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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

FC-PLACER (Fuel Cell Plant Layout and Cost Estimation Resource) [SWR-26-027]

The Fuel Cell Plant Layout and Cost Estimation Resource (FC-PLACER) is a tool to perform a footprint and cost analysis for hydrogen fuel cell based power plants. This analysis tool provides a comprehensive design and cost assessment for a 100-MW stationary PEM fuel cell power plant, utilizing specifications from commercially available PEM fuel cell modules originally designed for heavy-duty vehicle applications. Additionally, the tool offers flexibility, enabling adaptation to various capacity requirements or plant configurations and facilitating the evaluation of system layout and overnight costs. In particular, it includes a detailed accounting of balance of plant material and labor costs and enables a precise estimate of plant spatial footprint.

Reznicek, Evan [National Laboratory of the Rockies↗
DOE OSTI2020

Coordinated Multiscale Modeling and Synthesis of Novel Nanostructured Composite Membranes for Solar Fuels Generation (Final Report)

Generation of carbon-based liquid fuels from reduction of CO 2 using solar energy requires the development of improved membranes that provide good ionic conductivity and mechanical properties while minimizing the crossover of gases and reduction products. Using closely coordinated multiscale modeling, synthesis and characterization studies we propose to investigate and develop novel nanostructured composite membranes with applications to conversion of carbon dioxide to storable chemical fuels. The envisioned proton exchange membranes (PEMs) will be based on a support of self- assembling polymer-modified nanoparticles with controllable porosity and tortuosity. The use of a nanoparticle support will provide control of transport and mechanical properties of the membranes. Tuning the copolymer modification of nanoparticles (polymer architectures, brush grafting density) will allow to optimize the ion (proton) transport via the Grotthuss mechanism through narrow hydrated channels while minimizing crossover of gases and reaction products due to the high density of the grafted brush and use of a non-ionic conducting glassy polymers to fill spaces between polymer-grafted nanoparticles. In Phase I synthesis of the copolymers and their attachment to the nanoparticle support will be guided by multiscale simulations that include atomistic molecular dynamics and continuum-level transport simulations. The former will include reactive and non-reactive atomistic simulations that will provide key insight into nanoscale polymer morphology and ion/molecular transport mechanisms need to optimize the copolymer structure. The latter will provide insight into the role of nanoparticle self-assembly on the global transport of ionic and molecular species. The proton conduction and CO 2 /methanol permeability of the membranes will be experimentally characterized as well as simulated and will be correlated with morphology and polymer structure. Prototypes of optimal membranes will be fabricated and characterized at the end of the project. Successful development of improved nanostructured composite PEMs and demonstration of the simulation-guided materials-by-design paradigm will result in our ability to design and synthesize membranes for a wide variety of solar fuels generation and related electrochemical applications.

14 SOLAR ENERGY↗
DOE OSTI2021

Hydrogen isotope fractionation using graphene and related 2-D materials. Final report

This report provides a final technical report and listing of products from the research on a research project from Clemson university, focused on use of two-dimensional materials within membranes to accomplish hydrogen ion separations. The project used CVD graphene and related 2D materials to accomplish hydrogen / deuterium / tritium (H/D/T) separation during water electrolysis in proton-exchange-membrane (PEM)-style cells. 2D materials were incorporated into PEM cells at varying places with the aim of accomplishing isotopic sieving through 2D materials by selective hydron transport at high rates and with high selectivity. The project work scope included studies on H/D separation with small-scale cells at Clemson, collaborative work between Clemson and SRNL on computational modeling and tritium separations, and issues associated with scaleup.

