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NASA NTRS2015

Ground Operations Demonstration Unit for Liquid Hydrogen Initial Test Results

NASA operations for handling cryogens in ground support equipment have not changed substantially in 50 years, despite major technology advances in the field of cryogenics. NASA loses approximately 50% of the hydrogen purchased because of a continuous heat leak into ground and flight vessels, transient chill down of warm cryogenic equipment, liquid bleeds, and vent losses. NASA Kennedy Space Center (KSC) needs to develop energy-efficient cryogenic ground systems to minimize propellant losses, simplify operations, and reduce cost associated with hydrogen usage. The GODU LH2 project has designed, assembled, and started testing of a prototype storage and distribution system for liquid hydrogen that represents an advanced end-to-end cryogenic propellant system for a ground launch complex. The project has multiple objectives including zero loss storage and transfer, liquefaction of gaseous hydrogen, and densification of liquid hydrogen. The system is unique because it uses an integrated refrigeration and storage system (IRAS) to control the state of the fluid. This paper will present and discuss the results of the initial phase of testing of the GODU LH2 system.

liquefaction↗
NASA NTRS2011

Development Status of PEM Non-Flow-Through Fuel Cell System Technology for NASA Applications

Today s widespread development of proton-exchange-membrane (PEM) fuel cell technology for commercial users owes its existence to NASA, where fuel cell technology saw its first applications. Beginning with the early Gemini and Apollo programs, and continuing to this day with the Shuttle Orbiter program, fuel cells have been a primary source of electrical power for many NASA missions. This is particularly true for manned missions, where astronauts are able to make use of the by-product of the fuel cell reaction, potable water. But fuel cells also offer advantages for unmanned missions, specifically when power requirements exceed several hundred watts and primary batteries are not a viable alternative. In recent years, NASA s Exploration Technology Development Program (ETDP) funded the development of fuel cell technology for applications that provide both primary power and regenerative fuel cell energy storage for planned Exploration missions that involved a return to the moon. Under this program, the Altair Lunar Lander was a mission requiring fuel cell primary power. There were also various Lunar Surface System applications requiring regenerative fuel cell energy storage, in which a fuel cell and electrolyzer combine to form an energy storage system with hydrogen, oxygen, and water as common reactants. Examples of these systems include habitat modules and large rovers. In FY11, the ETDP has been replaced by the Enabling Technology Development and Demonstration Program (ETDDP), with many of the same technology goals and requirements applied against NASA s revised Exploration portfolio.

Hoberecht, Mark A.↗
NASA NTRS2018

Large Scale Cryogenic Storage with Active Refrigeration

Storage and transfer of cryogenic liquefied gases on volume scales from under 10 liters for lab use, up to hundreds of millions of liters for industrial applications is of paramount importance across a vast range of industries. Traditionally, these commodities have been stored at or near the normal boiling point due to relative ease of operation and safety-related considerations; however, this also means that some percentage will always be lost due to environmental heat leaking into the vessel and causing boil-off. These losses become more concerning as scales increase, and are of particular importance for high-cost commodities such helium and hydrogen. Additionally, the normal boiling point marks the highest liquid density achievable; which becomes a strong driver of end-use system designs such as space launch vehicles. Recent development and testing of an Integrated Refrigeration and Storage (IRAS) system for liquid hydrogen has proven that next generation cryogenic storage operations such as zero boil-off and densification are feasible on a large scale. This IRAS system married an 850 Watt at 20 Kelvin reverse-Brayton cycle commercial cryogenic refrigerator with a 125,000 liter LH2 storage tank via and internal tubular heat exchanger. This allowed heat to be removed directly from the hydrogen, and by extension, provided a means to control the bulk thermodynamic state. Zero boil-off, in-situ liquefaction, and densification down to the triple point was performed during testing, and data such as fluid temperature profiles and tank pressure were gathered. Details regarding the design, setup, and testing of the IRAS system are discussed herein, and the data used to anchor various physics models created to predict the behavior of the system during transient and steady state operation. It is hoped that these efforts will provide a useful basis for the design and implementation of future large scale IRAS systems across numerous industries.

