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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Hydrogen Production Cost with Anion Exchange Membrane Electrolysis

Rigorous stakeholder-vetted techno-economic analysis was performed to assess the cost of hydrogen (H 2 ) produced using state-of-the-art Anion Exchange Membrane (AEM) electrolysis. Projected high-volume, untaxed and unsubsidized levelized cost of hydrogen (LCOH)1 range from 2020 $\$$1.78 to $\$$3.68/kg H 2 depending on technology year, process design, and electrolyzer project scale, assuming an electricity price of $\$$0.03/kWh and a capacity factor of 97%. The total installed capital cost for an AEM electrolysis plant was estimated from bottom-up stack and process plant cost models. The stack cost model accounts for manufacturing equipment, equipment maintenance, material, tooling, cycle time, yield, labor, utilities and general overhead. The process plant cost model accounts for purchased equipment, installation costs, site preparation, and general overhead costs. For this study, the AEM electrolysis plant is assumed to be a stick-built, greenfield project developed by an engineering, procurement, and construction (EPC) firm with electrolysis stacks purchased directly from an electrolysis stack manufacturer. The price of the electrolysis stacks is based on a bottom-up cost assessment with business markup for the electrolysis company fabricator. Methods from the Hydrogen Analysis (H2A) production model, a peer-reviewed national laboratory-developed discounted cash flow (DCF) model, were used to calculate the production LCOH in 2020 $\$$/kg H 2 . The baseline electricity price case ($\$$0.03/kWh) corresponds to average wholesale electricity prices currently possible in U.S. markets with plentiful wind. Similar low-cost electricity pricing is possible from solar Power Purchase Agreements (PPA) although these prices are typically limited by renewable energy capacity factors.

08 HYDROGEN↗
DOE OSTI2024

Heat Transfer Through a Passive Fire Protective Board from an Impinging Hydrogen Flame

This report documents analysis to determine whether a hydrogen jet flame impinging on a tunnel ceiling structure could result in permanent damage to the Callahan tunnel in Boston, Massachusetts. This tunnel ceiling structure consists of a passive fire protective board supported by stainless steel hangers anchored to the tunnel ceiling with epoxy. Three types of fire protective boards were considered to determine whether heat from the flame could reach the stainless-steel hangers and the epoxy and cause the ceiling structure to collapse. Heat transfer analyses performed showed that the temperature remains constant where the steel hangers are attached to the passive fire protective board. According to these results, the passive fire protective board should provide adequate protection to the tunnel structure in this release scenario. Tunnel structures with similar suspended fire-resistant liner board materials should protect the integrity of the structure against the extremely low probability of an impinging hydrogen jet flame.

08 HYDROGEN↗
DOE OSTI2025

Outgassing measurements of bare and magnetite-coated low-carbon steel vacuum chambers

The outgassing properties of bare and magnetite-coated AISI 1020 low-carbon steel vacuum chambers were evaluated to establish material selection criteria for extreme high vacuum applications, namely, to explore the possibility of using these materials to build next-generation spin-polarized photoelectron guns. Water outgassing measurements using the throughput method revealed that the magnetite-coated chamber exhibited five times lower outgassing at room temperature prior to baking, but this advantage disappears after 80 °C baking. Hydrogen outgassing measurements demonstrated significant differences after intensive heat treatment: the bare low-carbon steel vacuum chamber achieved a specific outgassing rate of 9.6 × 10 −16 Torr L s −1 cm −2 after 400 °C/50 h bake plus additional heat treatment at lower temperatures, 25 times lower than the magnetite-coated low-carbon steel chamber. Residual gas analysis showed >99% hydrogen composition after heat treatment for both materials, with carbon species below detection limits for bare low-carbon steel versus 0.8% for magnetite-coated surfaces. These measurements indicate that properly conditioned bare low-carbon steel can achieve the <10 −12 Torr pressures required for next-generation spin-polarized photogun applications. In conclusion, the paper includes various analysis techniques intended to explain observed behaviors: isotherm analysis of pump-down plots, Arrhenius analysis of hydrogen outgassing rate data, and residual gas composition tracking.

