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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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DOE OSTI2024

Atomically Dispersed Zn/Co–N–C as ORR Electrocatalysts for Alkaline Fuel Cells

Hydrogen fuel cells have drawn increasing attention as one of the most promising next-generation power sources for future automotive transportation. Developing efficient, durable, and low-cost electrocatalysts, to accelerate the sluggish oxygen reduction reaction (ORR) kinetics, is urgently needed to advance fuel cell technologies. Herein, we report on metal–organic frameworks-derived nonprecious dual metal single-atom catalysts (SACs) (Zn/Co–N–C), consisting of Co–N 4 and Zn–N 4 local structures. These catalysts exhibited superior ORR activity with a half-wave potential (E 1/2 ) of 0.938 V versus RHE (reversible hydrogen electrode) and robust stability (ΔE 1/2 = –8.5 mV) after 50k electrochemical cycles. Moreover, this remarkable performance was validated under realistic fuel cell working conditions, achieving a record-high peak power density of ~1 W cm –2 among the reported SACs for alkaline fuel cells. Operando X-ray absorption spectroscopy was conducted to identify the active sites and reveal catalytic mechanistic insights. The results indicated that the Co atom in the Co–N 4 structure was the main catalytically active center, where one axial oxygenated species binds to form an O ads –Co–N 4 moiety during the ORR. In addition, theoretical studies, based on a potential-dependent microkinetic model and core-level shift calculations, showed good agreement with the experimental results and provided insights into the bonding of oxygen species on Co–N 4 centers during the ORR. Furthermore, this work provides a comprehensive mechanistic understanding of the active sites in the Zn/Co–N–C catalysts and will pave the way for the future design and advancement of high-performance single-site electrocatalysts for fuel cells and other energy applications.

25 ENERGY STORAGE↗
DOE OSTI2022

Nonprecious transition metal nitrides as efficient oxygen reduction electrocatalysts for alkaline fuel cells

Hydrogen fuel cells have attracted growing attention for high-performance automotive power but are hindered by the scarcity of platinum (and other precious metals) used to catalyze the sluggish oxygen reduction reaction (ORR). We report on a family of nonprecious transition metal nitrides (TMNs) as ORR electrocatalysts in alkaline medium. The air-exposed nitrides spontaneously form a several-nanometer-thick oxide shell on the conductive nitride core, serving as a highly active catalyst architecture. The most active catalyst, carbon-supported cobalt nitride (Co 3 N/C), exhibited a half-wave potential of 0.862 V and achieved a record-high peak power density among reported nitride cathode catalysts of 700 mW cm –2 in alkaline membrane electrode assemblies. Operando x-ray absorption spectroscopy studies revealed that Co 3 N/C remains stable below 1.0 V but experiences irreversible oxidation at higher potentials. This work provides a comprehensive analysis of nonprecious TMNs as ORR electrocatalysts and will help inform future design of TMNs for alkaline fuel cells and other energy applications.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Design and requirements of a hydrogen component reliability database (HyCReD)

Hydrogen technologies are expected to play a key role in the decarbonization of several sectors including energy storage and transportation. Rigorous investigation and quantification of the risk and reliability issues associated with hydrogen technologies will be critical to ensuring both their wider adoption and safe, economical operations. Quantitative risk assessment (QRA) is an important tool that has been used to enable the safe deployment of many engineering systems, including hydrogen fueling stations and hydrogen storage systems. However, QRA studies require reliability data which is currently lacking for expanding applications of hydrogen systems. Here, to address this gap, we present a new structure for a hydrogen component reliability database (HyCReD) that can be used to generate reliability data to be used in QRA, reliability, safety studies, maintenance planning, and more. Building on our previous work examining four major hydrogen safety data collection tools (West et al., 2022) [1], our approach in this work was to consult scientific literature on reliability data collection as well as a number of existing reliability engineering databases in the oil & gas, chemical processing, and nuclear power plant sectors. The evaluation of these databases led to identifying best practices to be implemented in a data collection framework for a hydrogen component reliability database. Based on these best practices, a set of 24 requirements for the proposed database are presented, covering its characteristics and the types of data to be collected. We define the structure of the HyCReD database and 25 data elements to be collected, spanning system description, failure, shutdown, or near-miss events, and maintenance events. The data elements are then defined according to international standards used in the safety and reliability practice and potential choice lists are provided for each field. Since this database is being piloted for hydrogen fueling stations, a generic station component hierarchy developed by West (2021) [2] is used to standardize system data. Finally, we demonstrate populating the database with information extracted from five narrative reports on hydrogen fueling station incidents.