Swanger, Adam M.↗
NASA NTRS2017

Research and Development History of Glass Bubbles Bulk-Fill Thermal Insulation Systems for Large-Scale Cryogenic Liquid Hydrogen Storage Tanks

Based on the published literature record, this document provides an overview of the research and development of glass bubbles bulk-fill thermal insulation systems for cryogenic equipment in general and, in particular, for large-scale cryogenic liquid hydrogen (LH2) storage spheres. Glass bubbles (also known as hollow glass microspheres) are used in place of perlite powder which began use in double-wall cryogenic tanks in the 1930s. Included in this overview is a historical summary, a development timeline, a selected publications list, and the key technical points from those publications.

Cryogenic storage tanks↗
NASA NTRS2008

Hydrogen Research for Spaceport and Space-Based Applications: Hydrogen Production, Storage, and Transport

The activities presented are a broad based approach to advancing key hydrogen related technologies in areas such as fuel cells, hydrogen production, and distributed sensors for hydrogen-leak detection, laser instrumentation for hydrogen-leak detection, and cryogenic transport and storage. Presented are the results from research projects, education and outreach activities, system and trade studies. The work will aid in advancing the state-of-the-art for several critical technologies related to the implementation of a hydrogen infrastructure. Activities conducted are relevant to a number of propulsion and power systems for terrestrial, aeronautics and aerospace applications. Hydrogen storage and in-space hydrogen transport research focused on developing and verifying design concepts for efficient, safe, lightweight liquid hydrogen cryogenic storage systems. Research into hydrogen production had a specific goal of further advancing proton conducting membrane technology in the laboratory at a larger scale. System and process trade studies evaluated the proton conducting membrane technology, specifically, scale-up issues.

Anderson, Tim↗
NASA NTRS2021

PEM Fuel Cell MODEL for Conceptual Design of Hydrogen eVTOL Aircraft

A model and software for design and analysis of a Proton Exchange Membrane fuel cell (PEMFC) system are developed for hydrogen eVTOL aircraft. Examples are provided of stacks designed for 80 kWe and 500 kWe net electrical power. Examples are provided of eVTOL designed for 250 and 400 lb payload. The trade-offs included stack characteristics, hydrogen storage characteristics, and aircraft payload and range. The objectives were to identify the key technology drivers of a hydrogen rotorcraft, establish technology targets for a viable aircraft, and recommend research to address the fundamental pre-competitive barriers. The current U.S. infrastructure on hydrogen informed the targets and recommendations. The key conclusion is that the advances made in cell electrochemical power density over the last decade might allow a PEMFC system to meet, or even beat, piston engine powered light-utility rotorcraft. The development must focus on the key drivers of a hydrogen eVTOL. The drivers are ultra-light stack cooling and short-term hydrogen storage. A stack system of net electrical power 100−150 kWe with specific power 1.1 kWe/kg including air, cooling, and electrical subsystems, and a tank storage of 15% weight fraction hydrogen are the minimum targets to meet the performance of a modern piston-engine rotorcraft, with a range of 180 nautical miles, payload of 400 lb, and gross weight of about 1400 lb. This is defined as the objective aircraft. If only one target is met, an aircraft of half the range could be produced, with a 30% greater gross take-off weight. This is defined as an intermediate aircraft. Because definitive conclusions are premature without weights and loads data on a flight-worthy stack system, it is recommended that a fuel cell powered hydrogen eVTOL demonstrator be built and flown. The existing hydrogen infrastructure for cars provide ample opportunity to create a pilot program. About 12 metric tons of retail hydrogen are available for cars every day in California, which is less than 0.05% of the yearly hydrogen production in the U.S.. A hypothetical fleet of 100 aircraft, operating 3 flights a day, would increase the demand by 2.25 tons per day and require 140 MWh of renewable electricity for green hydrogen.