Adsorption isotherm↗
DOE OSTI2023

Scale-up and techno-economic analysis of microbial electrolysis cells for hydrogen production from wastewater

Microbial electrolysis cells (MECs) have demonstrated high-rate H 2 production while concurrently treating wastewater, but the transition in scale from laboratory research to systems that can be practically applied has encountered challenges. It has been more than a decade since the first pilot-scale MEC was reported, and in recent years, many attempts have been made to overcome the barriers and move the technology to the market. This study provided a detailed analysis of MEC scale-up efforts and summarized the key factors that should be considered to further develop the technology. We compared the major scale-up configurations and systematically evaluated their performance from both technical and economic perspectives. We characterized how system scale-up impacts the key performance metrics such as volumetric current density and H 2 production rate, and we proposed methods to evaluate and optimize system design and fabrication. In addition, preliminary techno-economic analysis indicates that MECs can be profitable in many different market scenarios with or without subsidies. Here, we also provide perspectives on future development needed to transition MEC technology to the marketplace.

42 ENGINEERING↗
DOE OSTI2021

Hydrogen bond network and bond valence analysis on uranyl sulfate compounds with organic-based interstitial cations

Seven new uranyl sulfate compounds with organic charge-balancing cations have been synthesized and structurally characterized. The structural unit topologies of the two chains and five sheets have been previously reported in uranyl sulfate crystal chemistry, although they were synthesized using different organic molecules. With the inclusion of six of these structures to the 48 previously published uranyl sulfate compounds, a total of 54 known uranyl sulfate compounds with organic charge-balancing cations were compiled and analyzed. A graphical approach was used to compare the structural unit topologies, and a bond valence approach was used to quantify the hydrogen bond networks that exist between the interstitial cationic and solvent species to the uranyl sulfate anionic structural units. Finally, this analysis helped elucidate which oxygen atoms in the structural unit receive hydrogen bonds and how the organic cations stabilize the overall crystal structures in this subclass of U(VI) materials.

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

Technoeconomic and Life Cycle Analysis of Synthetic Methanol Production from Hydrogen and Industrial Byproduct CO 2

Here CO 2 capture and utilization provides an alternative pathway for low-carbon hydrocarbon production. Given the ample supply of high-purity CO 2 emitted from ethanol and ammonia plants, this study conducted technoeconomic analysis and environmental life cycle analysis of several systems: integrated methanol-ethanol coproduction, integrated methanol-ammonia coproduction, and stand-alone methanol production systems, using CO 2 feedstock from ethanol plants, ammonia plants, and general market CO 2 supply. The cradle-to-grave greenhouse gas emissions of methanol produced from the stand-alone methanol, integrated methanol-ethanol, and integrated methanol-ammonia systems are 13.6, 37.9, and 84.6 g CO 2 -equiv/MJ, respectively, compared to 91.5 g CO 2 -equiv/MJ of conventional methanol produced from natural gas. The minimum fuel selling price (MFSP) of methanol ($\$0.61-0.64$/kg) is 61-68% higher than the average market methanol price of $\$0.38$/kg, when using a Department of Energy target renewable hydrogen production price of $\$2.0$/kg. The methanol price increases to $\$1.24-1.28$/kg when the hydrogen price is $\$5.0$/kg. Without CO 2 abatement credits, the H 2 price needs to be within $\$0.77-0.95$/kg for the MFSP of methanol to equal the average methanol market price. With a CO 2 credit of $\$35$/MT according to tax credit per metric ton of CO 2 captured and used, the methanol price is reduced to $\$0.56-0.59$/kg.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1990

