7.1M, and the added LCOE is reduced to ~$\$$85/MWh. With the bipartisan Infrastructure Investment and Jobs Act, the cost of domestically produced HyPeaker sub-systems would be at the level of today’s global suppliers. Since the peaking units generally operate at peak usage period, thereby demanding higher price, the projected $\$$85/MWh LCOE would be within the realm of financial viability for utility operators.

08 HYDROGEN↗

DOE OSTI2021

Low-Cost, Dispatch-Constrained Electricity for H2 Production

The presentation, part of the Solar-Derived Hydrogen: Understanding and Implementing the Cost Reduction Drivers Panel at the North America Smart Energy Week 2019, discusses considerations for using low-cost, dispatch-constrained electricity for hydrogen production.

39 EE - Hydrogen and Fuel Cell Technologies (EE-3F↗

DOE OSTI2025

Learning from Arctic Microgrids: Cost and Resiliency Projections for Renewable Energy Expansion with Hydrogen and Battery Storage

Electricity in rural Alaska is provided by more than 200 standalone microgrid systems powered predominantly by diesel generators. Incorporating renewable energy generation and storage to these systems can reduce their reliance on costly imported fuel and improve sustainability; however, uncertainty remains about optimal grid architectures to minimize cost, including how and when to incorporate long-duration energy storage. This study implements a novel, multi-pronged approach to assess the techno-economic feasibility of future energy pathways in the community of Kotzebue, which has already successfully deployed solar photovoltaics, wind turbines, and battery storage systems. Using real community load, resource, and generation data, we develop a series of comparison models using the HOMER Pro software tool to evaluate microgrid architectures to meet over 90% of the annual community electricity demand with renewable generation, considering both battery and hydrogen energy storage. We find that near-term planned capacity expansions in the community could enable over 50% renewable generation and reduce the total cost of energy. Additional build-outs to reach 75% renewable generation are shown to be competitive with current costs, but further capacity expansion is not currently economical. We additionally include a cost sensitivity analysis and a storage capacity sizing assessment that suggest hydrogen storage may be economically viable if battery costs increase, but large-scale seasonal storage via hydrogen is currently unlikely to be cost-effective nor practical for the region considered. While these findings are based on data and community priorities in Kotzebue, we expect this approach to be relevant to many communities in the Arctic and Sub-Arctic regions working to improve energy reliability, sustainability, and security.

25 ENERGY STORAGE↗

NASA NTRS1993

Production of O2 on the Moon: A lab-top demonstration of ilmenite reduction with hydrogen

Estimates of the costs of transporting materials from Earth to the Moon are around $25,000 per pound. Therefore, it is imperative that we learn to utilize the resources on the Moon to partially offset these 'astronomical' expenses. The production of oxygen on the Moon utilizing indigenous materials is crucial to the establishment and development of an autonomous lunar colony. Besides obvious biologic needs, this lunar liquid oxygen (LLOX) could result in tremendous cost savings on fuel for effective transportation systems, particularly with its export to low-Earth orbit. Over 20 different process concepts were proposed and evaluated for the production of oxygen from lunar materials. Simplicity, low energy, easily attainable feedstock, and low resupply mass are the keywords for the process(es) which will ultimately be selected for the initial production of oxygen on the Moon. One of these schemes, which has received considerable study to date, is the hydrogen reduction of ilmenite. In fact, Carbotek, Inc. (Houston, TX) patented an ilmenite, hydrogen-reduction technique involving a three-stage, fluidized-bed process for the production of LLOX. A lab-top demonstration unit of the basic concepts of this oxygen generation process that was constructed by our group at the University of Tennessee is explained. It utilizes many of the principles which must be addressed in designing an effective production plant for operation on the Moon.

Taylor, Lawrence A.↗

DOE OSTI2023

Mixed Oxygenate Conversion to Sustainable Aviation Fuel via Ketones Intermediate

This report describes our effort in developing Pd based bimetallic catalysts during Tandem ketone condensation-hydrogenation reaction. We have synthesized a series of bimetallic catalysts containing equimolar amount of Pd with various other 3d, 4d and 5d transition and coinage metals. The activity of theses bimetallic catalysts towards C=C and C=O hydrogenation was evaluated using mesityl oxide and 2-heptanone as model compounds. All these catalysts show much higher activity towards C=C hydrogenation compared to C=O hydrogenation at a given temperature and at different H2 pressure, indicated the higher intrinsic activity of Pd based bimetallic catalysts towards C=C hydrogenation. Alloy catalysts with Pd and other 4d and 5d metals such as PdRu, PdRh, PdPt and PdIr shows higher activity towards both C=C and C=O hydrogenation compared to baseline Pd catalyst as well as alloy catalysts containing Pd and 3d transition metals. Among the different Pd-3d metal alloy catalysts, the activity of the bimetallic catalysts depends on alloying transition metals. Although, PdRu, PdRh, PdPt and PdIr catalysts shows very high activity towards C=O hydrogenation of 2-heptanone, the same catalysts didn’t show any C=O hydrogenation when ?,?-unsaturated carbonyl compound such as mesityl oxide was used as the model substrate. Based on these results, it is evident that Pd based bimetallic catalysts are very selective to the C=C hydrogenation and their activity could be tuned by the judicious choice of the alloying elements. Although alloying with Ru, Rh and Pt shows significant rate enhancement in case of C=C hydrogenation reaction, higher cost of those metals prevents their usage in industry as it significantly increases the cost of the catalyst. Considering all the factors, we have identified PdZn as one of promising alternative of Pd catalyst as it shows comparable activity towards C=C hydrogenation and reduces the activity for C=O hydrogenation. Based on the electrochemical CO stripping, we unambiguously established the weaker bonding CO on the PdZn surface compared to pristine Pd and highlight the benefits of its usage due to higher CO tolerance.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2024