07 ISOTOPE AND RADIATION SOURCES↗
DOE OSTI2022

Platinum Group Metal Catalysts: Supply Chain Deep Dive Assessment

The report “America’s Strategy to Secure the Supply Chain for a Robust Clean Energy Transition” lays out the challenges and opportunities faced by the United States in the energy supply chain as well as the federal government plans to address these challenges and opportunities. It is accompanied by several issue-specific deep dive assessments, including this one, in response to Executive Order 14017 “America’s Supply Chains,” which directs the Secretary of Energy to submit a report on supply chains for the energy sector industrial base. The Executive Order is helping the federal government to build more secure and diverse U.S. supply chains, including energy supply chains. This report focuses on the supply chain for catalysts, specifically platinum group metal (PGM) catalysts, used for decarbonizing energy technologies. Catalysts are substances that increase the rate, conversion, and selectivity of chemical reactions and are used in a variety of applications such as chemical manufacturing, petroleum refining, and catalytic converters. Catalysts containing PGMs (“PGM catalysts”) are particularly useful in widespread industrial applications, including the production of high-volume chemicals such as ammonia, acetic acid, nitric acid, and the refining of crude oil into petroleum products. The PGM metals possess extraordinary properties such as being active oxidation and hydrogenation catalysts; excellent electrical conductors and electrodes; and outstanding adsorbers of oxygen and hydrogen. Within the energy industrial base, PGM catalysts improve the energy and materials efficiency of petroleum refining and chemical industry processes and reduce energy consumption in manufacturing. In addition to their use in catalytic converters, PGM catalysts are important to maximizing the efficiency of emerging decarbonization technologies, specifically in proton exchange membrane (PEM) electrolyzers for green hydrogen production from water and PEM fuel cells for transportation and stationary energy storage. Green hydrogen is expected to play a significant role in decarbonization scenarios.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2022

Crosslinked Anionic Exchange Membranes (Spring Quarter Report)

With ever growing climate concerns, studying and optimizing hydrogen gas electrolyzers and fuel cells are of high importance. Polymeric anionic exchange membranes (AEM) are attractive replacements to the industry standard proton exchange membranes (PEM) due to their lack of precious metal catalysts and acidic conditions. However, AEMs on the market have yet to preform comparatively to PEMs. To bring AEMs to a competitive level, crosslinking chemistry within the polymer membranes is being investigated to enhance mechanical properties and performance. For this quarter, electrochemical systems, important AEM properties and considerations, and some characterization methods will be reviewed.

08 HYDROGEN↗
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 OSTI2023

Reference Station Design for Heavy-Duty Vehicles

Five alternative design configurations for a heavy-duty hydrogen refueling truck stop are detailed in this work. Each of the station concepts provides fast, 5-minute, 50 kg fills of up to 4 vehicles simultaneously, with a station capacity of 4200 kg/day. Two on-site production stations using PEM electrolysis are considered: one with off-peak production of the daily capacity; and one with on-demand production of hydrogen during vehicle refueling. Three delivered liquid hydrogen station concepts are considered: one with the same, high-pressure cascade storage system for dispensing as the electrolysis supplied stations, with low-pressure vaporization of the liquid hydrogen and pressurization via a compressor; and two with on-demand pressurization: one by low-pressure vaporization and compressors; and one with a cryogenic pump and high-pressure vaporization. Design, economic, and operational considerations for each of the components needed in these station concepts is provided. Of all the station concepts, the delivered liquid station with a low-pressure vaporizer and a cascade dispensing system has the lowest capital costs and equipment footprint, but the second highest operating costs primarily due to high costs for liquid hydrogen delivery. The lowest operating cost station is that with on-site production via PEM electrolysis at off-peak hours with a cascade delivery system. The low-pressure buffer storage system and electrolyzers have a large footprint and considerable capital costs, but could result in a low total cost of ownership, depending on the design timeline. The liquid hydrogen station with a cryo-pump has moderate capital costs, the lowest operating costs of the three delivered hydrogen stations, and the same small equipment footprint as the delivered liquid, cascade dispensing system. As cryogenic pumping technology improves and the capital costs for these pumps decreases, this station concept will become even more favorable. Three-dimensional renderings of the five station concepts provide station designers with a starting point for the development of heavy-duty refueling stations.

08 HYDROGEN↗
DOE OSTI2024

Techno-Economic Analysis of Hydrogen Production and Compressed Air Energy Storage from Variable Renewable Energy

Examines the performance and cost of pairing variable renewable energy (VRE) sources with compressed air energy storage and hydrogen production through PEM electrolysis. Sensitivities were performed on H2 cost, PEM electrolyzer capital cost, and hydrogen cavern capital cost. The analysis shows that the cost of VRE has the most impact on the overall cost results.

Teel, Troy↗
DOE OSTI2026

Detection of Critical Surface Features in PTLs and GDLs for Improved Device Performance and Manufacturing Reliability