08 HYDROGEN↗
DOE OSTI2022

Michigan Hydrogen and Fuel Cell Electric Vehicle Deployment Plan: H2 FCEV Roadmap 2022

This report describes a roadmap for hydrogen fuel cell electric vehicles in the state of Michigan. This plan provides links to relevant information to assess, plan, and initiate hydrogen and FCEV deployment to help meet the energy, economic, and environmental goals for the State of Michigan. Policies and incentives that support hydrogen and fuel cell technology will increase deployment, thus increasing production and creating jobs throughout the supply chain. As deployment increases, an economy of scale will develop and manufacturing costs will decline, positioning hydrogen and fuel cell technology to compete more effectively in a global market without incentives. Policies and incentives to purchase and support the deployment of FCEVs, FCEBs, and hydrogen refueling can be coordinated regionally to maintain this advanced clean transportation sector as a global exporter for long-term growth and economic development. Overall, the execution of this plan will maintain Michigan's role as a global showcase for regionally manufactured transportation technology while reducing NOx and CO 2 emissions and as new jobs are created for businesses and industry.

08 HYDROGEN↗
DOE OSTI2024

From Fossil Fuels to Green Mines: Understanding Hydrogen-Shale Interactions for Secure Underground Storage

Hydrogen-powered mining trucks are rapidly gaining traction as a key driver of decarbonization in the mining industry. This surge necessitates a decisive shift towards renewable energy sources, primarily for hydrogen production. However, the inherent intermittency of renewables poses a challenge for continuous operations, demanding efficient storage solutions for hydrogen fuel. Hydrogen, derived from renewables, requires large-scale storage, with underground hydrogen storage (UHS) in depleted oil and gas reservoirs projected to provide this capacity. An impermeable seal (caprock) overlying depleted reservoirs is crucial for preventing leakage and ensuring secure storage. Shale, a potential caprock, has been recognized for its effectiveness in containing natural gas for geological time-periods. This study investigates the impact of hydrogen exposure on the matrix permeability of Marcellus shale, a key factor influencing its sealing capacity. A novel time-resolved approach was employed, measuring matrix permeability after each exposure to understand the dynamic interactions between hydrogen and the shale matrix. Samples were exposed to hydrogen in pressure reactions at realistic reservoir conditions at varying time durations. Preliminary results reveal an initial increase in permeability, while subsequent exposures show a decrease, indicating potential microstructural changes.

08 HYDROGEN↗
DOE OSTI2022

2020 Hydrogen and Fuel Cell Technologies Market Report

This report features summaries of relevant hydrogen and fuel cell activity in 2020, consistent with prior annual reports across applications and sectors. However, 2020 was no ordinary year. Despite pandemic hardships, the hydrogen and fuel cell industry not only stepped up to assist with humanitarian and healthcare efforts but saw continued momentum in several growing market sectors with numerous partnerships, initiatives, and investments. Using hydrogen and fuel cell technologies to provide an environmental and economic pathway to clean, reliable power was a key feature of world economic recovery and energy infrastructure plans. Today, hydrogen energy and fuel cell systems are being developed and deployed in a range of stationary power, portable power, and transportation applications around the world. Throughout 2020, there were significant achievements in each sector, building on years of research and development (R&D), field testing, large-scale demonstration projects, and real-world customer experience. The heavy-duty truck market in particular continued to make substantial gains, with new players entering the space and a coalition of companies pledging to produce and deploy more than 100,000 fuel cell trucks in the next two decades. To provide hydrogen for trucks and other end users, larger and larger electrolyzer projects were announced throughout the year. Collectively, there were more than 430 megawatts (MW) of electrolyzer systems either deployed, ordered, or proposed around the world. This 2020 report also provides special “Spotlights” on the collective industry response to the COVID-19 pandemic as well as international commitments and hydrogen strategies, providing overviews of significant activity during and after the initial onset of COVID-19 around the world.