Role of Hydrogen as Fuel in Decarbonizing US Clinker Manufacturing for Cement Production: Costs and CO2 Emissions Reduction Potentials

As a low-carbon fuel, feedstock, and energy source, hydrogen is expected to play a vital role in the decarbonization of high-temperature process heat during the pyroprocessing steps of clinker production in cement manufacturing. However, to accurately assess its potential for reducing CO2 emissions and the associated costs in clinker production applications, a techno-economic analysis and a study of facility-level CO2 emissions are necessary. Assuming that up to 20% hydrogen can be blended in clinker fuel mix without significant changes in equipment configuration, this study evaluates the potential reduction in CO2 emissions (scopes 1 and 2) and cost implications when replacing current carbon-intensive fuels with hydrogen. Using the direct energy substitution method, we developed an Excel-based model of clinker production, considering different hydrogenblend scenarios. Hydrogen from steam methane reformer (gray) and renewable-based electrolysis (green) are considered as sources of hydrogen fuel for blend scenarios of 5%20%. Metrics such as the cost of cement production, facility-level CO2 emissions, and cost of CO2 avoided were computed. Results show that for hydrogen blends (gray or green) between 5% and 20%, the cost of cement increases by 0.6% to 16%, with only a 0.4% to 6% reduction in CO2 emissions. When the cost of CO2 avoided was computed, the extra cost required to reduce CO2 emissions is $229 to $358/ metric ton CO2. In summary, although green hydrogen shows promise as a low-carbon fuel, its adoption for decarbonizing clinker production is currently impeded by costs.

Okeke, Ikenna J.↗

DOE OSTI2023

Review AMR 2023 Presentation

Provide a an overall outline of the project for durable low-cost pressure vessels for bulk hydrogen storage. Includes project objectives, benefits, task, results and concluding remarks.

25 ENERGY STORAGE↗

DOE OSTI2022

HydroGEN Overview: A Consortium on Advanced Water Splitting Materials

advanced water splitting technologies↗

DOE OSTI2023

HydroGEN and H2NEW Data Hub

HydroGEN is a multi-lab consortium focused on early-stage R&D in H2 production, supported by the U.S. Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy (EERE), Hydrogen and Fuel Cell Technologies Office (HFTO). The consortium advances research and development (R&D) of innovative materials for advanced water splitting (AWS) technologies to enable clean, sustainable and low-cost ($1/kg H2) hydrogen production and fosters cross-cutting innovation using theory-guided applied materials R&D to advance all emerging water-splitting pathways for hydrogen production. Hydrogen from Next-generation Electrolyzers of Water (H2NEW) is a consortium of nine U.S. Department of Energy (DOE) national laboratories focused on making large-scale electrolyzers, which produce hydrogen from electricity and water, more durable, efficient, and affordable. The presentation introduces the HydroGEN data hub to the H2NEW consortium and encourages H2NEW members to use it to store and share data with team members and eventually the public. The two consortia share this data hub.

advanced water splitting technologies↗

DOE OSTI2023

HydroGEN Overview: A Consortium on Advanced Water Splitting Materials

HydroGEN is a multi-lab consortium focused on early-stage R&D in H2 production, supported by the U.S. Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy (EERE), Hydrogen and Fuel Cell Technologies Office (HFTO). The consortium advances research and development (R&D) of innovative materials for advanced water splitting (AWS) technologies to enable clean, sustainable and low-cost ($1/kg H2) hydrogen production and fosters cross-cutting innovation using theory-guided applied materials R&D to advance all emerging water-splitting pathways for hydrogen production. HydroGEN is focused on low technology readiness level AWS technologies, including low- (alkaline exchanged membrane electrolysis) and high-temperature electrolysis (proton-conducting solid oxide electrolysis), photoelectrochecmical (PEC) and solar thermochemical (STCH) water splitting. This presentation will provide an overview of the HydroGEN EMN and technical highlights of a few lab-led and FOA-awarded R&D projects. HydroGEN continues to grow its community of industry, university, and national laboratories, forming a national innovation ecosystem focused on renewable hydrogen production.

