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Fuel cell technology program contract summary report

A fuel cell technology program which was established to advance the state-of-the-art of hydrogen-oxygen fuel cells using the P and WA PC8B technology as the base is reported. The major tasks of this program consisted of (1) fuel cell system studies of a space shuttle powerplant conceptual design (designated engineering model -1, EM-1) supported by liaison with the space shuttle prime contractors; (2) component and subsystem technology advancement and; (3) a demonstrator powerplant test. Fuel cell system studies, with the EM-1 as the focal point of design activities, included determination of voltage regulation, specific reactant consumption, weight, voltage level and performance characteristics. These studies provided the basis for coordination activities with the space shuttle vehicle prime contractor. Interface information, on-board checkout and in-flight monitoring requirements, and development cost data were also provided as part of this activity. Even though the two vehicles primes had different voltage requirements (115 volts in one case and 28 volts in the other), it was concluded that either option could be provided in the fuel cell power system by the electrical hook-up of the cells in the stack.

Source record↗

Light-Duty Vehicle Choice Modeling and Benefits Analysis

The U.S. Department of Energy's Vehicle Technologies and Hydrogen and Fuel Cell Technologies Offices (VTO and HFTO) support research and development of efficient and sustainable transportation technologies that will improve energy efficiency, minimize emissions, and enable America to use less petroleum. This presentation steps through the approach, updates to the approach, and preliminary estimates of light-duty vehicle energy and emissions benefits from the continuation and success of VTO and HFTO programs. The programs include research on batteries, electric drive technologies (EDT), combustion, materials, fuel cells, and hydrogen storage. Preliminary results for battery and EDT program success show an annual 24% reduction in petroleum use and 13% reduction in carbon emissions.

47 OTHER INSTRUMENTATION↗

Nuclear Energy for Economy-wide Net Zero Solutions: Advancing Nuclear-Hydrogen Production

This presentation was prepared for the Canadian Standards Association Virtual Seminar on Hydrogen Production using Nuclear Energy, held on February 15, 2022. The presentation introduces the US DOE program on Integrated Energy Systems and provides an overview of the Light Water Reactor Sustainability projects to demonstrate hydrogen production at operating nuclear plants in the US.

08 HYDROGEN↗

Hydrogen adsorption and desorption at the Pt(110)-(1×2) surface: experimental and theoretical study

The interaction of hydrogen with the Pt(110)-(1×2) surface is studied using temperature programmed desorption (TPD) measurements and density functional theory (DFT) calculations. The ridges in this surface resemble edges between micro-facets of Pt nano-particle catalysts used for hydrogen evolution (HER) and hydrogen oxidation reactions (HOR). The binding energy and activation energy for desorption are found to depend strongly on hydrogen coverage. At low coverage, the strongest binding sites are found to be the low coordination bridge sites at the edge and this is shown to agree well with the He-atom interaction and work function change which have been reported previously. At higher hydrogen coverage, the higher coordination sites on the micro-facet and in the trough get populated. The simulated TPD spectra based on the DFT results are in close agreement with our experimental spectra and provide microscopic interpretation of the three measured peaks. The lowest temperature peak obtained from the surface with highest hydrogen coverage does not correspond to desorption directly from the weakest binding sites, the trough sites, but is due to desorption from the ridge sites, followed by subsequent, thermally activated rearrangement of the H-adatoms. The reason is low catalytic activity of the Pt-atoms at the trough sites and large reduction in the binding energy at the ridge sites at high coverage. The intermediate temperature peak corresponds to desorption from the micro-facet. The highest temperature peak again corresponds to desorption from the ridge sites, giving rise to a re-entrant mechanism for the thermal desorption.