PEM↗
NASA NTRS1989

Cryogenic reactant storage for lunar base regenerative fuel cells

There are major advantages to be gained by integrating a cryogenic reactant storage system with a hydrogen-oxygen regenerative fuel cell (RFC) to provide on-site electrical power during the lunar night. Although applicable to any power system using hydrogen-oxygen RFC's for energy storage, cryogenic reactant storage offers a significant benefit whenever the sun/shade cycle and energy storage period approach hundreds of hours. For solar power installations on the moon, cryogenic reactant storage reduces overall specific mass and meteoroid vulnerability of the system. In addition, it offers synergistic benefits to on-site users, such as availability of primary fuel cell reactants for surface rover vehicles and cryogenic propellants for OTV's. The integration involves processing and storing the RFC reactant streams as cryogenic liquids rather than pressurized gases, so that reactant containment (tankage per unit mass of reactants) can be greatly reduced. Hydrogen-oxygen alkaline RFC's, GaAs photovoltaic (PV) arrays, and space cryogenic processing/refrigeration technologies are assumed to be available for the conceptual system design. Advantages are demonstrated by comparing the characteristics of two power system concepts: a conventional lunar surface PV/RFC power system using pressurized gas storage in SOA filament wound pressure vessels and, that same system with gas liquefaction and storage replacing the pressurized storage. Comparisons are made at 20 and 250 kWe. Although cryogenic storage adds a processing plant (drying and liquefaction) to the system plus 30 percent more solar array to provide processing power, the approximate order of magnitude reduction in tankage mass, confirmed by this analysis, results in a reduction in overall total system mass of approximately 50 percent.

Kohout, Lisa L.↗
NASA NTRS1989

Cryogenic reactant storage for lunar base regenerative fuel cells

There are major advantages to be gained by integrating a cryogenic reactant storage system with a hydrogen-oxygen regenerative fuel cell (RFC) to provide on-site electrical power during the lunar night. Although applicable to any power system using hydrogen-oxygen RFC's for energy storage, cryogenic reactant storage offers a significant benefit whenever the sun/shade cycle and energy storage period approach hundreds of hours. For solar power installations on the moon, cryogenic reactant storage reduces overall specific mass and meteoroid vulnerability of the system. In addition, it offers synergistic benefits to on-site users, such as availability of primary fuel cell reactants for surface rover vehicles and cryogenic propellants for OTV's. The integration involves processing and storing the RFC reactant streams as cryogenic liquids rather than pressurized gases, so that reactant containment (tankage per unit mass of reactants) can be greatly reduced. Hydrogen-oxygen alkaline RFC's, GaAs photovoltaic (PV) arrays, and space cryogenic processing/refrigeration technologies are assumed to be available for the conceptual system design. Advantages are demonstrated by comparing the characteristics of two power system concepts: a conventional lunar surface PV/RFC power system using pressurized gas storage in SOA filament wound pressure vessels and, that same system with gas liquefaction and storage replacing the pressurized storage. Comparisons are made at 20 and 250 kWe. Although cryogenic storage adds a processing plant (drying and liquefaction) to the system plus 30 percent more solar array to provide processing power, the approximate order of magnitude reduction in tankage mass, confirmed by this analysis, results in a reduction in overall total system mass of approximately 50 percent.

Kohout, Lisa L.↗
NASA NTRSDate not supplied

Techno-Economic Analysis of Green Hydrogen Energy Storage in A Cryogenic Flux Capacitor

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 (GH 2 ) storage and liquid hydrogen (LH 2 ) region near the normal boiling point. Hydrogen 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 m 2 /g) allows its storage performance to easily exceed capacities of high-pressure GH 2 storage for an equivalent volume. With the integrated aerogel, subscale tests have shown that storage is increased by about 36% over a simple tank filled with GH 2 at the same operating temperature and pressure. For LH 2 conditions, the CFC is shown to operate at improved densities, but testing is ongoing. 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 green GH 2 . The TEA compares pure hydrogen produced at a small scale for a 25 MW power system and at a large scale in a 500 MW power system. The system allowed for hydrogen imports and exports at a set price with a tank sized for 10 hours of power production. The two power producing technologies are a combined cycle gas turbine (CCGT) and hydrogen fuel cells. The SMR system uses natural gas as an input and includes a carbon capture and storage (CCS) system. The levelized cost of electricity (LCOE), levelized cost of hydrogen (LCOH), and levelized cost of storage (LCOS) are developed based on the capital cost and operating cost of the systems. The results are shown for current costs using a 2021 benchmark and DOE projections for cost improvements by 2030. The TEA showed that onsite hydrogen generation from SMR has an LCOH of about 1.4 to 2 USD per kg over the life of the plant and the PV hydrogen production LCOH is about 5.2 to 5.5 USD per kg. The LCOS of conventional GH 2 systems is estimated to be $210/MWh and cost of storage for LH 2 systems is $205/MWh for fuel cell systems and $249/MWh for CCGT systems. CFC improved the LCOS of all these systems to $198/MWh, $191/MWh and $233/MWh respectively. The LCOE also improved with conventional systems between $171/MWh and $228/MWh improved by CFC to between $167/MWh and $212/MWh. Using projections for improvement in costs following DOE’s goals by 2030, green hydrogen improved to as low as $78/MWh LCOS and LCOE for conventional cases. CFC improved over conventional storage with the lowest LCOS being $62/MWh and the lowest LCOE being $73/MWh. These results correspond to an LCOH of $2/kg. Finally, the TEA shows how LCOE is improved for hydrogen conditioning and storage over conventional systems and caverns in the 10 to 50 hour range.