Atomic hydrogen as a launch vehicle propellant

An analysis of several atomic hydrogen launch vehicles was conducted. A discussion of the facilities and the technologies that would be needed for these vehicles is also presented. The Gross Liftoff Weights (GLOW) for two systems were estimated; their specific impulses (I sub sp) were 750 and 1500 lb(sub f)/s/lb(sub m). The atomic hydrogen launch vehicles were also compared to the currently planned Advanced Launch System design concepts. Very significant GLOW reductions of 52 to 58 percent are possible over the Advanced Launch System designs. Applying atomic hydrogen propellants to upper stages was also considered. Very high I(sub sp) (greater than 750 lb(sub f)/s/lb(sub m)) is needed to enable a mass savings over advanced oxygen/hydrogen propulsion. Associated with the potential benefits of high I(sub sp) atomic hydrogen are several challenging problems. Very high magnetic fields are required to maintain the atomic hydrogen in a solid hydrogen matrix. The magnetic field strength was estimated to be 30 kilogauss (3 Tesla). Also the storage temperature of the propellant is 4 K. This very low temperature will require a large refrigeration facility for the launch vehicle. The design considerations for a very high recombination rate for the propellant are also discussed. A recombination rate of 210 cm/s is predicted for atomic hydrogen. This high recombination rate can produce very high acceleration for the launch vehicle. Unique insulation or segmentation to inhibit the propellant may be needed to reduce its recombination rate.

Palaszewski, Bryan A.↗
NASA NTRS1990

Atomic hydrogen as a launch vehicle propellant

An analysis of several atomic hydrogen launch vehicles was conducted. A discussion of the facilities and the technologies that would be needed for these vehicles is also presented. The Gross Liftoff Weights (GLOW) for two systems were estimated; their specific impulses (I sub sp) were 750 and 1500 lb (sub f)/s/lb(sub m). The atomic hydrogen launch vehicles were also compared to the currently planned Advanced Launch System design concepts. Very significant GLOW reductions of 52 to 58 percent are possible over the Advanced Launch System designs. Applying atomic hydrogen propellants to upper stages was also considered. Very high I(sub sp) (greater than 750 1b(sub f)/s/lb(sub m) is needed to enable a mass savings over advanced oxygen/hydrogen propulsion. Associated with the potential benefits of high I(sub sp) atomic hydrogen are several challenging problems. Very high magnetic fields are required to maintain the atomic hydrogen in a solid kilogauss (3 Tesla). Also the storage temperature of the propellant is 4 K. This very low temperature will require a large refrigeration facility for the launch vehicle. The design considerations for a very high recombination rate for the propellant are also discussed. A recombination rate of 210 cm/s is predicted for atomic hydrogen. This high recombination rate can produce very high acceleration for the launch vehicle. Unique insulation or segmentation to inhibit the propellant may be needed to reduce its recombination rate.

Palaszewski, Bryan A.↗
DOE OSTI2021

A Multiscale Modeling Approach to Cryocompressed Hydrogen Storage Pressure Vessels – Part II: Constitutive Modeling and Finite Element Analysis

Subjected to thermomechanical cycling, composite cryogenic hydrogen (H2) storage pressure vessels experience high stresses in the carbon fiber (CF)/epoxy overwrap which can lead to vessel failure due to a combination of degradation mechanisms such as matrix cracking, fiber/matrix debonding, delamination, and fiber rupture. The present paper is the second part of a set of two articles on this subject that addresses analysis and design of these pressure vessels. Predictive finite element (FE) modeling capabilities have been used to support a material acceptance process that aims at providing guidance to evaluate specialty resins, vessel liner options, and CF composites through thermomechanical testing. We have applied a multiscale modeling approach recently developed (B.N. Nguyen et al., International Journal of Hydrogen Energy, 2019, https://doi.org/10.1016/j.ijhydene.2019.09.200) to perform three-dimensional (3D) FE analysis and design of a cryo-compressed H2 storage pressure vessel for its operation in a large temperature range from room to cryogenic temperatures. The developed approach termed the micro-meso-macro approach determines the laminar stresses in different layers of the vessel in addition to constituent (i.e., fiber and matrix) stresses that are important to the design of the composite overwrap for its layup and material combination to reduce the risk of vessel failure.