High points, or features that protrude above the surface of the material, on porous transport layers (PTLs) and gas diffusion layers (GDLs) can be critical features that may affect the manufacturing process and the performance of the device containing the feature. High points on PTLs and GDLs may stress the membrane of a polymer electrolyte membrane (PEM) during lamination and cell operation of a PEM electrolyzer or fuel cell. Additionally, high points on GDLs may impact the reliability of the manufacturing process. Thus, understanding these critical features and developing procedures to detect them are a key part of developing quality control techniques for PTLs and GDLs. This work evaluates the effectiveness of the Keyence VR6200 benchtop-scale structured light optical profilometer for detection of surface protrusions on PTLs and GDLs. Standard testing procedures for detecting and measuring high points were created for use on both material types. These procedures were evaluated using Gage Repeatability and Reproducibility (Gage R&R), where the repeatability, reproducibility, and effectiveness of the system to detect and measure high points were quantified. We have shown with high statistical power that the system is very effective in detection and measurement of high points, with Gage R&R contributions measured to be 2.2% and 3.6% for PTLs and GDLs, respectively.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Environmental Evaluation of Gas Switching Reforming for Low Carbon Hydrogen: A Power-to-X Study

Gas Switching Reforming for hydrogen production (GSR-H2) offers a promising pathway for producing low-carbon hydrogen at scale, with significant implications for Power-to-X (PtX) systems that rely on clean hydrogen as a feedstock for synthetic fuels and chemicals. GSR-H2 integrates inherent carbon capture and thermal self-sufficiency, positioning it as an efficient alternative to conventional steam methane reforming (SMR), proton exchange membrane (PEM) electrolysis, and chemical looping reforming (CLR). Unlike SMR, GSR-H2 avoids external natural gas combustion by leveraging exothermic redox cycles to generate process steam and recover electricity internally. Its innovative reactor design consolidates all reforming stages within a single reactor cluster, eliminating the need for solid circulation found in CLR, thereby reducing capital costs and improving system reliability and scalability. This presentation describes the first environmental life cycle assessment (LCA) of GSR-H2, evaluating its environmental performance across U.S. grid and renewable energy scenarios. In a renewables-powered configuration, GSR-H2 achieves a global warming potential (GWP) of 2.77 kg CO2 equivalent per kg H2, substantially lower than SMR (10.4 kg) and competitive with PEM electrolysis (1.85 kg) and CLR (1.84 kg). Results across additional impact categories, including air quality and water use, support GSR-H2’s role as a complementary hydrogen source in PtX applications. Its reduced environmental burden, thermal integration, and simplified scale-up potential make GSR-H2 a viable contributor to net-zero PtX systems, particularly where renewable energy is abundant and electricity-intensive hydrogen production faces economic or infrastructure constraints.

03 NATURAL GAS↗
DOE OSTI2020

Disulfonated Poly(arylene ether sulfone) Random Copolymers Containing Hierarchical Iptycene Units for Proton Exchange Membranes

Two series of disulfonated iptycene-based poly(arylene ether sulfone) random copolymers, i.e., TRP-BP (triptycene-based) and PENT-BP (pentiptycene-based), were synthesized via condensation polymerization from disulfonated monomer and comonomers to prepare proton exchange membranes (PEMs) for potential applications in electrochemical devices such as fuel cell. To investigate the effect of iptycene units on membrane performance, these copolymers were systematically varied in composition (i.e., iptycene content) and the degree of sulfonation (i.e., 30–50%), which were characterized comprehensively in terms of water uptake, swelling ratio, oxidative stability, thermal and mechanical properties, and proton conductivity at various temperatures. Comparing to copolymers without iptycene units, TRP-BP and PENT-BP ionomers showed greatly enhanced thermal and oxidative stabilities due to strong intra- and inter-molecular supramolecular interactions induced by hierarchical iptycene units. In addition, the introduction of iptycene units in general provides PEMs with exceptional dimensional stability of low volume swelling ratio at high water uptakes, which is ascribed to the supramolecularly interlocked structure as well as high fractional free volume of iptycene-based polymers. It is demonstrated that the combination of high proton conductivity and good membrane dimension stability is the result of the synergistic effects of multiple factors including free volume (iptycene content), sulfonation degree, hydrophobicity, and swelling behavior (supramolecular interactions).

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2026

A Relief Zone Architecture for Enhanced Durability of Ultrathin Membranes in Electrochemical Conversion Devices

Premature cell failures in electrochemical conversion systems often result when membrane electrode assemblies (MEAs) are prepared with ultra-thin (= 15 micrometer-thick) polymer electrolyte membranes (PEMs). These high-performance PEMs are susceptible to mechanical degradation from stress concentrations arising from component and device-level integration. Herein, a relief zone was developed to mitigate mechanical degradation by alleviating excess and non-uniform compression across the active area. Relief zones, created through the ablation of carbonaceous diffusion material achieves a seamless adaptation across a range of MEA dimensions and electrochemical applications without need for costly hardware modifications. This concept was demonstrated using fuel cells as a case study. Accelerated stress test (AST) validations yielded a 6-fold improvement for MEAs prepared with relief zones (i.e., lifetime approximately 1500 h) compared to those fabricated using conventional edge-protection techniques, showcasing the utility of this technique in decoupling integration and device-level engineering effects from intrinsic material limitations for durable electrochemical devices.