Joshua Schmitt↗
NASA NTRS1972

A 10,000-gpm liquid hydrogen transfer system for the Saturn/Apollo program.

Brief description of the design and operation of the liquid hydrogen transfer system used to service the Saturn V launch vehicle. The cryogenic loading of the huge booster begins eight hours before the scheduled liftoff. The first three hours of fueling are spent in cold hydrogen gas conditioning of the fuel tank. The cold hydrogen gas is provided by vaporizing liquid hydrogen from the storage tank and routing the resultant gas through the fill system. Boil-off losses after loading are continuously replaced through control valves which are driven by a computer system. The liquid hydrogen transfer system is made up of a number of subsystems including the 850,000 gal storage tank whose boil-off losses amount to only 200 gal/day, the pressurization system, the burn pond for controlled disposal of hydrogen waste gas, the storage tank fill manifold, and the hazardous gas monitoring system. Some of the subsystems and components are redundant to provide a high degree of reliability.

Wybranowski, E., Jr.↗
NASA NTRS1980

Influence of Microstructure on the Fatigue Crack Growth of A516 in Hydrogen

Some day hydrogen may be used as a viable energy storage and transport medium within the United States. Hydrogen gas may be used to dilute and extend our present methane supply as a blend or may even be used in its pure elemental form as a primary fuel. Independent of the methods of production, storage, and distribution, the interaction of hydrogen with its containment material will play an integral role in the success of a hydrogen energy program. Presently, the selection of hydrogen containment materials can be made such that the material will remain reasonably free from environmental degradation; however, costly alloying additions are required. Unfortunately, high alloy steels are economically prohibitive when large-scale hydrogen energy storage, transmission, and conversion systems are desired. Therefore, in order to implement such hydrogen energy systems in the future, existing low-cost materials must be improved via mechanical, thermal, or thermo-mechanical processing methods or new low-cost materials which are compatible with hydrogen must be developed. Originally, low strength, low alloy steels at room temperature were thought to be immune to hydrogen gas embrittlement, since no sustained load crack growth is observed. However, results of Clark in HY8O and Nelson in SAE 1020 have shown that the fatigue crack growth rate can be greatly accelerated in the presence of hydrogen gas. In recent results reported by Louthan and Mucci, the smooth bar fatigue life of an A1068 pipeline steel was reduced up to a factor of ten when the tests were performed in a 13.8 MPa hydrogen environment. These results suggest that the selection of material for structures designed to operate in hydrogen under cyclic loads must include consideration of hydrogen/metal fatigue interaction. Although the hydrogen/metal fatigue interaction can be severe in low strength low alloy steels, the degree of degradation may be altered by the underlying ferrous microstructure. At present, no correlation between microstructure and degree of hydrogen susceptibility exists for low strength steels. However, in high strength steels, susceptibility to hydrogen embrittlement has been shown to be strongly sensitive to the metallurgical microstructure. In addition, compositional effects and grain size can 703 Some day hydrogen may be used as a viable energy storage and transport medium within the United States. Hydrogen gas may be used to dilute and extend our present methane supply as a blend or may even be used in its pure elemental form as a primary fuel. Independent of the methods of production, storage, and distribution, the interaction of hydrogen with its containment material will play an integral role in the success of a hydrogen energy program. Presently, the selection of hydrogen containment materials can be made such that the material will remain reasonably free from environmental degradation; however, costly alloying additions are required. Unfortunately, high alloy steels are economically prohibitive when large-scale hydrogen energy storage, transmission, and conversion systems are desired. Therefore, in order to implement such hydrogen energy systems in the future, existing low-cost materials must be improved via mechanical, thermal, or thermo-mechanical processing methods or new low-cost materials which are compatible with hydrogen must be developed.

