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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 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Material Developments for 3D/4D Additive Manufacturing (AM) Technologies

Additive Manufacturing (AM), or 3D printing, is a unique technology in which structurally complex objects can be easily manufactured. While AM allows for the creation of intricate 3D objects, these objects are inactive and motionless. With recent incorporation of a “pre-programmed functionality’’ to the 3D printed objects, a new concept has emerged, 4D printing. Specifically, the 4D printing technology enables a static 3D printed object to change its shape, functionality or property over time upon exposure to a specific stimulus such as heat, stress, light, pH, and moisture, etc. We designed and produced compact 3D/4D printable materials that can be used as (a) structural components of the unmanned aerial vehicles (UAVs), and (b) as hydrogen storage materials that supply hydrogen to a fuel cell to expand the operational reach, namely flight time, and endurance of the UA Vs.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Material Developments for 3D/4D Additive Manufacturing (AM) Technologies

Additive Manufacturing (AM), or 3D printing, is a unique technology in which structurally complex objects can be easily manufactured. While AM allows for the creation of intricate 3D objects, these objects are inactive and motionless. With recent incorporation of a “pre-programmed functionality” to the 3D printed objects, a new concept has emerged, 4D printing. Specifically, the 4D printing technology enables a static 3D printed object to change its shape, functionality or property over time upon exposure to a specific stimulus such as heat, stress, light, pH, and moisture, etc. We designed and produced compact 3D/4D printable materials that can be used as (a) structural components of the unmanned aerial vehicles (UAVs), and (b) as hydrogen storage materials that supply hydrogen to a fuel cell to expand the operational reach, namely flight time, and endurance of the UAVs.

08 HYDROGEN↗
DOE OSTI2026

Assessment of Vibration and Shock Loading Environments on Steels Used in Railroad Applications Considering Hydrogen Embrittlement

Studies that examine the combined effects of hydrogen and rail loading environments in the context of hydrogen embrittlement of steels have not been performed. Large-scale hydrogen storage requires either gaseous hydrogen stored in pressure vessels and tubing or liquid hydrogen in cryogenic, insulated tanks. Since the focus of this study is on steels, we examine the influence of hydrogen on stainless steel used for high pressure tubing and cryogenic tanks and Cr-Mo steel liners used in gaseous pressure vessels. Literature studies show that despite hydrogen degradation, these steels can be used effectively and safely if the stresses are managed. The shock and vibration environment on railcars present unique environments where stresses and loading rates can be high. A literature review was conducted to understand the accelerations experienced in rail by examining instrumented railcars of nuclear fuel casks. Hydrogen studies were examined that focused on steel pressure hardware with an emphasis on fatigue, fast loading rates, and low temperatures. A simplified fatigue assessment was performed to examine design cycles for three different hydrogen components: stainless steel tubing, stainless steel cryogenic tanks, and gaseous pressure vessels. The assessments were idealized and used bounding cases of accelerations in both normal rail conditions and coupling events. In normal shock and vibration environments when accelerations were less than 2 g, infinite design life was calculated. In extreme shock or coupling environments, finite design life was calculated which was shown to be dependent on unsupported lengths of pressure components. It was shown that adjusting the unsupported length can reduce the bending stress thereby increasing design life.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Modeling of Liquid Hydrogen Tank Cooled with Para-Orthohydrogen Conversion

With the accelerating development of liquid-hydrogen storage facilities, the problem of boil-off hydrogen losses becomes very important. A promising method to reduce these losses is to utilize the endothermic para-orthohydrogen conversion of vented hydrogen, which can effectively decrease heat loads on a hydrogen tank. To model such a process, a hybrid computational model has been developed, based on the application of computational fluid dynamics for an ullage space, where knowledge of thermal stratification is important, and reduced-order models for other system elements. The simulation results for a spheroidal tank in selected conditions indicated a 10–25% reduction of boil-off losses due to cooling produced by vented hydrogen undergoing para-ortho-conversion.

08 HYDROGEN↗
DOE OSTI2023

Techno-economic Analysis of the Cryogenic Flux Capacitor Compared to Other forms of Hydrogen Production and Storage

