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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Risk Assessment and Ventilation Modeling for Hydrogen Release in Vehicle Repair Garages

The availability of repair garage infrastructure for hydrogen fuel cell vehicles is becoming increasingly important for future industry growth. Ventilation requirements for hydrogen fuel cell vehicles can affect both retrofitted and purpose-built repair garages and the costs associated with these requirements can be significant. A hazard and operability study (HAZOP) was performed to identify key risk-significant scenarios related to hydrogen vehicles in a repair garage. Detailed simulations and modeling were performed using appropriate computational tools to estimate the location, behavior, and severity of hydrogen release based on key HAZOP scenarios. This work compares current fire code requirements to an alternate ventilation strategy to further reduce potentially hazardous conditions. Overall, the amount of flammable mass of hydrogen at any one time in the simulation is low compared to the total mass of hydrogen released, due to the low flow rate of a low pressure release. It is shown that position, direction, and velocity of ventilation have a significant impact on the amount of instantaneous flammable mass in the domain.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Operational optimization for multi-functional charging station with electric and hydrogen-powered vehicles

The rapid adoption of electric vehicles (EVs) and hydrogen fuel cell vehicles (HFCVs), combined with global efforts to reduce carbon emissions, has accelerated the development of EV charging and hydrogen refueling stations. In response to this demand, this paper introduces the concept of Multi-Functional Charging Station (MFCS) that integrates power generation, EV charging, battery swapping, and hydrogen refueling. A comprehensive operational model is developed for the MFCS that couples electricity and hydrogen conversion and storage technologies to enhance infrastructure utilization and improve overall system efficiency. The model also considers multiple revenue streams, including participation in energy and ancillary markets. To validate the effectiveness of the proposed model and evaluate its performance, a series of numerical experiments are conducted with different charger numbers, different electricity purchase limits, and different charger allocations. Numerical results demonstrate that shared charger configurations can lead to 8.11 % improvement in operational profit by improving resource utilization and reducing the number of depleted batteries at the end of operations compared to allocated charger setups. By varying the number of chargers, sensitivity analysis identifies diminishing marginal returns beyond about 45 chargers, suggesting it as an optimal sizing point under current settings. The integration of electricity and hydrogen conversion is also explored under scenarios with limited external electricity purchases. In conclusion, these findings indicate that optimizing charger allocation and energy management can significantly enhance station productivity and profitability, ultimately supporting the broader adoption of electrified and hydrogen-based transportation solutions.

Charging station↗
DOE OSTI2023

Optimizing Long Term Hydrogen Fueling Infrastructure Plans on Freight Corridors for Heavy Duty Fuel Cell Electric Vehicles

The development of a future hydrogen energy economy will require the development of several hydrogen market and industry segments including a hydrogen based commercial freight transportation ecosystem. For a sustainable freight transportation ecosystem, the supporting fueling infrastructure and the associated vehicle powertrains making use of hydrogen fuel will need to be co-established. This paper develops a long-term plan for refueling infrastructure deployment using the OR-AGENT (Optimal Regional Architecture Generation for Electrified National Transportation) tool developed at the Oak Ridge National Laboratory, which has been used to optimize the hydrogen refueling infrastructure requirements on the I-75 corridor for heavy duty (HD) fuel cell electric commercial vehicles (FCEV). This constraint-based optimization model considers existing fueling locations, regional specific vehicle fuel economy and weight, vehicle origin and destination (OD), vehicle volume by class and infrastructure costs to characterize in-mission refueling requirements for a given freight corridor. The authors applied this framework to determine the ideal long term public access locations for hydrogen refueling (constrained by existing fueling stations and dispensing technology), the minimal viable cost to deploy sufficient hydrogen fuel dispensers, and associated equipment, to accommodate a growing population of hydrogen fuel cell trucks. So the framework discussed in this paper can be expanded and applied to additional electrified powertrains as well as a larger interstate system, expanded regional corridor, or other transportation networks.