08 HYDROGEN↗
DOE OSTI2023

The Port of Los Angeles Zero- and Near-Zero-Emission Freight Facilities Shore to Store Project

The City of Los Angeles Harbor Department (Harbor Department, Port of Los Angeles) partnered with Equilon Enterprises LLC (d/b/a Shell Oil Products US) (Shell), Toyota Motor North America (Toyota), and Kenworth Truck Company (Kenworth) partnered with the Port of Hueneme, United Parcel Service, Total Transportation Services Inc., Southern Counties Express, Toyota Logistics Services, Air Liquide, National Renewable Energy Laboratory, Coalition For A Safe Environment, and the South Coast Air Quality Management District to introduce hydrogen fuel into the Southern California drayage truck market by demonstrating near-commercial heavy-duty hydrogen fuel cell electric trucks at and between freight facilities throughout the region, while continuing to lay the groundwork for battery-electric operations. The Shore to Store project built on project team experience to help realize our vision of zero-emission freight operations in the future. Ten Kenworth zero-emission Class 8 fuel cell electric trucks, integrated with Toyota’s fuel cell drive technology, were operated by United Parcel Service, Total Transportation Services Inc., Southern Counties Express, and Toyota Logistics Services in commercial service. The demonstration fleet fueled at the Shore to Store hydrogen fueling stations that were built in Ontario, California, and Wilmington, California. An additional station at the Port of Long Beach (Portal Station) was available for fueling the fleet. Portal Station was supported by grants from the California Energy Commission and South Coast Air Quality Management District and used as match funding for the Shore to Store project. The Port of Hueneme demonstrated two battery-electric yard tractors, and Toyota Logistics Services demonstrated two zero-emission forklifts at their warehouse facility, showcasing elements of the entire supply chain operating with zero emissions. This project showcased a snapshot of the zero-emission supply chain of the future, providing a model by which freight facilities can support zero-emission operations. The Shore to Store project: Demonstrated the technical feasibility of zero-emission hydrogen fueled Class 8 heavy-duty trucks and electric cargo handling equipment in rigorous goods movement operation throughout the Southern California region. Cumulatively completed 59,212 miles of zero-emission operation, with 21,650 miles driven in-service with the fleets, using hydrogen fuel cell electric Class 8 heavy-duty trucks. Operated zero-emission yard tractors for a total of 2,749.6 hours. Created direct localized emission reductions in designated disadvantaged communities, including those in zip codes 90220, 90247, 90248, 90731, 90744, 90802, and 91761. For the 59,212 miles of zero-emission operation, reduced emissions by an estimated total of 15.5 kg NOX (0.163 g/km), 1.01 kg SOX (0.0106 g/km), and 304.8 metric tonnes of CO2e (3.2 kg/km) compared to diesel baseline vehicles including both tailpipe emissions and the emissions from producing the fuel sources.

08 HYDROGEN↗
DOE OSTI2023

Gaseous fuel engine system and operating method for same

Operating a gaseous hydrogen fuel engine includes controlling an injection timing of a gaseous hydrogen fuel injected into a flow of pressurized intake air so as to produce a leading cooling flow of pressurized intake air into a cylinder in an engine, a trailing purging flow through an intake conduit, and a middle flow of both pressurized intake air and gaseous hydrogen fuel into the cylinder. Undesired combustion such as preignition and/or backfire can be limited. Related apparatus and control logic is also disclosed.

Singh, Jaswinder↗
DOE OSTI2021

Vehicle Technologies and Hydrogen and Fuel Cell Technologies Research and Development Programs Benefits Assessment Report for 2020

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. VTO and HFTO regularly revisit and update relevant research and development goals and areas of emphasis in response to the latest technological advancements and in alignment with current national priorities. As such, analyses of expected benefits resulting from VTO and HFTO investments and anticipated goal achievements are updated periodically and will be again for 2021 in the context of the latest national-level transportation decarbonization goals. The analysis in the present report is based on technical progress goals established in VTO and HFTO in the years immediately prior to and including 2020, and it summarizes the estimated energy and emissions benefits corresponding to achievement of those goals. The goals span research activities on batteries, electric drive technologies (EDT), combustion, lightweight materials, fuel cells, and hydrogen storage. The evaluation includes detailed analyses into the benefits of technology improvements on the U.S. light-duty (LD) vehicle fleet and separately on the U.S. medium- and heavy-duty (MDHD) vehicle fleet. This report summarizes the outcomes from each of these analyses both independently and in combination.