advanced water splitting materials↗

DOE OSTI2023

Foundational Low-Carbon Hydrogen Research

HydroGEN is a multi-lab consortium focused on early-stage R&D in H2 production, supported by the U.S. Department of Energy (DOE), Office of Energy Efficiency and Renewable Energy (EERE), Hydrogen and Fuel Cell Technologies Office (HFTO). The consortium advances research and development (R&D) of innovative materials for advanced water splitting (AWS) technologies to enable clean, sustainable and low-cost ($1/kg H2) hydrogen production and fosters cross-cutting innovation using theory-guided applied materials R&D to advance all emerging water-splitting pathways for hydrogen production. HydroGEN is focused on low technology readiness level AWS technologies, including low- (alkaline exchanged membrane electrolysis) and high-temperature electrolysis (proton-conducting solid oxide electrolysis), photoelectrochecmical (PEC) and solar thermochemical (STCH) water splitting. This presentation will provide an overview of the HydroGEN EMN, its relationship to the H2NEW consortium, technical highlights of a few lab-led R&D projects, and the community appproach to benchmarking and protocol development for advanced water splitting technologies. Low-carbon hydrogen plays a vital role in the carbon dioxide utilization and decarbonization of several chemical and fuel industries.

advanced water splitting materials AEM↗

NASA NTRS1978

Reduction of liquid hydrogen boiloff: Optimal reliquefaction system design and cost study

The refrigeration cycles investigated are referred to as Joule-Thomson cycles because they depend on the J-T effect to produce the low temperatures. Two basic competitive refrigeration cycles were evaluated. The first vents a portion of cold H2 gas to achieve the required precooling; the second uses LN2 for precooling. Both open loop and closed loop cycles were evaluated as well as combinations of venting to supplement the LN2 precooling. All cycles use a H2 compressor to achieve the desired high pressure (1325 psig). The heat compression was removed by cooling water. The high pressure H2 gas was cooled in counter flow heat exchangers by flowing cold H2 to the compressor. Further cooling was achieved for cycles using LN2 by passing H2 vapors through a LN2 heat exchanger. Finally, the high pressure H2 gas was expanded through a J-T valve where a portion of H2 was liquefied. The low pressure H2 gas flow back through the heat exchangers to the compressor is that portion not liquefied and makes up hydrogen gas from the dewar.

Source record↗

NASA NTRS1997

NASA-UVA Light Aerospace Alloy and Structures Technology Program (LA2ST)

This report documents the progress achieved over the past 6 to 12 months on four graduate student projects conducted within the NASA-UVA Light Aerospace Alloy and Structures Technology Program. These studies were aimed specifically at light metallic alloy issues relevant to the High Speed Civil Transport. Research on Hydrogen-Enhanced Fracture of High-Strength Titanium Alloy Sheet refined successfully the high resolution R-curve method necessary to characterize initiation and growth fracture toughnesses. For solution treated and aged Low Cost Beta without hydrogen precharging, fracture is by ductile transgranular processes at 25 C, but standardized initiation toughnesses are somewhat low and crack extension is resolved at still lower K-levels. This fracture resistance is degraded substantially, by between 700 and 1000 wppm of dissolved hydrogen, and a fracture mode change is affected. The surface oxide on P-titanium alloys hinders hydrogen uptake and complicates the electrochemical introduction of low hydrogen concentrations that are critical to applications of these alloys. Ti-15-3 sheet was obtained for study during the next reporting period. Research on Mechanisms of deformation and Fracture in High-Strength Titanium Alloys is examining the microstructure and fatigue resistance of very thin sheet. Aging experiments on 0. 14 mm thick (0.0055 inch) foil show microstructural agility that may be used to enhance fatigue performance. Fatigue testing of Ti-15-3 sheet has begun. The effects of various thermo-mechanical processing regimens on mechanical properties will be examined and deformation modes identified. Research on the Effect of Texture and Precipitates on Mechanical Property Anisotropy of Al-Cu-Mg-X and Al-Cu alloys demonstrated that models predict a minor influence of stress-induced alignment of Phi, caused by the application of a tensile stress during aging, on the yield stress anisotropy of both modified AA2519 and a model Al-Cu binary alloy. This project is no longer included in the NASA-UVA LAST program. Research on the Creep Behavior and Microstructural stability of Al-Cu-Mg-Ag and Al-Cu-Li-Mg-Ag showed that the creep resistance of three candidate aluminum alloys (C415, C416 and ML377) was much superior compared to that of the current Concorde alloy, AA2618. Creep induced change in precipitates at grain boundaries was observed in the alloy which exhibits the highest creep strain of the three examined. The other two alloys developed no detectable microstructural changes at grain boundaries under the creep conditions tested.

Gangloff, Richard P.↗

NASA NTRS2002

Hydrogen generation by electrolysis of aqueous organic solutions

A device for electrolysis of an aqueous solution of an organic fuel. The electrolyte is a solid-state polymer membrane with anode and cathode catalysts on both surfaces for electro-oxidization and electro-reduction. A low-cost and portable hydrogen generator can be made based on the device with organic fuels such as methanol.

Narayanan, Sekharipuram R.↗

NASA NTRS2002

Hydrogen generation by electrolysis of aqueous organic solutions

Narayanan, Sekharipuram R.↗