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DOE OSTI2021

Cost of a potential hydrogen-refueling network for heavy-duty vehicles with long-haul application in Germany 2050

Long-distance road-freight transport emits a large share of Germany's greenhouse gas (GHG) emissions. A potential solution for reducing GHG emissions in this sector is to use green hydrogen in fuel cell electric vehicles (FC-HDV) and establish an accompanying hydrogen refueling station (HRS) network. In this paper, we apply an existing refueling network design model to a HDV-HRS network for Germany until 2050 based on German traffic data for heavy-duty trucks and estimate its costs. Comparing different fuel supply scenarios (pipeline vs. on-site), the on-site scenario results show a network consisting of 137 stations at a cost of 8.38 billion € per year in 2050 (0.40 € per vehicle km), while the centralized scenario with the same amount of stations shows a cheaper cost with 7.25 billion euros per year (0.35 € per vehicle km). Finally, the hydrogen cost (LCOH) varies from 5.59 €/kg (pipeline) to 6.47 €/kg (on-site) in 2050.

08 HYDROGEN↗

DOE OSTI2024

Stochastic Optimization to Find Optimum Beginning-of-Life Core Configuration of Stable Salt Reactor with Online Refueling

A stochastic optimization method has been developed to find an optimum equilibrium cycle core configuration of the waste-burning stable salt reactor, which is a fast-spectrum molten salt reactor with frequent online refueling. An optimum core configuration was determined with the goal of minimizing radial power peaking. Because of the vast number of potential candidate core configurations, stochastic optimization was applied based on simulated annealing and an additional acceleration method, which screened out unpromising core configurations. It has been demonstrated that the developed stochastic optimization method successfully finds the optimal core configuration regardless of the initial guess and outperforms the gradient descent approach. In addition, it has been observed that the use of a so-called out-in core configuration as the initial guess speeds up convergence of the iterative solution more than five times. Based on the searched optimum equilibrium cycle core configuration, new beginning-of-life (BOL) core configurations have been developed. In conclusion, the new BOL core configurations will be used in developing optimum refueling strategies.

Moltex static salt reactor↗

NASA NTRSDate not supplied

Attitude Dynamics of On-orbit Refueling Configurations

On-orbit refueling is a key enabling technology that will allow a significant increase in the amount of payload mass delivered beyond low-Earth orbit. Despite the potential benefits, there are numerous concerns regarding the operability and scalability of this critical technology. This paper explores the attitude dynamics of two docked spacecraft performing propellant transfer. A vector-dyadic equation is derived to account for the change over time in the mass distribution and the position of the mass center of the stack and moving mass terms omitted in previous literature. Subsequently, the result is applied to two SpaceX-inspired refueling configurations to assess the relative magnitudes of the various terms in the vector-dyadic equation in comparison to the gravity gradient torque.

vector-dyadic equation↗

DOE OSTI2022

Sustainable hydrogen manufacturing via renewable-integrated intensified process for refueling stations

The widescale consumer adoption of hydrogen fuel cell electric vehicles (HFCEVs) is currently hindered by the high cost of small-scale hydrogen generation and the lack of extensive hydrogen refueling infrastructure. Natural gas-based hydrogen is cheaper when produced in large volumes but is also associated with high CO 2 emissions. To counter these challenges, we propose a hybrid approach where both natural gas and renewables are integrated in a synergistic manner using a dynamic process intensification technology that can be deployed on-site for meeting local demands of refueling stations. The technology is based on sorption enhanced steam methane reforming (SE-SMR) that utilizes a combination of reaction with in-situ CO 2 adsorption for enhancing process modularity, productivity and efficiency thereby outperforming conventional SMR at small scale. We develop a mixed integer linear programming (MILP)-based optimization framework for simultaneous design and scheduling of the SE-SMR process. The simultaneous optimization provides a synergistic combination whereby the renewables allow sustainable hydrogen manufacturing and the dynamic SE-SMR allows optimal use of the intermittency of the renewables. The U.S. nationwide analysis indicates that for futuristic renewable prices and a hydrogen production capacity of 2 ton/day, hydrogen can be produced at 50% less cost compared to the current cost of small-scale hydrogen generation. Finally, the city-wise analysis with varying hydrogen demand shows that even with just 5% HFCEV market penetration level, hydrogen production cost less than $3/kg can be obtained at small scales across the United States with even cheaper hydrogen for large cities.