08 HYDROGEN↗
DOE OSTI2025

Cybersecurity Considerations for Hydrogen Infrastructure in Airport Environments

This report explores key cybersecurity concerns and best practices within environments that serve as reference points for the development of hydrogen fueling infrastructure for aviation. This cybersecurity analysis leverages prior NREL studies: 1) hydrogen fueling station component validation to identify vulnerabilities and failure events documented in physical equipment, and 2) electric aircraft charging infrastructure analysis to explore primary cybersecurity vulnerabilities. It reviews the criticality of digitized technologies in sustaining hydrogen fuel production, storage, and fueling systems, noting cybersecurity concerns that are universal to power systems and industrial control systems in general. In considering cybersecurity vulnerabilities within a future landscape of hydrogen energy for aviation applications, a reference architecture was intended to reveal the points of connection between assets and the potential sensors that are vulnerable to manipulation in the event of compromised access or communication within a SCADA system. A generalized reference architecture can help stakeholders, engineers, or strategists understand connections, criticalities, and standard practices when it comes to designing and planning for new systems. There are several gaps to account for in assessing the future of hydrogen production, storage, and fueling for aviation. Engaging stakeholders, including aircraft manufacturers, electric utilities, site property owners, and local communities, will inform decision-making around site structure, operations, and resources for future hydrogen fueling infrastructure to understand operational needs and cybersecurity awareness. Cybersecurity mitigation strategy must consider physical attack vectors that emerge with the integration of hydrogen systems into existing airport security requirements. The cybersecurity risk assessment contained in this report is an entry point into potential future granular-level analyses to be conducted as part of hazard and risk assessments for safe aviation hydrogen infrastructure, determining how the scale of hydrogen fuel infrastructure for aviation impacts the volume of cyber attack vectors, and what, if any, are the vulnerabilities associated with different types of on-board hydrogen systems. In this nascent development phase, assessing how best to integrate cybersecurity practices into an evolving U.S. aviation landscape provides critical insights into building increased awareness and stakeholder engagement to support a cyber-resilient infrastructure.

08 HYDROGEN↗
DOE OSTI2022

In Situ Nanoscale Dynamics Imaging in a Proton‐Conducting Solid Oxide for Protonic Ceramic Fuel Cells

Abstract Hydrogen fuel cells and electrolyzers operating below 600 °C, ideally below 400 °C, are essential components in the clean energy transition. Yttrium‐doped barium zirconate BaZr 0.8 Y 0.2 O 3‐d (BZY) has attracted a lot of attention as a proton‐conducting solid oxide for electrochemical devices due to its high chemical stability and proton conductivity in the desired temperature range. Grain interfaces and topological defects modulate bulk proton conductivity and hydration, especially at low temperatures. Therefore, understanding the nanoscale crystal structure dynamics in situ is crucial to achieving high proton transport, material stability, and extending the operating range of proton‐conducting solid oxides. Here, Bragg coherent X‐ray diffractive imaging is applied to investigate in situ and in 3D nanoscale dynamics in BZY during hydration over 40 h at 200 °C, in the low‐temperature range. An unexpected activity of topological defects and subsequent cracking is found on a nanoscale covered by the macroscale stability. The rearrangements in structure correlate with emergent regions of different lattice constants, suggesting heterogeneous hydration. The results highlight the extent and impact of nanoscale processes in proton‐conducting solid oxides, informing future development of low‐temperature protonic ceramic electrochemical cells.