08 HYDROGEN↗
DOE OSTI2025

Degradation of Fuel Cell Membrane Electrode Assemblies from Buses Operated More than 25,000 h

This study investigates the performance losses and degradation of proton-exchange-membrane fuel-cell stacks taken from the Alameda Contra Costa Transit District (AC Transit) bus system (Alameda and Contra Costa counties, California, United States) that were operated for over 25,000 h. Here, we focus on the origin of differences in electrochemical performance between beginning-of-life (BOL) and end-of-life states as well as diagnostic data acquired during the lifetime of the buses. In doing so, we employ in- and ex- situ characterization methods such as polarization curves, electrochemical impedance spectroscopy, electron microscopy, and X-ray characterization. Uniform degradation of the catalyst layer including Pt agglomeration/migration and electrode thinning was observed in all of the post-teardown measurements compared to BOL materials resulting from years of field operation. Despite these changes, the measured post-teardown performance suggests a sufficient output for the expected load, which indicate factors other than degradation of the membrane-electrode assemblies (MEAs) are likely responsible for the decommissioning of the stacks. The findings indicate that these MEA materials can enable long lifetime in fuel-cell vehicles, if the MEAs are not subjected to adverse operating conditions. The results also highlight the need for more in-vehicle diagnostics to maximize the lifetime of fuel cell vehicle (FCV) powerplants.

25 ENERGY STORAGE↗
DOE OSTI2022

Exploring the potential of hydrogen in decarbonizing China's light-duty vehicle market

The Chinese government has pledged to achieve overall carbon neutrality by 2060. Currently, the transportation sector contributes to about 10% of total greenhouse gas (GHG) emissions in China. Hence, China has created a well-defined energy vehicle development strategy to reduce GHG emissions from the transportation sector, further expanding into hydrogen vehicle technologies. In this study, the Transportation Energy Analysis Model (TEAM) investigates the potential of hydrogen internal combustion engine vehicles (H2- ICEVs) and fuel cell vehicles (FCEVs) as a reliable pathway towards the government's aspiration of carbon neutrality in the transportation sector. According to TEAM, by adopting FCEVs and H2-ICEVs in the vehicle market, hydrogen demand could reach 25% of the total light-duty transportation energy demand in 2050. Consequently, this will lead to an annual reduction of more than 35 million tons GHG compared to only counting on the electrification pathway in the decarbonization task. Besides, FCEVs would take longer to penetrate the light-duty vehicle market compared to H2-ICEVs, as the current fuel cell technology still requires much improvement to attain a competitive vehicle cost of production.

Life cycle analysis↗
NASA NTRS2010

Fuel-Cell-Powered Vehicle with Hybrid Power Management

Figure 1 depicts a hybrid electric utility vehicle that is powered by hydrogenburning proton-exchange-membrane (PEM) fuel cells operating in conjunction with a metal hydride hydrogen-storage unit. Unlike conventional hybrid electric vehicles, this vehicle utilizes ultracapacitors, rather than batteries, for storing electric energy. This vehicle is a product of continuing efforts to develop the technological discipline known as hybrid power management (HPM), which is oriented toward integration of diverse electric energy-generating, energy-storing, and energy- consuming devices in optimal configurations. Instances of HPM were reported in five prior NASA Tech Briefs articles, though not explicitly labeled as HPM in the first three articles: "Ultracapacitors Store Energy in a Hybrid Electric Vehicle" (LEW-16876), Vol. 24, No. 4 (April 2000), page 63; "Photovoltaic Power Station With Ultracapacitors for Storage" (LEW- 17177), Vol. 27, No. 8 (August 2003), page 38; "Flasher Powered by Photovoltaic Cells and Ultracapacitors" (LEW-17246), Vol. 27, No. 10 (October 2003), page 37; "Hybrid Power Management" (LEW-17520), Vol. 29, No. 12 (December 2005), page 35; and "Ultracapacitor-Powered Cordless Drill" (LEW-18116-1), Vol. 31, No. 8 (August 2007), page 34. To recapitulate from the cited prior articles: The use of ultracapacitors as energy- storage devices lies at the heart of HPM. An ultracapacitor is an electrochemical energy-storage device, but unlike in a conventional rechargeable electrochemical cell or battery, chemical reactions do not take place during operation. Instead, energy is stored electrostatically at an electrode/electrolyte interface. The capacitance per unit volume of an ultracapacitor is much greater than that of a conventional capacitor because its electrodes have much greater surface area per unit volume and the separation between the electrodes is much smaller.