08 HYDROGEN↗

DOE OSTI2024

Refueling Infrastructure Deployment in Low-Income and Non-Urban Communities

The U.S. National Blueprint for Transportation Decarbonization identifies the need to invest in infrastructure supporting low- and zero-emission vehicles, especially in low-income and overburdened communities, to eliminate nearly all greenhouse gas emissions from the transportation sector by 2050. The alternative fuel vehicle refueling property tax credit (26 U.S. Code § 30C) includes eligibility criteria intended to encourage investment in underserved communities based on the economic characteristics or urban character of the census tract in which the fueling infrastructure is installed. Eligible census tracts are those that qualify for the New Markets Tax Credit or that are not located within urban areas as defined by the U.S. Census Bureau. This study quantifies how many fueling-related amenities are currently located in census tracts that qualify and do not qualify for the 30C tax credit based on IRS Notice 2024-20. For existing electric vehicle charging stations, 51% of Level 2 and 60% of Direct Current Fast Charging public stations are located in eligible census tracts. 73% of natural gas, propane, and hydrogen fueling stations are in qualifying census tracts and 75% of biodiesel and renewable fuel stations are in qualifying census tracts. This compares with 73% of existing gas stations in eligible census tracts. For deploying the refueling infrastructure to satisfy future demand, this study shows that truck stops (94%), commercial truck stops (92%), and Federal Highway alternative fuel corridors (89%) are predominantly located in eligible locations. Additionally, significant percentages of the population (62%), light-duty vehicle registrations (64%), and medium- and heavy-duty vehicle registrations (68%) fall within eligible areas.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

Quantitative Risk Assessment for Hydrogen-Powered Locomotive Refueling

Hydrogen powered locomotives are being explored to reduce emissions in rail applications. The risks of operations like refueling should be understood to ensure safe environments for workers and members of the public. Sensitivity analyses were conducted using HyRAM+ to identify major drivers of risk and compare effects of system parameters on individual risk. The consequences of jet fires from full-bore leaks dominated the risk, compared to explosions or smaller leaks. Pipe size, leak detection capability, and leak frequencies of system components greatly affected risk while overpressure modeling parameters and ambient conditions had little effect. The effects of personal protective equipment (PPE) materials on individual risk were quantified by reducing the individual’s exposure time or absorbed thermal dose. PPE only showed a risk reduction in low-risk cases. This study highlighted target areas for risk mitigation, including leak detection equipment and component maintenance, and indicated that the minimal effects of other parameters on risk may not justify prescriptive requirements for refueling operators.

08 HYDROGEN↗

DOE OSTI2024

Reference Station Risk Assessment for Refueling Heavy-Duty Vehicles Using HyRAM+

The deployment of heavy-duty (HD) hydrogen fuel cell vehicles that are entering the market now is driving the need for expanded HD hydrogen refueling station infrastructure to meet demand. This expansion must prioritize safety and reliability, necessitating careful consideration of the associated risks. In this study, we use a light-duty (LD) hydrogen refueling station as a comparative tool to quantify the risks for a HD station, which is essentially a scaled-up version of a LD station.

08 HYDROGEN↗

DOE OSTI2025

Hazard and Operability Analysis for Operating, Refueling, and Maintenance of Fuel Cell Electric Buses

Since hydrogen vehicles can be implemented in heavy-duty transportation applications such as buses, it is important to understand safety hazards and risks of hydrogen fuel cell electric bus (FCEB) and refueling technology. We conducted a hazard and operability analysis for FCEB operation/driving, refueling, and maintenance/inspection. We identified failure modes and consequences and defined a qualitative risk metric as the product of the likelihood of a failure and the severity of the worst-ca

08 HYDROGEN↗

NASA NTRS1973

A flight study of the use of direct-lift-control flaps to improve station keeping during in-flight refueling

To investigate the effectiveness of fast-acting flaps as direct-lift-control (DLC) devices on a fighter airplane, the aileron servo systems of an F-100C variable-stability airplane were modified to provide symmetrical actuation of the surfaces. Initial flight tests using DLC indicated that the task of formation flying and, hence, in-flight refueling could be eased by actuating the DLC flaps through the conventional control stick, with the degree of improvement depending on the basic stability of the receiver aircraft. Results of refueling approaches and connections with U.S. Air Force tankers indicated a moderate overall improvement in vertical station-keeping performance (approximately 19 percent) and a sizeable overall decrease in receiver airplane motions and control activity (approximately 40 percent) with DLC.

Mcneill, W. E.↗

NASA NTRS1985

F-8 refueling boom ground vibration test

A ground vibration test was conducted on a simulated refueling boom mounted on an F-8 airplane. The ground vibration test was conducted to determine if the refueling boom modal frequencies were close to the airplane frequencies. The data presented in this report include modal frequencies, mode shape data, and structural damping coefficients.