Nguyen, Ba Nghiep↗
DOE OSTI2023

Experimental Comparison of Hydrogen Refueling with Directly Pressurized vs. Cascade Method

This paper presents a comparative analysis of two hydrogen station configurations during the refueling process: the conventional “directly pressurized refueling process” and the innovative “cascade refueling process.” The objective of the cascade process is to refuel vehicles without the need for booster compressors. The experiments were conducted at the Hydrogen Research and Fueling Facility located at California State University, Los Angeles. In the cascade refueling process, the facility buffer tanks were utilized as high-pressure storage, enabling the refueling operation. Three different scenarios were tested: one involving the cascade refueling process and two involving compressor-driven refueling processes. On average, each refueling event delivered 1.6 kg of hydrogen. Although the cascade refueling process using the high-pressure buffer tanks did not achieve the pressure target, it resulted in a notable improvement in the nozzle outlet temperature trend, reducing it by approximately 8 °C. Moreover, the overall hydrogen chiller load for the two directly pressurized refuelings was 66 Wh/kg and 62 Wh/kg, respectively, whereas the cascading process only required 55 Wh/kg. This represents a 20% and 12% reduction in energy consumption compared to the scenarios involving booster compressors during fueling. The observed refueling range of 150–350 bar showed that the cascade process consistently required 12–20% less energy for hydrogen chilling. Additionally, the nozzle outlet temperature demonstrated an approximate 8 °C improvement within this pressure range. These findings indicate that further improvements can be expected in the high-pressure region, specifically above 350 bar. This research suggests the potential for significant improvements in the high-pressure range, emphasizing the viability of the cascade refueling process as a promising alternative to the direct compression approach.

08 HYDROGEN↗
DOE OSTI2024

Hybrid power plant design for low-carbon hydrogen in the United States

In this study, we provide a nationwide techno-economic analysis of clean hydrogen production powered by a hybrid renewable energy plant for over 50,000 locations in the United States. We leverage the open-source Hybrid Optimization Performance Platform (HOPP) tool to simulate the hourly performance of an off-grid wind-solar plant integrated with a 1-GW polymer exchange membrane electrolyzer system. The levelized cost of hydrogen is calculated for varying technology costs, and tax credits to explore cost sensitivities independent of plant design, performance, and site selection. Our findings suggest that strategies for cost reduction include selecting sites with abundant wind resources, complementary wind and solar resources, and optimizing the sizing of wind and solar assets to maximize the hybrid plant capacity factor. These strategies are linked to increased hydrogen production and reduced electrolyzer stack replacements, thereby lowering the overall cost of hydrogen.

08 HYDROGEN↗
DOE OSTI2022

Combining PCA and nonlinear fitting of peak models to re-evaluate C 1s XPS spectrum of cellulose

Cellulose is an example of a material that responds to XPS by the creation of new chemistry not present in the as-received sample. While improvements in instrumentation may be seen in general as beneficial to surface science, recent studies have shown that the consequences for some materials are detrimental. Here, in this work, these problems are illustrated through an analysis of cellulose spectra obtained during a degradation study. C 1s spectra are decomposed into two well-formed component curves that are open to chemical interpretation. In particular, a component-curve representative of pure cellulose is obtained as well as a second component curve that implies cellulose is degraded through the creation of carbon chemistry involving C—O, C$=$O and O—C$=$O. Since cellulose is a crystalline material, formed through the alignment of molecules under the influence of hydrogen bonds, the analysis and findings presented in this paper are relevant to any material analyzed by XPS whose properties are dependent on hydrogen bonds. The analysis techniques are based on an informed vectorial approach, which extracts directly from data spectral shapes that are used to monitor sample degradation via linear least squares optimization. Related mathematics of Principal Component Analysis and linear analysis are presented.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Techno-Economic Analysis of Repurposing Natural Gas Transmission Pipeline Networks to Accommodate Hydrogen Blends

Blending hydrogen into natural gas infrastructure could supplement natural gas supply and increase resilience for applications such as ammonia production, peaking and load-following power plants, and heating. The United States has an extensive network of natural gas pipelines, but the feasibility of employing this infrastructure to transport hydrogen is unclear. We analyze the costs associated with repurposing three distinct natural gas transmission pipelines in different locations within the United States to carry blends of hydrogen up to 100% via three different pipeline network modification methods and compare against the cost of building a new dedicated hydrogen pipeline. We conduct a sensitivity analysis on the hoop stress limit of the existing pipe, techno-economic parameters, emissions, and relative capacity. The results show that the capital costs required to upgrade a pipeline can vary from tens of millions to billions of dollars depending on the length and capacity of the existing pipeline section, whether the existing pipeline already operates at or below its maximum allowable operating pressure, whether future demand is expected to increase or decrease, the network modification method selected, and pipe material costs. The delivered cost of energy to end users is impacted less by the levelized cost of transporting hydrogen blends than by the cost of the natural gas and hydrogen fuels being transported. The emissions impact of blending hydrogen into natural gas transmission networks scales proportionally with the amount of energy displaced with low-emission hydrogen (such as from natural gas with carbon capture and sequestration or electrolysis powered by nuclear, renewable, or geothermal electricity), therefore low blend ratios (e.g., < 20% vol. hydrogen) will result in low emissions impacts. Factors such as permitting and right-of-way costs, the proximity of the pipeline to hydrogen demand and production, and the compatibility of and/or retrofitting costs of end-use gas-fueled technologies will likely be greater drivers in determining whether converting a particular natural gas pipeline to carry hydrogen makes economic sense.