Eichenberg, Dennis J.↗
DOE OSTI2023

Methods for Estimating Hydrogen Fuel Tank Characteristics

The pressure vessels needed to store hydrogen for next-generation hydrogen fuel cell vehicles are expected to be a substantial portion of the total system mass, volume, and cost. Gravimetric capacity, volumetric capacity, and cost per kilogram of usable hydrogen are key performance metrics that the U.S. Department of Energy (DOE) uses to determine the viability of hydrogen fuel cell systems. Research and development related to hydrogen storage systems covers a wide range of potential operating conditions, from cryogenic temperatures to high temperatures (above ambient) and low pressure to high pressure. Researchers at PNNL have developed methods for estimating these key pressure vessel characteristics to support on-board hydrogen storage system design and performance evaluation and to support decision-making about DOE hydrogen storage system research investments. This article describes the pressure tank estimation methodology that has been used as a stand-alone calculation and has been incorporated into larger system evaluation tools. The methodology estimates the geometry, mass, and material cost of type I, type III, and type IV pressure vessels based on operating pressure and material strength at the system's operating temperature, using classical thin-wall and thick-wall pressure vessel stress calculations. The geometry, mass, and material cost requirements of the pressure vessel have significant impacts on the total system performance. For example, hydrogen storage materials that can separately achieve a very high hydrogen density can be deemed impractical for use in fuel cell vehicle hydrogen storage systems because the pressure tank containing them is too large, heavy, or expensive. This article describes the design philosophy and analytical process of the tank characteristic estimation methodology, which has been implemented in spreadsheet calculation tools and system-level analysis tools used by DOE researchers. Each of the three tank types (type I, type III, and type IV) uses a different analysis methodology with some common elements. This article also provides examples of implementing the methodology to perform parametric studies of all three pressure vessel types. The goal of this article is to present the methodology in sufficient detail so it can be implemented in other hydrogen fuel cell vehicle design and analysis tools.

42 ENGINEERING↗
DOE OSTI2026

Innovating High Throughput Hydrogen Stations: Cooperative Research and Development Final Report, CRADA Number CRD-18-00773

Hydrogen stations today serve the emerging market of light duty fuel cell vehicles, primarily in California with over 30 public retail locations. There has been a steady increase in the number of stations open and hydrogen dispensed, especially in the last two years. From 2015 to 2016, the annual amount of hydrogen dispensed increased from 27,400 kg to 109,200 kg, a nearly fourfold increase in just one year. One station dispensed nearly 12,000 kg in the second quarter of 2017. Despite the significant progress, gaps exist between current infrastructure capabilities and future requirements. For example, fuel cell vehicle applications such as buses, medium-duty, and heavy-duty trucks will gain market share and this must be considered as future customers at hydrogen stations. The expected number of light duty fuel cell vehicles in California alone are expected to grow from approximately 4,000 to over 13,000 by 2020, and 37,000 by 2023. To serve the multiple mobile fuel cell technologies and increased demand, hydrogen stations will have to increase output, decrease cost, and improve reliability. To address these challenges, the project team will demonstrate a hydrogen-focused integrated renewable energy production, storage, and transportation fuel distribution/retailing system. The proposed R&D tasks address key challenges related to light duty station/component reliability and development and validation of high flow rate system models for new applications like medium and heavy-duty truck fueling.

08 HYDROGEN↗
DOE OSTI2021

Assessment of Technologies for Improving Light-Duty Vehicle Fuel Economy—2025-2035

From daily commutes to cross-country road trips, millions of light-duty vehicles are on the road every day. The transportation sector is one of the United States’ largest sources of greenhouse gas emissions, and fuel is an important cost for drivers. The period from 2025-2035 could bring the most fundamental transformation in the 100-plus year history of the automobile. Battery electric vehicle costs are likely to fall and reach parity with internal combustion engine vehicles. New generations of fuel cell vehicles will be produced. Connected and automated vehicle technologies will become more common, including likely deployment of some fully automated vehicles. These new categories of vehicles will for the first time assume a major portion of new vehicle sales, while internal combustion engine vehicles with improved powertrain, design, and aerodynamics will continue to be an important part of new vehicle sales and fuel economy improvement.This study is a technical evaluation of the potential for internal combustion engine, hybrid, battery electric, fuel cell, nonpowertrain, and connected and automated vehicle technologies to contribute to efficiency in 2025-2035. In addition to making findings and recommendations related to technology cost and capabilities, Assessment of Technologies for Improving Light-Duty Vehicle Fuel Economy - 2025-2035 considers the impacts of changes in consumer behavior and regulatory regimes.