Gudmundsdóttir, Sigrídur↗

Recombination of Hydrogen in the Iodine Reactors

The H-Canyon facility is currently dissolving spent nuclear fuel, including Material Test Reactor (MTR) and High Flux Isotope Reactor (HFIR) fuel. Dissolution of aluminum spent nuclear fuel produces hydrogen and other NOx gases. A theory long held by H-Canyon Engineering and Facility Technical Advisors that the silver nitrate-coated berl saddles, present in the iodine reactor, used for off-gas treatment were acting as a catalytic hydrogen recombiner was captured during an external review of the Accelerated Basin Deinventory program. Results from a separate SRNL project using a Raman Spectrometer to monitor the offgas from the dissolution process indicated a lack of the expected hydrogen in the off-gas stream. To test this hypothesis, a laboratory scale iodine reactor was assembled and filled with silver nitrate-coated berl saddles. Testing with this laboratory scale reactor confirmed the recombination of hydrogen when a simulated dissolver off-gas was passed through the reactor containing silver nitrate-coated berl saddles at 173-188 °C. Control experiments performed with uncoated berl saddles resulted in no change to the hydrogen concentration after passing through the reactor. The residence time of the gas in the reactor was varied to determine if residence time had an impact on the amount of hydrogen recombination occurring. Results from these experiments indicated that at the shortest residence times tested (~5 seconds) recombination of the hydrogen still exceeded 90%; however, the percent recombination did increase at longer residence times, reaching 97.9% or greater for residence times over 10 seconds. Finally, testing performed with a simplified off-gas composition containing only hydrogen and air gave similar results, indicating that the presence of NO and N 2 O gases in the stream do not play a role in the recombination reaction.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Conformable, Composite Tank for Liquid Hydrogen Storage in Heavy-duty Ground Transportation

Raytheon Technologies Research Center (RTRC), with its partners, Argonne National Labs and University of Dayton Research Institute proposed to design and manufacture a conformable composite tank prototype to store liquid Hydrogen (LH2) for heavy-duty truck applications. A dual-wall tank concept was proposed where an outer shell covers and protects an inner pressure vessel that stores liquid hydrogen. The inner pressure vessel is liner-less and designed with a conformable concept, derived from prior RTRC ARPA-E program where multiple vessels are coalesced into one, maximizing space utilization and reducing surface area for heat leak. The gap between the dual wall is evacuated of air pressure, and filled with multi-layer insulation to minimize radiative heat transfer. Fiber reinforced composites were proposed for light-weighting and conformable shape manufacture. To minimize LH2 leakage, carbon nanotubes-infused composites were proposed, in addition to use of thin plies. The project was divided into two 18-month budget periods (BP), BP1 and BP2, separated by a Go/No-Go gate review. The high-level goal for BP1 was to demonstrate the feasibility of the overall approach, the tank design, material selection, and manufacturing methodology, build and test a prototype tank; and the goal for BP2 was to design and manufacture a conformal tank per DOE requirements (minimum 20 kg of LH2) and perform a successful test of the tank. The program was terminated about two-thirds of the way through BP1. The outcome of this program would have permitted long-haul trucks and construction vehicles to use liquid Hydrogen, reducing the emission of green-house gases. This technology is applicable to other transportation sectors as well.

08 HYDROGEN↗

Axisymmetric reacting gas nonequilibrium performance program

Computer program calculates the inviscid one-dimensional equilibrium, frozen, and nonequilibrium nozzle expansion of propellant exhaust mixtures containing these six elements - carbon, hydrogen, oxygen, nitrogen, fluorine, and chlorine plus either aluminum, beryllium, boron or lithium. This program will perform calculations for contoured and conical nozzles.

Kliegel, J. R.↗

Vehicle Technologies and Fuel Cell Technologies Program: Prospective Benefits Assessment Report for Fiscal Year 2016

