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All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Smart Composite Pressure Vessels (SCPV) with Integrated Health Monitoring

The U.S. Department of Energy (DOE) is promoting and developing more energy efficient and environmentally friendly technologies that will enable America to use less petroleum. Hydrogen fuel cells – which directly convert the chemical energy in hydrogen to electricity with only water and heat as byproducts – are a very attractive solution that can enable this to happen. To date, DOE's efforts have culminated in commercial demonstration of on-board vehicular hydrogen storage systems that can allow for a driving range of greater than 300 miles. This requires storing 5 Kgs of hydrogen onboard a light vehicle. In order to store this quantity of hydrogen, the hydrogen gas needs to be stored in a composite overwrapped pressure vessel (COPV) at a very high internal pressure. The objective of the program was to demonstrate continuous and predictable health-monitoring of composite pressure vessels. A higher confidence in the operational safety of the vessels will lead to reduced burst factor of safety imposed by regulatory standards and hence will help reduce the structural wall thickness that drives the cost of the vessel. Highly optimized Type III (metal lined) and Type IV (polymer lined) COPVs that are manufactured using filament winding process have been designed and qualified for the above mentioned application. However, the main structural component of the COPVs is carbon fiber and the high cost of carbon fiber composite in a pressure vessel is a primary challenge in reducing the cost of gaseous hydrogen storage. Continuous and remote monitoring of structural health of the COPVs as well as optimization of the strength translation of carbon fibers have the potential to allow for reduced factor of safety, thereby reduced amount of carbon and associated cost of the vessel. In the current program, the project team including Steelhead Composites (SHC), University of Tennessee, Knoxville (UTK), Teijin Carbon America, Oak Ridge National Laboratory (ORNL) and LUNA designed, fabricated, and tested smart composite pressure vessels with integrated sensors. Iterative loops of design and testing using coupons, subscale STEB vessels and full size vessels proved that a new generation of high performance carbon fiber can be used for efficient design of Type 3 vessels for H2 storage. Novel analysis techniques were developed to predict the initiation and propagation of interlaminar damage inside the composite shell due to impact damage, a real threat in practical operation. Such an analysis scheme is typically not used in tank design but is an essential tool for health monitoring of composite vessels. Remote sensing of the key signatures of the tank’s operating parameters such as pressure, acceleration and humidity was demonstrated using a unique device that can wirelessly transmit and stream the data to a remote server. Fiber optic sensors were successfully integrated during fabrication of the tanks. These sensors provide a wealth of information regarding the structural health of the vessel when it is subsequently pressurized or subjected to impact damage. Excellent correlation was demonstrated between the fiber optic sensor and mechanical strain gage data, and between the measurements and analytical predictions.

08 HYDROGEN↗
DOE OSTI2023

Achieving Economy-wide Net-Zero Solutions: The Essential Role of Nuclear Energy

The Biden administration has committed to full decarbonization of the U.S. electricity grid by 2035 and economy-wide net zero emissions by 2050. These aggressive goals demand immediate action if we are to be successful, and they require us to think more holistically about our clean energy options. Programs within the Department of Energy are addressing these holistic solutions. Traditionally, electricity generation and management and meeting energy demands for industry and transportation are considered independently. As we seek to achieve net zero, we need to reassess our energy demands. When we consider overall energy use, only one-third is in the form of electricity. Additional energy demands are in the form of heat or steam for industrial processes, as well as transportation. These sectors are much harder to abate, and electrification may not be the best option. Reducing environmental emissions at an affordable cost, while maintaining grid reliability and resilience, will require us to use all of the clean energy resources that we have available. That means coordinating the use of nuclear, renewables, and fossil fuels with carbon capture to meet growing demands for electricity, industrial applications, and mobility. Various energy applications and product streams beyond electricity are being evaluated, ranging from generation of potable water to production of hydrogen, fertilizers, synthetic fuels, and various chemicals. This presentation will highlight advanced nuclear technologies under development today and will provide a glimpse into the wide array of R&D being conducted across multiple DOE-funded programs.