MARCHANT, GARY↗
DOE OSTI2023

Improved Fuel Cell Chemical Durability of an Heteropoly Acid Functionalized Perfluorinated Terpolymer-Perfluorosulfonic Acid Composite Membrane

Commercial proton exchange membrane heavy-duty fuel cell vehicles will require a five-fold increase in durability compared to current state-of-the art light-duty fuel cell vehicles. We describe a new composite membrane that incorporates silicotungstic heteroply acid (HPA), α -K 8 SiW 11 O 40 ▪13H 2 O, a radical decomposition catalyst and when acid-exchanged can potentially conduct protons. The HPA was covalently bound to a terpolymer of tetrafluoroethylene, vinylidene fluoride, and sulfonyl fluoride containing monomer (1,1,2,2,3,3,4,4-octafluoro-4-((1,2,2-trifluorovinyl)oxy)butane-1-sulfonyl fluoride) by dehydrofluorination followed by addition of diethyl (4-hydroxyphenyl) phosphonate, giving a perfluorosulfonic acid-vinylidene fluoride-heteropoly acid (PFSA-VDF-HPA). A composite membrane was fabricated using a blend of the PFSA-VDF-HPA and the 800EW 3M perfluoro sulfonic acid polymer. The bottom liner-side of the membrane tended to have a higher proportion of HPA moieties compared to the air-side as gravity caused the higher mass density PFSA-VDF-HPA to settle. The composite membrane was shown to have less swelling, more hydrophobic properties, and higher crystallinity than the pure PFSA membrane. The proton conductivity of the membrane was 0.130 ± 0.03 S cm −1 at 80 °C and 95% RH. Impressively, when the membrane with HPA-rich side was facing the anode, the membrane survived more than 800 h under accelerated stress test conditions of open-circuit voltage, 90 °C and 30% RH.

08 HYDROGEN↗
DOE OSTI2026

Operational Simulation of Multi-Functional Charging Station for Sustainable Transportation

As transportation systems move toward electrification and decarbonization, multifunctional charging stations (MFCS) are emerging as key infrastructure for electric vehicles (EVs) and hydrogen fuel cell vehicles (HFCVs). This paper presents a simulation model of an MFCS that integrates solar photovoltaic (PV), wind power, battery storage, hydrogen (\mathrm{H}_{2}) production, dual-pressure \mathrm{H}_{2} storage, fuel cells, and dynamic grid interactions. The model simulates daily operations using 5 -minute resolution data to capture realtime variability in renewable energy (RE), demand, and electricity prices. A flexible dispatch algorithm dynamically allocates energy for EV charging, \mathrm{H}_{2} production, storage, and grid transactions while respecting system constraints. Results show that the MFCS effectively prioritizes RE usage, minimizes waste, meets diverse energy demands, and achieves net operational profit. The model serves as a valuable decision-support tool for designing and optimizing integrated clean energy hubs for zero-emission transportation.

Gbadegoye, Jeremiah [University of Tennessee, Knox↗
DOE OSTI2021

Demonstration of Electrochemically-Driven CO 2 Separation Using Hydroxide Exchange Membranes

Hydroxide exchange membrane fuel cells (HEMFCs) are a potentially lower-cost hydrogen fuel cell technology; however, ambient levels of CO 2 in air significantly reduce HEMFCs’ performance. In this work, we demonstrate an electrochemically-driven CO 2 separator (EDCS) which can be used to remove ambient levels of CO 2 from air upstream of the HEMFC stack in fuel cell vehicles, protecting it from CO 2 -related performance losses. The EDCS operating window was explored for current density, anode flow, and cathode flow with respect to its impact on CO 2 separation performance. Additionally, gas-phase mass transport was improved by selecting flow fields and gas diffusion layers conducive to the EDCS operating regime. The use of a carbon-ionomer interlayer at the cathode was explored and improved CO 2 removal performance from 77.7% to 98.2% at 20 mA cm −2 . An analytical, 1-D model is used to explain the experimental observations and design improvements. A single-cell, 25 cm 2 EDCS using the aforementioned improved design demonstrated greater than 98% CO 2 removal at a cathode flow rate of 1300 sccm for 100 h with 2.7% hydrogen stack consumption.