08 HYDROGEN↗
NASA NTRS1978

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

A preliminary design and economic analysis of candidate hydrogen reliquefaction systems was performed. All candidate systems are of the same general type; differences and size, compressor arrangement, and amount of hydrogen venting. The potential application of the hydrogen reliquefaction will be to reduce the boil-off from the 850,000 gallon storage dewars at LC-39.

Source record↗
NASA NTRS1976

Hydrogen-fueled scramjets: Potential for detailed combustor analysis

Combustion research related to hypersonic scramjet (supersonic combustion ramjet) propulsion is discussed from the analytical point of view. Because the fuel is gaseous hydrogen, mixing is single phase and the chemical kinetics are well known; therefore, the potential for analysis is good relative to hydro-carbon fueled engines. Recent progress in applying two and three dimensional analytical techniques to mixing and reacting flows indicates cause for optimism, and identifies several areas for continuing effort.

Beach, H. L., Jr.↗
DOE OSTI2023

Structure, Dynamics, and Hydrogen Transport in Amorphous Polymers: An Analysis of the Interplay between Free Volume Element Distribution and Local Segmental Dynamics from Molecular Dynamics Simulations

Polymers are attractive membrane materials owing to their mechanical robustness and relatively inexpensive fabrication. An important indicator of membrane performance are free volume elements (FVE): microporous void spaces created by the inefficient packing of bulky groups along the polymer chain. FVEs tend to degrade over time, as polymer chains reorganize irreversibly. While it is widely accepted that polymer flexibility has an impact on membrane transport properties, the molecular nature of this impact is still not well understood. By the establishment of a correlation between local chain dynamics and the distribution of free volume elements (FVEs), penetrant transport can be regulated more efficiently in amorphous polymer membranes. In this work, we implement all-atom molecular dynamics (MD) simulations to explore the relationship between chain dynamics and free volume in three polymers with different levels of backbone flexibility: polymethylpentene (PMP), polystyrene (PS), and HAB-6FDA thermally rearranged polymer (TRP). We construct these polymers at different temperatures and examine how temperature impacts the FVE distribution and segmental mobility. Our analysis shows that chain segments near FVEs have higher mobility compared with the atoms in the bulk; the extent of this difference increases with chain flexibility. Increasing the chain flexibility by increasing the temperature results in a broader FVE distribution. Rigid polymers such as TRP show the most robust FVE distribution and are not significantly affected by the temperature change. To capture penetrant diffusion through the polymer matrix, hydrogen is inserted and the diffusion is measured at different temperatures; hydrogen mobility is influenced by the FVE structure and overall mobility of polymer chains. Lastly, at low temperatures, hydrogen mobility is influenced by void distribution, while at high temperatures, polymer dynamics dictate hydrogen transport.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1976

Benefits of hydrogen production research

An economic analysis of total monetary benefits arising from increased volume and efficiency of hydrogen production from various primary energy sources is carried out. The analysis is based on NASA's projections of future hydrogen demand in terms of both established industrial-chemical uses and new energy system applications, along with the mix of primary energy sources needed to meet this demand. A cost methodology model is worked out with the basic cost elements being plant construction costs, feedstock and energy costs, and operating and labor-related costs. A computer simulation technique was developed and a set of model calculations was performed. Some representative outputs of the computer analysis are displayed and conclusions are drawn on major factors determining the overall savings possible in hydrogen production and on its technological and economic impact.

Manvi, R.↗