Kahoe, M. W.↗

NASA NTRS1985

A Space Station tethered orbital refueling facility

A planned function of the Space Station is to refurbish and refuel an advanced space-based LO2/LH2 orbit transfer vehicle. An alternative to propellant storage at the station is to use a remote facility tied to the station with a long tether. Preliminary design of such a facility is described with emphasis on fluid transfer and storage requirements. Using tether lengths of at least 300 ft, gravity gradient forces will dominate surface tension in such a system. Although gravity driven transfer is difficult because of line pressure drops, fluid settling over the tank outlet greatly alleviates acquisition concerns and will facilitate vented tank fills. The major concern with a tethered orbital refueling facility is its considerable operational complexity including transport of the OTV to and from the facility.

Fester, D. A.↗

NASA NTRS1986

Tethered orbital refueling study

Objectives are to evaluate the feasibility and limitations of fluid acquisition and transfer under an accleration induced in a tethered orbital refueling facility and to provide conceptual designs. Program tasks consist of recommendation of fluid transfer method and parameters; evaluation of disturbances, fluid motion, and damping; selection of passive devices to augment inherent fluid damping and determination of the resultant envelope of operation; assessment of the effect of tether lengths on hazards; and identification of ground and flight tests necessary to prove the tethered orbital refueling concepts.

Fester, D. A.↗

NASA NTRS1987

Dynamical Considerations for Tethered Orbital Refueling Facility

Report summarizes feasibility study for proposed gravity-gradient-stabilized refueling facility tethered to orbiting station. Includes results of preliminary dynamical analysis of fluid transfer and storage and compares alternative system configurations. Concepts introduced in these documents applied to design problems in more detailed study described in "Propellant Tanks for Tethered Orbital Refueling Facility (MSC-21074).

Abbott, Peter W.↗

NASA NTRS1987

An analysis of bipropellant neutralization for spacecraft refueling operations

Refueling of satellites on orbit with storable propellants will involve venting part or all of the pressurant gas from the propellant tanks. This gas will be saturated with propellant vapor, and it may also have significant amounts of entrained fine droplets of propellant. The two most commonly used bipropellants, monomethyl hydrazine (MMH) and nitrogen tetroxide (N2O4), are highly reactive and toxic. Various possible ways of neutralizing the vented propellants are examined. The amount of propellant vented in a typical refueling operation is shown to be in the range of 0.2 to 5% of the tank capacity. Four potential neutralization schemes are examined: chemical decomposition, chemical reaction, condensation and adsorption. Chemical decomposition to essentially inert materials is thermodynamically feasible for both MMH and N2O4. It would be the simplest and easiest neutralization method to implement. Chemical decomposition would require more complex control. Condensation would require a refrigeration system and a very efficent phase separator. Adsorption is likely to be much heavier. A preliminary assessment of the four neutralization shemes is presented, along with suggested research and development plans.

Kauffman, David↗

NASA NTRS1993

On-orbit refueling

The goal of this program is to increase operational availability of space assets by refueling with an expendable launch vehicle (not the Shuttle) in LEO or GEO. Information is drawn from the on-orbit refueling model, COSEMS model, COMA study, and information provided from the San Antonio Air Logistics Center.

POSPISIL↗

NASA NTRS1992

Manned mission to Mars with periodic refueling from electrically propelled tankers

In a joint study by students from the Ecole Polytechnique Feminine, France, and the University of California, Los Angeles, a mission concept that had the objective of evaluating the feasibility of a non-nuclear, yet fast, manned mission to Mars was considered. Ion-engine propelled tankers are postulated that would provide mid-coarse refueling of LOX and LH2 to the manned ship. The scenario is therefore one of a 'split mission', yet with the added feature that the cargo ships include tankers for mid-course refueling. The present study is a continuation of one first conducted last year. Emphasis this year was on the design of the tanker fleet.

Gogan, Laura↗

NASA NTRS2005

Low Gravity Issues of Deep Space Refueling

This paper discusses the technologies required to develop deep space refueling of cryogenic propellants and low cost flight experiments to develop them. Key technologies include long term storage, pressure control, mass gauging, liquid acquisition, and fluid transfer. Prior flight experiments used to mature technologies are discussed. A plan is presented to systematically study the deep space refueling problem and devise low-cost experiments to further mature technologies and prepare for full scale flight demonstrations.

Chato, David J.↗

NASA NTRS2007

Autonomous Airborne Refueling Demonstration Phase I Flight Test Results

This viewgraph presentation provides flight test results of the automatic in-flight refueling of an Uninhabited Aerial Vehicle (UAV) using an automated hose-and-drogue refueling method. The program objective was to demonstrate one fully automatic engagement between the receiver and tanker aircraft. Systems involved, concept of operations, results and conclusions are included.

Dibley, Ryan↗