Under a diverse set of programs, the Vehicle Technologies and Fuel Cell Technologies offices of DOE’s Office of Energy Efficiency and Renewable Energy invest in research, development, demonstration, and deployment of advanced vehicle, hydrogen production, delivery and storage, and fuel cell technologies. This report estimates the benefits of successfully developing and deploying these technologies (a “Program Success” case) relative to a base case (the “No Program” case). The Program Success case represents the future with completely successful deployment of Vehicle Technologies Office (VTO) and Fuel Cell Technologies Office (FCTO) technologies. The No Program case represents a future in which there is no contribution after FY 2016 by the VTO or FCTO to these technologies. The benefits of advanced vehicle, hydrogen production, delivery and storage, and fuel cell technologies were estimated on the basis of differences in fuel use, primary energy use, and greenhouse gas (GHG) emissions from light-, medium- and heavy-duty vehicles, including energy and emissions from fuel production, between the base case and the Program Success case. Improvements in fuel economy of various vehicle types, growth in the stock of fuel cell vehicles and other advanced technology vehicles, and decreased GHG intensity of hydrogen production and delivery in the Program Success case over the No Program case were projected to result in savings in petroleum use and GHG emissions. Benefits were disaggregated by individual program technology areas, which included the FCTO program and the VTO subprograms of batteries and electric drives; advanced combustion engines; fuels and lubricants; materials (for reduction in vehicle mass, or “lightweighting”); and, for medium- and heavy-duty vehicles, reduction in rolling and aerodynamic resistance. Projections for the Program Success case indicate that by 2035, the average fuel economy of on-road, light-duty vehicle stock could be 47% to 76% higher than in the No Program case. On-road medium- and heavy-duty vehicle stock could be as much as 39% higher. The resulting petroleum savings in 2035 were estimated to be as high as 3.1 million barrels per day, and reductions in GHG emissions were estimated to be as high as 500 million metric tons of CO2 equivalent per year. The benefits of continuing to invest government resources in advanced vehicle and fuel cell technologies would have significant economic value in the U.S. transportation sector and reduce its dependency on oil and its vulnerability to oil price shocks.

33 ADVANCED PROPULSION SYSTEMS↗

Hydrogen Generation at the ARM Utqiagvik Site

Sandia National Laboratories/New Mexico (SNL/NM Atmospheric Sciences Department 8863 operates the ARM site at Utqiagvik, Alaska as part of the DOE Office of Science Atmospheric Radiation Measurement (ARM) research program. This TWD identifies the hazards, control measures, required training, and procedure for Hydrogen Generation at the Utqiagvik site.

54 ENVIRONMENTAL SCIENCES↗

Catalytic ignition of hydrogen/oxygen

An experimental program was conducted to evaluate the catalytic ignition of gaseous hydrogen and oxygen. Shell 405 granular catalyst and a unique monolithic sponge catalyst were tested. Mixture ratio, mass flow rate, propellant inlet temperature, and back pressure were varied parametrically in testing to determine the operational limits of a catalytic igniter. The test results showed that the gaseous hydrogen/oxygen propellant combination can be ignited catalytically using Shell 405 catalyst over a wide range of mixture ratios, mass flow rates, and propellant injection temperatures. These operating conditions must be optimized to ensure reliable ignition for an extended period of time. The results of the experimental program and the established operational limits for a catalytic igniter using both the granular and monolithic catalysts are presented. The capabilities of a facility constructed to conduct the igniter testing and the advantages of a catalytic igniter over other ignition systems for gaseous hydrogen and oxygen are also discussed.

Green, James M.↗

Advanced space engine component technology status

Key to the achievement of maximum benefit from the Space Tug transportation system is the availability of a low-cost, high-performance engine system. To define this engine system, studies have been conducted under Air Force and NASA direction, and pertinent hardware technology programs have been initiated. From among the several candidate systems studied, the cryogenic, staged-combustion cycle, high chamber pressure system in conjunction with a large-area-ratio nozzle was selected for component and subsystem demonstration. Main turbopump, high-area-ratio thrust chamber, preburner, and igniter components are being evaluated. A brief description of the engine capabilities, the main liquid hydrogen and liquid oxygen turbopump/preburner, and the main thrust chamber programs are presented; designs and progress in fabrication are shown and test results discussed.