Matz, Stephanie↗
DOE OSTI2026

Agent-Based Simulation of Price-Demand Dynamics in Multi-Service Charging Station

As the adoption of electric vehicles and hydrogen fuel-cell vehicles grows, understanding how dynamic pricing strategies influence charging and refueling behaviors becomes crucial for optimizing local energy markets. This paper proposes a simulation-based analysis of a hydrogen-electricity integrated charging station that serves both types of vehicles. A multi-agent simulation framework is developed to model the interactions between vehicles and the station, incorporating price- and delay-sensitive behaviors in decision-making. The station can dynamically adjust energy prices, while vehicles optimize their charging or refueling choices based on their utility values. A series of sensitivity analyses are conducted to evaluate how electricity pricing, infrastructure capacity, and waiting behavior impact station performance. Results highlight that moderate electricity prices maximize user participation without sacrificing profit, infrastructure should be right-sized to demand to avoid over- or underutilization, and delay-toleration also affects service outcomes, which may reach the maximum service coverage at the threshold of 45 minutes.

Wang, Xudong [University of Tennessee, Knoxville (↗
DOE OSTI2026

Detailed Simulation Datasets Quantifying U.S. DOE VTO/HFTO R&D Benefits Across Light- to Heavy-Duty Vehicles

For more than 20 years, Argonne National Laboratory’s Vehicle & Mobility Systems Department has assessed how R&D investments by the U.S. Department of Energy’s Transportation Technologies Office and Alternative Fuels and Feedstocks Office affect vehicle energy use and cost. The analyses are performed using Autonomie, Argonne’s full-vehicle simulation tool for energy consumption, performance, and cost. The study covers five time frames ranging from present day through 2050, with more than 30 vehicle classes and applications (10 light duty and >20 medium and heavy duty), as well as six powertrain configurations (conventional, start-stop, hybrid electric vehicle, plug-in hybrid electric vehicle, battery-electric vehicle, and fuel cell electric vehicle) and five fuels (gasoline, diesel, natural gas, hydrogen, and electricity). Low and high technology uncertainty scenarios have been considered to capture a realistic range of outcomes. The resulting datasets include the assumptions used (i.e., efficiency, $/kWh), vehicle-level data (power, energy, weight, and cost), and outputs such as energy consumption, manufacturer’s suggested retail price, and total cost of ownership. These data are critical to stakeholders working in transportation, technology assessment, and long-term R&D planning.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Viability of Vehicles Utilizing On-Board CO 2 Capture

Although battery electric and hydrogen fuel cell vehicles hold great promise for mitigating CO 2 emissions, there are still unaddressed sectors for electrified transport, e.g., the heavy-duty and long-range global shipping industry. In this Viewpoint, we examine the viability of CO 2 -neutral transportation using hydrocarbon or alcohol fuels, in which the CO 2 product is captured on-board the vehicle. This approach takes advantage of the unparalleled energy density of carbon-based fuels as needed for these energy-intensive applications. Here, a concept is developed considering the power technologies, infrastructure, and fuels required. Storage volume and mass requirements are calculated for a wide range of vehicle types and compared with those for other CO 2 -neutral options, namely hydrogen fuel cell and battery electric vehicles, and research and development needs to implement this technology are discussed.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Precursor Processing Development for Low Cost, High Strength Carbon Fiber for Composite Overwrapped Pressure Vessel Applications

Carbon fiber (CF) is central to produce lightweight, high pressure, composite overwrapped pressure vessels (COPVs), which are used for on-board storage of hydrogen for fuel cell vehicles. In 2015, carbon fiber cost accounted for 62% of the cost of a hydrogen storage system, as COPVs were manufactured with T700S CF at $\$ $29.40/kg CF. The high cost of hydrogen storage, largely attributed to the carbon fiber cost, limits the application of fuel cells in vehicles. Therefore, our team endeavored to develop fiber processing to demonstrate carbon fiber tensile properties similar to T700S with a production cost potential of $\$ $12.60/kg or less. Here, the overarching goal of the project was the development of low cost, high strength carbon fiber for composite overwrapped pressure vessels. Within the project, our team investigated a new low-cost, high-volume, high quality polyacrylonitrile (PAN)-based precursor terpolymer for the production of carbon fiber precursors, methods for increasing water and energy use efficiency in wash-water/solvent separation, and ultimately developed a multifilament spinning and conversion process for the production of hollow carbon fibers from a segmented arc spinneret utilizing a solution spinning method.

08 HYDROGEN↗