08 HYDROGEN↗
DOE OSTI2013

Overview of the U.S. DOE Accident Tolerant Fuel Development Program

The United States Fuel Cycle Research and Development Advanced Fuels Campaign has been given the responsibility to conduct research and development on enhanced accident tolerant fuels with the goal of performing a lead test assembly or lead test rod irradiation in a commercial reactor by 2022. The Advanced Fuels Campaign has defined fuels with enhanced accident tolerance as those that, in comparison with the standard UO2-Zircaloy system currently used by the nuclear industry, can tolerate loss of active cooling in the reactor core for a considerably longer time period (depending on the LWR system and accident scenario) while maintaining or improving the fuel performance during normal operations and operational transients, as well as design-basis and beyond design-basis events. This paper provides an overview of the FCRD Accident Tolerant Fuel program. The ATF attributes will be presented and discussed. Attributes identified as potentially important to enhance accident tolerance include reduced hydrogen generation (resulting from cladding oxidation), enhanced fission product retention under severe accident conditions, reduced cladding reaction with high-temperature steam, and improved fuel-cladding interaction for enhanced performance under extreme conditions. To demonstrate the enhanced accident tolerance of candidate fuel designs, metrics must be developed and evaluated using a combination of design features for a given LWR design, potential improvements to that design, and the design of an advanced fuel/cladding system. The aforementioned attributes provide qualitative guidance for parameters that will be considered for fuels with enhanced accident tolerance. It may be unnecessary to improve in all attributes and it is likely that some attributes or combination of attributes provide meaningful gains in accident tolerance, while others may provide only marginal benefits. Thus, an initial step in program implementation will be the development of quantitative metrics. A companion paper in these proceedings provides an update on the status of establishing these quantitative metrics for accident tolerant LWR fuel.1 The United States FCRD Advanced Fuels Campaign has embarked on an aggressive schedule for development of enhanced accident tolerant LWR fuels. The goal of developing such a fuel system that can be deployed in the U.S. LWR fleet in the next 10 to 20 years supports the sustainability of clean nuclear power generation in the United States.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2015

Large Eddy Simulation Modeling of Flashback and Flame Stabilization in Hydrogen-Rich Gas Turbines Using a Hierarchical Validation Approach

This project was a combined computational and experimental effort to improve predictive capability for boundary layer flashback of premixed swirl flames relevant to gas-turbine power plants operating with high-hydrogen-content fuels. During the course of this project, significant progress in modeling was made on four major fronts: 1) use of direct numerical simulation of turbulent flames to understand the coupling between the flame and the turbulent boundary layer; 2) improved modeling capability for flame propagation in stratified pre-mixtures; 3) improved portability of computer codes using the OpenFOAM platform to facilitate transfer to industry and other researchers; and 4) application of LES to flashback in swirl combustors, and a detailed assessment of its capabilities and limitations for predictive purposes. A major component of the project was an experimental program that focused on developing a rich experimental database of boundary layer flashback in swirl flames. Both methane and high-hydrogen fuels, including effects of elevated pressure (1 to 5 atm), were explored. For this project, a new model swirl combustor was developed. Kilohertz-rate stereoscopic PIV and chemiluminescence imaging were used to investigate the flame propagation dynamics. In addition to the planar measurements, a technique capable of detecting the instantaneous, time-resolved 3D flame front topography was developed and applied successfully to investigate the flow-flame interaction. The UT measurements and legacy data were used in a hierarchical validation approach where flows with increasingly complex physics were used for validation. First component models were validated with DNS and literature data in simplified configurations, and this was followed by validation with the UT 1-atm flashback cases, and then the UT high-pressure flashback cases. The new models and portable code represent a major improvement over what was available before this project was initiated.

42 ENGINEERING↗
DOE OSTI2011

Fuel cell collaboration in the United States. A report to the Danish Partnership for Hydrogen and Fuel Cells

The purpose of this report is to provide members of the Danish Partnership for Hydrogen and Fuel Cells with information regarding collaborative opportunities in the United States. The report is designed to provide an overview of key issues and activities and to provide guidance on strategies for finding U.S. research and commercial partners and gaining access to the U.S. market. Section 1 of this report provides an overview of the key drivers of policy at the federal and state government levels regarding hydrogen and fuel cell technologies and provides a perspective of the U.S. industry and key players. It also suggests three general pathways for accessing U.S. opportunities: enhancing visibility; developing vendor relationships; and establishing a formal presence in the U.S. The next sections summarize focus areas for commercial and research activity that currently are of the greatest interest in the U.S. Section 2 describes major programs within the federal government and national laboratories, and discusses various methods for identifying R and D funding opportunities, with an overview of federal acquisition regulations. Section 3 reviews the efforts of several state governments engaging the fuel cell industry as an economic driver and presents an overview of acquisition at the state level. Section 4 discusses university research and development (R and D) and university-industry partnerships. There are 12 appendices attached to the report. These appendices provide more detailed information regarding the key federal government agencies involved in fuel cells and hydrogen, state-specific policies and activities, national laboratories and universities, and other information regarding the fuel cell and hydrogen industry in the U.S. (Author)