Zachary, A. T.↗

Lifecycle Verification of Tank Liner Polymers

This report describes a method that was developed for the purpose of assessing the durability of thermoplastic liners used in a Type IV hydrogen storage tank during the tank s expected service life. In the method, a thermoplastic liner specimen is cycled between the maximum and minimum expected working temperatures while it is differentially pressurized with high-pressure hydrogen gas. The number of thermal cycling intervals corresponds to those expected within the tank s design lifetime. At prescribed intervals, hydrogen permeation measurements are done in situ to assess the ability of the liner specimen to maintain its hydrogen barrier properties and to model its permeability over the tank lifetime. Finally, the model is used to assess whether the steady-state leakage rate in the tank could potentially exceed the leakage specification for hydrogen fuel cell passenger vehicles. A durability assessment was performed on a specimen of high-density polyethylene (HDPE) that is in current use as a tank liner. Hydrogen permeation measurements were performed on several additional tank liner polymers as well as novel polymers proposed for use as storage tank liners and hydrogen barrier materials. The following technical barriers from the Fuel Cell Technologies Program MYRDD were addressed by the project: D. Durability of on-board storage systems lifetime of at least 1500 cycles G. Materials of construction vessel containment that is resistant to hydrogen permeation M. Lack of Tank Performance Data and Understanding of Failure Mechanisms And the following technical targets1 for on-board hydrogen storage systems R&D were likewise addressed: Operational cycle life (1/4 tank to full) FY 2017: 1500 cycles; Ultimate: 1500 cycles Environmental health & safety Permeation and leakage: Meets or exceeds applicable standards Loss of useable H2: FY 2017: 0.05 g/h/kg H2; Ultimate: 0.05 g/h/kg H2

hydrogen permeation polymer temperature cycling du↗

Development of advanced fuel cell system, phase 2

A multiple task research and development program was performed to improve the weight, life, and performance characteristics of hydrogen-oxygen alkaline fuel cells for advanced power systems. Development and characterization of a very stable gold alloy catalyst was continued from Phase I of the program. A polymer material for fabrication of cell structural components was identified and its long term compatibility with the fuel cell environment was demonstrated in cell tests. Full scale partial cell stacks, with advanced design closed cycle evaporative coolers, were tested. The characteristics demonstrated in these tests verified the feasibility of developing the engineering model system concept into an advanced lightweight long life powerplant.

Handley, L. M.↗

NASA/General Electric broad-specification fuels combustion technology program

The NASA/General Electric Broad Specification Fuels Combustion Technology Program is being conducted to evolve and demonstrate the technology required to use broadened-properties fuels in current and next generation commercial aircraft engines. The first phase of this program, completed in 1982, involved the design and test evaluation of three different combustor concepts. All combustors were designed for the General Electric CF6-80A engine envelope and operating conditions, using Experimental Referee Broad Specification (ERBS) fuel having a fuel hydrogen content of 12.8% by weight. Several different configurations of each combustor concept were evaluated in a series of high pressure sector combustor component tests. A total of 25 sector tests were conducted during phase 1. Combustor metal temperatures, emissions, exit temperature profiles, and radiant heat flux were measured over the full range of steady-state operating conditions using four fuels having nominal hydrogen contents between 11.8 and 14%. During the current phase 2 program, the two most promising concepts from phase 1 are being further refined and evaluated. For phase 2 testing, two additional fuels representing a wider range of fluidity and volatility are also being used in combustion system tests.

Dodds, W. J.↗

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.↗

California Power-to-Gas and Power-to-Hydrogen Near-Term Business Case Evaluation

Flexible operation of electrolysis systems represents an opportunity to reduce the cost of hydrogen for a variety of end-uses while also supporting grid operations and thereby enabling greater renewable penetration. California is an ideal location to realize that value on account of growing renewable capacity and markets for hydrogen as a fuel cell electric vehicle (FCEV) fuel, refineries, and other end-uses. Shifting the production of hydrogen to avoid high cost electricity and participation in utility and system operator markets along with installing renewable generation to avoid utility charges and increase revenue from the Low Carbon Fuel Standard (LCFS) program can result in around $2.5/kg (21%) reduction in the production and delivery cost of hydrogen from electrolysis. This reduction can be achieved without impacting the consumers of hydrogen. Additionally, future strategies for reducing hydrogen cost were explored and include lower cost of capital, participation in the Renewable Fuel Standard program, capital cost reduction, and increased LCFS value. Each must be achieved independently and could each contribute to further reductions. Using the assumptions in this study found a 29% reduction in cost if all future strategies are realized. Flexible hydrogen production can simultaneously improve the performance and decarbonize multiple energy sectors. The lessons learned from this study should be used to understand near-term cost drivers and to support longer-term research activities to further improve cost effectiveness of grid integrated electrolysis systems.