The Cryogenic Flux Capacitor (CFC) is a cold, dense energy storage core that is being studied in the cryo-compressed, about 300 bar and 80K, region of gaseous hydrogen (GH2) storage and liquid hydrogen (LH2) region near the normal boiling point. The hydrogens storage is improved by physically bonding the molecules within the nanoscale pores of the aerogel composite blanket material. The process of bonding or debonding is governed by principles of physical adsorption (physisorption) and thermodynamics. The large surface area afforded by the nanoporous aerogel (~1,000 m2/g) allows its storage performance to easily exceed capacities of high-pressure GH2 storage for an equivalent volume. With the integrated aerogel, subscale tests have shown that storage is increased by about 49% over a simple tank filled with GH2 at the same operating temperature and pressure. For LH2 conditions, the CFC is shown to operate at equivalent densities. For the techno-economic analysis (TEA), the source of hydrogen is compared between onsite steam methane reforming (SMR) and onsite solar photovoltaic (PV) panels providing power to electrolyzers to produce GH2. The TEA compares pure hydrogen burning in a combined cycle gas turbine (CCGT) to hydrogen fuel cells with an overall net power output of 650 MW. The SMR system uses natural gas as an input and includes a carbon capture and storage (CCS) system. The levelized cost of electricity is developed based on the capital cost and operating cost of the systems. Sensitivities are discussed around the cost of natural gas, ranging from 1.93 USD per MMBTU to 6.75 USD per MMBTU, and carbon dioxide disposal, ranging from 7 USD per tonne to 10 USD per tonne. For comparison to the conventional CCGT baseline, a baseload scenario is adopted with 85% capacity factor. The results of the study show that onsite hydrogen generation from SMR is about 1 to 3 USD per kg over the life of the plant and the PV hydrogen production produces at 4 to 5 USD per kg. The cost of storage for CFC is compared to other systems, including high-pressure GH2 and atmospheric LH2. The system is shown to provide the lowest costs for all these options at the grid scale, due to its higher capacity than high-pressure GH2 and ability to operate at 80K, receiving refrigeration from liquid nitrogen systems reducing capital and operating costs when compared LH2 storage systems. SMR is competitive with CCGT at the gas prices, both of which have lower LCOE than the PV system. When accounting for variability in gas prices, the PV and electrolyzer system is less sensitive to these changes and provides the lowest LCOE across the whole range.

08 HYDROGEN↗
DOE OSTI2022

Neutron vibrational spectroscopic evidence for short H∙∙∙H contacts in the RNiInH 1.4; 1.6 (R = Ce, La) metal hydride

Intermetallic metal hydrides are critical materials for hydrogen storage applications, however, metal hydrides with greater storage capacities are still needed. Within metal hydrides, the volumetric storage capacities are limited by the number of hydrogen-accommodating interstitial sites which can be simultaneously occupied given a minimum hydride nearest-neighbor distance of ~2.1 A, according to the Switendick-Westlake criterion. To date, violations of this criterion are rare. Perhaps the most well studied compounds violating this criterion are the RNiInHx compounds (R = Ce, La, Nd). Previous neutron diffraction studies on the deuterated species revealed the presence of Ni-D∙∙∙D-Ni-D∙∙∙D-Ni chains with anomalously close D∙∙∙D contacts of ~1.6 A. Yet there are no neutron vibrational spectroscopic investigations reported for these atypical hydrides. Here we use neutron vibrational spectroscopy (NVS) measurements to probe the hydrogen dynamics in LaNiInHx (x = 0.67, 1.6) and CeNiInH 1.4 . For x > 0.67, the presence of close H...H contacts yields two related features in the vibrational spectrum centered near ~90 meV corresponding to the oscillations of paired H atoms simultaneously occupying neighboring R 3 Ni tetrahedra. Notably, these features are energetically distinct from comparable vibrational motions for "unpaired" H atoms when x = 0.67. To compare, we also present powder neutron diffraction and NVS measurements for the newly characterized, chemically similar Sn compounds CeNiSnH, CeNiSnH 2 , and CeNiSnD 2 . These compounds also contain R 3 Ni tetrahedra, however, the H-occupied tetrahedra are well separated from each other with the closest H∙∙∙H distances exceeding 2.1 A, and the Switendick-Westlake criterion is not violated. Consequently, the spectral signature of the close H∙∙∙H contacts is absent in these hydrides.

08 HYDROGEN↗
DOE OSTI2026

Analysis of synergies in converting underground storage sites: Natural gas to hydrogen with co-located CO2 storage

This study examines the untapped potential of synergistically converting underground natural gas storage (UGS) into underground hydrogen storage (UHS) with co-located CO2 storage. Current approaches to subsurface storage technology (SST) development often prioritise single-use scenarios, overlooking the benefits of integrating multiple technologies. We investigate converting UGS assets into UHS through gradual cushion-gas injection over multiple years, rather than injecting all cushion gas in the first year, and include on-site CO2 storage to offset site emissions. Mechanistic modelling shows this gradual transition reduces the Levelised Cost of Storage (LCOS) of H2 by 1.2-13.1% while retaining energy output within 3% of the current status quo. We also show that combined UHS and CO2 storage hubs can reduce the LCOS of CO2 by 45-77% for only a 3-10% increase in hydrogen LCOS relative to the status quo. This analysis framework may help future-proof SST sites and support a resilient, economically beneficial energy transition.