Wachob, Harry F.↗
NASA NTRS1980

LeRC reduced gravity fluid management technology program

The program reviewed in the present paper has provided information of the reduced-gravity behavior of fluids, thermal control of cryogenic tankage, and fluid management system design. The studies are currently shifting from the utilization of in-house experimental facilities to the development of Spacelab experiments. The cryogenic fluid management experiment, currently undergoing detailed design, is expected to provide an orbital evaluation of a subcritical liquid hydrogen storage and supply system, as part of the Shuttle/Spacelab program. Efforts are continuing to develop computer techniques for simulating reduced-gravity fluid dynamic processes.

Aydelott, J. C.↗
NASA NTRS1987

Electrochemical performance and transport properties of a Nafion membrane in a hydrogen-bromine cell environment

The overall energy conversion efficiency of a hydrogen-bromine energy storage system is highly dependent upon the characteristics and performance of the ion-exchange membrane utilized as a half-cell separator. The electrochemical performance and transport properties of a duPont Nafion membrane in an aqueous HBr-Br2 environment were investigated. Membrane conductivity data are presented as a function of HBr concentration and temperature for the determination of ohmic voltage losses across the membrane in an operational cell. Diffusion-controlled bromine permeation rates and permeabilities are presented as functions of solution composition and temperature. Relationships between the degree of membrane hydration and the membrane transport characteristics are discussed. The solution chemistry of an operational hydrogen-bromine cell undergoing charge from 45% HBr to 5% HBr is discussed, and, based upon the experimentally observed bromine permeation behavior, predicted cell coulombic losses due to bromine diffusion through the membrane are presented as a function of the cell state-of-charge.

Baldwin, Richard S.↗
NASA NTRS1976

Hydrogen embrittlement of structural alloys. A technology survey

Technical abstracts for about 90 significant documents relating to hydrogen embrittlement of structural metals and alloys are reviewed. Particular note was taken of documents regarding hydrogen effects in rocket propulsion, aircraft propulsion and hydrogen energy systems, including storage and transfer systems.

Carpenter, J. L., Jr.↗
NASA NTRSDate not supplied

Control System Development for A Zero Boil-Off Hydrogen Storage Demonstration With Two-Stage Active Cooling

A NASA team is designing and building a test article to demonstrate the long duration storage of liquid hydrogen via active cooling (cryocoolers) while implementing a two-stage cooling approach. This activity is one of a large portfolio of NASA’s Space Technology Mission Directorate funded activities which focuses on the technology maturation needed for long duration storage of cryogenic liquid in-space. The current state-of-the-art for liquid hydrogen storage on-orbit is on the order of hours while NASA’s planned missions require storage for months, or even years. To enable such a long duration, Zero Boil-Off conditions must be achieved which requires passive technologies to minimize environmental heat loads, but also active cooling to intercept and reject the remaining heat to deep space. The implementation of active cooling results in a significant amount of dry mass added to the vehicle. Utilizing a Two-Stage Cooling approach, analysis and testing to date indicates the Zero Boil-Off of liquid hydrogen can be achieved with less mass and electrical power relative to a single-stage cooling approach where only one cryocooler is used. This activity will demonstrate the fully integrated suite of technologies needed to enable the Two-Stage Cooling approach which includes Multi-Layer Insulation blankets, Low Conductivity Structures, a Tube-On-Tank Heat Exchanger, Tube-On-Shield Heat Exchanger and a Two-Stage Cryogenerator (both 90 Kelvin and 20 Kelvin) with each stage having an independently controlled circulation loop. The bulk of the heat load is intercepted by the 90 Kelvin loop via a thin foil heat exchanger internal to the insulation blankets (also known as a Broad Area Cooling Shield), with the remainder removed at cryofluid temperature (20 Kelvin) by tubes directly welded to the outer tank surface. In this paper, we examine the challenges of controlling the system, and describe the development of control algorithms and software for future testing with liquid hydrogen. The interactions between the cryofans which control circulation loop mass flow rates, electrical heaters which vary the cryocooler lift to simulate the operation of variable-lift flight units, tank heaters which can vary the overall heat load, and the effects of changes in circulation loop pressure as temperatures change, can be complex and must be well understood to maintain steady-state propellant conditions and achieve Zero Boil-Off. Parallel PID loops and watchdog programs implemented on the user interface system will help bring the systems to steady state operation and keep them at selected operating points within acceptable error, while avoiding runaway feedback loops.

cryogenics↗