14 SOLAR ENERGY↗
NASA NTRS1975

NASA/FRC wake turbulence flight test program: Ride quality aspects

To determine how much the ride quality of the Shuttle Carrier (Boeing 747) Aircraft is affected at various spoiler settings, the PEMS II (Portable Environmental Measuring System) was used to measure onboard motion during a test flight October 15, 1975. The PEMS II measures acceleration in the vertical, transverse and longitudinal directions as well as angular rates of pitch, roll, and yaw. The data acquired by this instrument, combined with an airline passenger comfort model, gives an indication of how passengers would react to the motion induced by flying in a vortex alleviation configuration.

Deptula, D. A.↗
NASA NTRS1988

Transmission X-ray diffraction grating alignment using a photoelastic modulator

A high-resolution alignment technique which utilizes the partial polarization property of fine period transmission gratings has been developed. It is especially useful when the grating period is sufficiently small so that there are no visible diffracted orders. This technique uses a photoelastic modulator (PEM) to produce an intensity signal that is proportional to the sine of twice the angle between the grating lines and the PEM crystal axis. The experimentally demonstrated resolution of this technique on 200-nm period gold transmission gratings is better than 1 arc sec. This technique was developed to align X-ray transmission gratings for spectroscopy and interferometry applications.

Anderson, Erik H.↗
NASA NTRS1989

Hydrogen-oxygen proton-exchange membrane fuel cells and electrolyzers

Hydrogen-oxygen SPE fuel cells and SPE electrolyzers (products of Hamilton Standard) both use a Proton-Exchange Membrane (PEM) as the sole electrolyte. The SPE cells have demonstrated a ten year life capability under load conditions. Ultimate life of PEM fuel cells and electrolyzers is primarily related to the chemical stability of the membrane. For perfluorocarbon proton-exchange membranes an accurate measure of the membrane stability is the fluoride loss rate. Millions of cell hours have contributed to establishing a relationship between fluroride loss rates and average expected ultimate cell life. Several features were introduced into SPE fuel cells and SPE electrolyzers such that applications requiring greater than or equal to 100,000 hours of life can be considered. Equally important as the ultimate life is the voltage stability of hydrogen-oxygen fuel cells and electrolyzers. Here again the features of SPE fuel cells and SPE electrolyzers have shown a cell voltage stability in the order of 1 microvolt per hour. That level of stability were demonstrated for tens of thousands of hours in SPE fuel cells at up to 500 amps per square foot (ASF) current density. The SPE electrolyzers have demonstrated the same at 1000 ASF. Many future extraterrestrial applications for fuel cells require that they be self recharged. To translate the proven SPE cell life and stability into a highly reliable extraterrestrial electrical energy storage system, a simplification of supporting equipment is required. Static phase separation, static fluid transport and static thermal control will be most useful in producting required system reliability. Although some 200,000 SPE fuel cell hours were recorded in earth orbit with static fluid phase separation, no SPE electrolyzer has, as yet, operated in space.

Baldwin, R.↗
NASA NTRS1989

Hydrogen-oxygen proton-exchange membrane fuel cells and electrolyzers

Hydrogen-oxygen solid polymer electrolyte (SPE) fuel cells and SPE electrolyzers (products of Hamilton Standard) both use a Proton-Exchange Membrane (PEM) as the sole electrolyte. These solid electrolyte devices have been under continuous development for over 30 years. This experience has resulted in a demonstrated ten-year SPE cell life capability under load conditions. Ultimate life of PEM fuel cells and electrolyzers is primarily related to the chemical stability of the membrane. For perfluorocarbon proton exchange membranes an accurate measure of the membrane stability is the fluoride loss rate. Millions of cell hours have contributed to establishing a relationship between fluoride loss rates and average expected ultimate cell life. This relationship is shown. Several features have been introduced into SPE fuel cells and SPE electrolyzers such that applications requiring greater than or equal to 100,000 hours of life can be considered. Equally important as the ultimate life is the voltage stability of hydrogen-oxygen fuel cells and electrolyzers. Here again the features of SPE fuel cells and SPE electrolyzers have shown a cell voltage stability in the order of 1 microvolt per hour. That level of stability has been demonstrated for tens of thousands of hours in SPE fuel cells at up to 500 amps per square foot (ASF) current density.

Baldwin, R.↗