Mouli-Castillo, Julien↗
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↗
DOE OSTI2022

Simultaneous flow of zero-carbon and conventional fuel liquids through Trans-Alaska Pipeline System (Abstract)

The purpose of this CRADA is to address key technical challenges specific to the transport of ammonia, a promising carbon-free fuel and hydrogen-carrier, through crude oil pipelines. Specifically, the project seeks to develop novel technologies for preparing liquid ammonia/ hydrocarbon mixtures for the dual purpose of (i) pipeline transport, and (ii) developing advanced marine fuel blends. By demonstrating compatibility with the Trans-Alaskan Pipeline System (TAPS) ammonia/oil blends may improve access to stranded natural gas and help overcome low-flow issues associated with declining oil productivity. In Alaska, this technology enhances the capabilities of TAPS allowing it to function as a statewide “Hydrogen Highway” for exporting green or blue ammonia. This is strategically important for Alaska which lacks statewide electrical transmission infrastructure but contains vast renewable and fossil resources located in remote regions with few local markets. Nationally, Alaska-sourced green (hydropower) or blue ammonia has the potential to improve reliability of a Pacific Northwest hydrogen storage hub as a hydrogen-carrier by helping to overcome seasonality of green hydrogen produced from solar or wind energy. Globally, this technology project has significant potential to improve the safety and efficacy of ammonia-rich fuel compositions for use in maritime propulsion and other mid-sized engines.

10 SYNTHETIC FUELS↗
DOE OSTI2024

Simultaneous flow of zero-carbon and conventional fuel liquids through Trans-Alaska Pipeline System [Abstract]

The purpose of this CRADA is to address key technical challenges specific to the transport of ammonia, a promising carbon-free fuel and hydrogen-carrier, through crude oil pipelines. Specifically, the project seeks to develop novel technologies for preparing liquid ammonia/ hydrocarbon mixtures for the dual purpose of (i) pipeline transport, and (ii) developing advanced marine fuel blends. By demonstrating compatibility with the Trans-Alaskan Pipeline System (TAPS) ammonia/oil blends may improve access to stranded natural gas and help overcome low-flow issues associated with declining oil productivity. In Alaska, this technology enhances the capabilities of TAPS allowing it to function as a statewide “Hydrogen Highway” for exporting green or blue ammonia. This is strategically important for Alaska which lacks statewide electrical transmission infrastructure but contains vast renewable and fossil resources located in remote regions with few local markets. Nationally, Alaska-sourced green (hydropower) or blue ammonia has the potential to improve reliability of a Pacific Northwest hydrogen storage hub as a hydrogen-carrier by helping to overcome seasonality of green hydrogen produced from solar or wind energy. Globally, this technology project has significant potential to improve the safety and efficacy of ammonia-rich fuel compositions for use in maritime propulsion and other mid-sized engines.

08 HYDROGEN↗
DOE OSTI2022

MULTIMARKET CONTROL AND OPERATION OF AN ADVANCED NUCLEAR REACTOR WITHIN AN INTEGRATED ENERGY PARK

Integrated energy systems (IES) are increasing in popularity and relevance given the heightened penetration of variable renewable energy sources. This variability is causing traditional baseload generators to reconsider their business cases as exclusively electrical generation stations and to instead consider ancillary products (e.g., hydrogen) to remain competitive in the current energy market. This work investigates the coupling, control, and overall viability of IES consisting of an advanced nuclear reactor coupled with a high-temperature steam electrolysis (HTSE) plant and hydrogen storage. The goal of such IES is to produce hydrogen without impacting reactor operations during periods of off-peak electricity demand and then sell electricity to the grid during periods of high demand. To accomplish this, a novel heat exchanger, control scheme, and coupling strategy were needed to ensure that the advanced nuclear power plant could make these transitions. Idaho National Laboratory’s open-source Framework for Optimization of Resources and Economics (FORCE) framework was used to develop novel coupling and control schemes that demonstrate the viability of multi-market operation of advanced nuclear reactors to produce both electricity and hydrogen. The results demonstrated the coupled IES could operate without impacting reactor systems while monetizing the electricity market and meeting all contractual hydrogen consumer demands.

08 HYDROGEN↗
DOE OSTI2022

A new perspective on the initial hydrogenation of $\mathrm{TiFe_{0.9}M_{0.1}}$ ($\mathrm{M = V, Cr, Fe, Co, Ni}$) gained from surface oxide analysis and nucleation thermodynamics

Despite the promise of TiFe-based alloys as low-cost solid-state hydrogen storage materials with mild operating conditions and reasonable hydrogen capacity, their initial hydrogenation process is difficult, hindering broad utilization. The effect of alloying element on the initial hydrogenation kinetics of TiFe alloys, TiFe 0.9 M 0.1 (M = V, Cr, Fe, Co and Ni), was evaluated by analyzing changes to the passivating surface oxide layer that inhibits hydrogen permeation, as well as the ease of initial-stage hydrogen absorption into the underlying matrix. X-ray photoelectron spectroscopy and atom probe tomography revealed key variations in surface oxide compositions and thinning of the passivating oxide layer compared to pure TiFe, which suggests suppressed oxide growth by alloying-induced elemental redistribution. At the same time, density functional theory calculations predicted exothermic formation of hydride nuclei when alloying with V or Cr, as well as a reduced nucleation barrier when alloying with Co or Ni. Overall, these results are consistent with the observed experimental trend of the activation kinetics. We propose that improvements in activation kinetics of TiFe with alloying arises from the combined effect of reduced passivating oxide thickness and easier hydride nucleation, offering a starting point for alloy design strategies towards further improvement.

25 ENERGY STORAGE↗