25 ENERGY STORAGE↗
DOE OSTI2026

Multiphysics and Multiscale Simulation Methods for Electromagnetic Energy Assisted Fossil Fuel to Hydrogen Conversion (Final Scientific/Technical Report)

This report summarizes the technical accomplishments of the four-year research project “Multiphysics and Multiscale Simulation Methods for Electromagnetic Energy Assisted Fossil Fuel to Hydrogen Conversion” (Award No. DE-FE0032092), conducted at Howard University and the University of Houston (subawardee) from September 2021 to August 2025. The project successfully achieved all four major objectives: 1. 3D Structural Characterization – Developed 3D optical imaging and mechanical sectioning methods to characterize catalyst distribution and support morphology in nickel foam substrates. Successfully reconstructed 3D geometries and imported them into COMSOL Multiphysics for electromagnetic simulations. 2. EM Hotspot Simulation – Created all-frequency stable electromagnetic formulations and 3D nodal discontinuous Galerkin (NDG) methods for coupled electromagnetic-thermal-fluid problems in multiscale catalytic media. Demonstrated stable solutions from DC to microwave frequencies. 3. Multiphysics Coupling – Developed multiscale simulation methods coupling FEM electromagnetic solvers with thermal transport equations. Reactive molecular dynamics (ReaxFF MD) simulations were performed to investigate catalytic reaction mechanisms at the atomistic level. Demonstrated electromagnetic-thermal co-simulation capabilities for porous catalyst structures. 4. System Optimization – Designed and optimized EM-assisted catalytic systems using nickel foam and carbon foam structures, demonstrating significant temperature increases due to microwave heating. Observed and characterized plasma generation in carbon fiber catalysts. Investigated multiple reaction chamber geometries for improved microwave energy deposition. The project produced significant scientific contributions including 15+ peer-reviewed publications, trained multiple Ph.D. students and undergraduate researchers, and advanced the understanding of microwave-assisted hydrogen production from fossil fuels.

08 HYDROGEN↗
DOE OSTI2020

U.S. Department of Energy Hydrogen and Fuel Cells Program: 2019 Annual Merit Review and Peer Evaluation Report; April 29 - May 1, 2019, Arlington, Virginia

The fiscal year 2019 U.S. Department of Energy (DOE) Hydrogen and Fuel Cells Program Annual Merit Review and Peer Evaluation Meeting (AMR) was held from April 29 to May 1, 2019, in Arlington, Virginia. This report is a summary of comments by AMR peer reviewers about the hydrogen and fuel cell projects funded by DOE's Office of Energy Efficiency and Renewable Energy.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2023

Thermodynamic parametric analysis of refueling heavy-duty hydrogen fuel-cell electric vehicles

Reliable design and safe operation of heavy-duty hydrogen refueling stations are essential for the successful deployment of heavy-duty fuel cell electric vehicles (FCEVs). Fueling heavy-duty FCEVs is different from light-duty vehicles in terms of the dispensed hydrogen quantities and fueling rates, requiring tailored fueling station design for each vehicle class. In particular, the selection and design of the onboard hydrogen storage tank system and the fueling performance requirements influence the safe design of hydrogen fueling stations. A thermodynamic modeling and analysis are performed to evaluate the impact of various fueling parameters and boundary conditions on the fueling performance of heavy-duty FCEVs. Here, we studied the effect of dispenser pressure ramp rate and precooling temperature, initial tank temperature and pressure, ambient temperature, and onboard storage design parameters, such as onboard storage pipe diameter and length, on the fueling rate and final vehicle state-of-charge, while observing prescribed tank pressure and temperature safety limits. An important finding was the sensitivity of the temporal fueling rate profile and the final tank state of charge to the design factors impacting pressure drop between the dispenser and vehicle tank, including onboard storage pipe diameter selection, and flow coefficients of nozzle, valves, and fittings. The fueling rate profile impacts the design and cost of the hydrogen precooling unit upstream of the dispenser.

08 HYDROGEN↗
DOE OSTI2023

Gaseous fuel engine and operating strategy for limiting preignition in prechamber sparkplug

Operating a gaseous fuel engine system includes spark-igniting a gaseous hydrogen fuel and air in a prechamber sparkplug to ignite a main charge containing gaseous hydrogen fuel and air in a cylinder. Operating the gaseous fuel engine system also includes determining a preignition condition and conveying cooling air to the prechamber sparkplug based on the preignition condition to limit preignition of gaseous hydrogen fuel and air in the prechamber sparkplug. Related apparatus and control logic is also disclosed.

Singh, Jaswinder↗