33 ADVANCED PROPULSION SYSTEMS↗

California-Specific Power-to-Hydrogen and Power-to-Gas Business Case Evaluation

Flexible operation of electrolysis systems represents an opportunity to reduce the cost of hydrogen for a variety of end-uses while also supporting grid operations and thereby enabling greater renewable penetration. California is an ideal location to realize that value on account of growing renewable capacity and markets for hydrogen as a fuel cell electric vehicle (FCEV) fuel, refineries, and other end-uses. Shifting the production of hydrogen to avoid high cost electricity and participation in utility and system operator markets along with installing renewable generation to avoid utility charges and increase revenue from the Low Carbon Fuel Standard (LCFS) program can result in around $2.5/kg (21%) reduction in the production and delivery cost of hydrogen from electrolysis. This reduction can be achieved without impacting the consumers of hydrogen. Additionally, future strategies for reducing hydrogen cost were explored and include lower cost of capital, participation in the Renewable Fuel Standard program, capital cost reduction, and increased LCFS value. Each must be achieved independently and could each contribute to further reductions. Using the assumptions in this study found a 29% reduction in cost if all future strategies are realized. Flexible hydrogen production can simultaneously improve the performance and decarbonize multiple energy sectors. The lessons learned from this study should be used to understand near-term cost drivers and to support longer-term research activities to further improve cost effectiveness of grid integrated electrolysis systems.

30 DIRECT ENERGY CONVERSION↗

Liquid hydrogen and liquid oxygen feedline passive recirculation analysis

The primary goal of the National Launch System (NLS) program was to design an operationally efficient, highly reliable vehicle with minimal recurring launch costs. To achieve this goal, trade studies of key main propulsion subsystems were performed to specify vehicle design requirements. These requirements include the use of passive recirculation to thermally condition the liquid hydrogen (LH2) and liquid oxygen (LO2) propellant feed systems and Space Transportation Main Engine (STME) fuel pumps. Rockwell International (RI) proposed a joint independent research and development (JIRAD) program with Marshall Space Flight Center (MSFC) to study the LH2 feed system passive recirculation concept. The testing was started in July 1992 and completed in November 1992. Vertical and sloped feedline designs were used. An engine simulator was attached at the bottom of the feedline. This simulator had strip heaters that were set to equal the corresponding heat input from different engines. A computer program is currently being used to analyze the passive recirculation concept in the LH2 vertical feedline tests. Four tests, where the heater setting is the independent variable, were chosen. While the JIRAD with RI was underway, General Dynamics Space Systems (GDSS) proposed a JIRAD with MSFC to explore passive recirculation in the LO2 feed system. Liquid nitrogen (LN2) is being used instead of LO2 for safety and economic concerns. To date, three sets of calibration tests have been completed on the sloped LN2 test article. The environmental heat was calculated from the calibration tests in which the strip heaters were turned off. During the LH2 testing, the environmental heat was assumed to be constant. Therefore, the total heat was equal to the environmental heat flux plus the heater input. However, the first two sets of LN2 calibration tests have shown that the environmental heat flux varies with heater input. A Systems Improved Numerical Differencing Analyzer and Fluid Integrator (SINDA/FLUINT) model is currently being built to determine if this variation in environmental heat is due to a change in the wall temperature. During the third set of calibration tests, a faulty reference junction was found. Based on this anomaly with the reference junction, the heat flux calculations from the first two calibration sets are now considered questionable.

Holt, Kimberly Ann↗