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2012

21st Century Renewable Fuels, Energy, and Materials

The objectives of this project were multi-fold: (i) conduct fundamental studies to develop a new class of high temperature PEM fuel cell material capable of conducting protons at elevated temperature (180°C), (ii) develop and fabricate a 5k We novel catalytic flat plate steam reforming process for extracting hydrogen from multi-fuels and integrate with high-temperature PEM fuel cell systems, (iii) research and develop improved oxygen permeable membranes for high power density lithium air battery with simple control systems and reduced cost, (iv) research on high energy yield agriculture bio-crop (Miscanthus) suitable for reformate fuel/alternative fuel with minimum impact on human food chain and develop a cost analysis and production model, and (v) develop math and science alternative energy educator program to include bio-energy and power.

08 HYDROGEN↗
NASA NTRS2003

Hydrogen Fuel Capability Added to Combustor Flametube Rig

Facility capabilities have been expanded at Test Cell 23, Research Combustor Lab (RCL23) at the NASA Glenn Research Center, with a new gaseous hydrogen fuel system. The purpose of this facility is to test a variety of fuel nozzle and flameholder hardware configurations for use in aircraft combustors. Previously, this facility only had jet fuel available to perform these various combustor flametube tests. The new hydrogen fuel system will support the testing and development of aircraft combustors with zero carbon dioxide (CO2) emissions. Research information generated from this test rig includes combustor emissions and performance data via gas sampling probes and emissions measuring equipment. The new gaseous hydrogen system is being supplied from a 70 000-standard-ft3 tube trailer at flow rates up to 0.05 lb/s (maximum). The hydrogen supply pressure is regulated, and the flow is controlled with a -in. remotely operated globe valve. Both a calibrated subsonic venturi and a coriolis mass flowmeter are used to measure flow. Safety concerns required the placement of all hydrogen connections within purge boxes, each of which contains a small nitrogen flow that is vented past a hydrogen detector. If any hydrogen leaks occur, the hydrogen detectors alert the operators and automatically safe the facility. Facility upgrades and modifications were also performed on other fluids systems, including the nitrogen gas, cooling water, and air systems. RCL23 can provide nonvitiated heated air to the research combustor, up to 350 psig at 1200 F and 3.0 lb/s. Significant modernization of the facility control systems and the data acquisition systems was completed. A flexible control architecture was installed that allows quick changes of research configurations. The labor-intensive hardware interface has been removed and changed to a software-based system. In addition, the operation of this facility has been greatly enhanced with new software programming and graphic operator interface stations. Glenn s RCL23 facility systems were successfully checked out in the spring of 2002, and hydrogen combustor research testing began in the summer of 2002.

Frankenfield, Bruce J.↗
NASA NTRS1989

Choice of gauge in 2-photon 1s-2s transition in atomic hydrogen and pseudostate expansions

The problem of gauge choice in multiphoton transitions in connection with the proper choice of the unperturbed wave functions require to insure gauge invariance was considered. J. Bassani, J. J. Forney, and A. Quattropani considered the case of 2-photon 1s-2s transition rate for hydrogen, using gauges vector E x vector r and vector A x vector p. Exactly the same results were obtained for the two gauges, but the findings indicate that the vector E x vector r interaction tends to the final result with a small number of intermediate states and is therefore the one to be used in any approximate calculation. Whether the so-called pseudostate expansion method works equally well with either gauge was tested. To accomplish this task, in addition to researching the problem, the FORTRAN programming was learned and a FORTRAN program was constructed for the calculation of the dimensionless 2-photon transition probability amplitude D(v) for 1s-2s transition in Hydrogen as a function as a function of the incident photon frequency v in gauge vector E x vector p at certain values of v, using the pseudostate method. However, some puzzling unresolved difficulties were experienced in the calculation. Then should the pseudostate calculations prove successful for gauge vector E x vector r the method will be applied to gauge vector A x vector p. If successful, then the problem is complete.

Shabazz, Abdulalim A.↗
DOE OSTI2015

Algal Systems for Hydrogen Photoproduction

The National Renewable Energy Laboratory (NREL), under the guidance of Drs. Michael Seibert (retired, Fellow Emeritus) and Maria Ghirardi (Fellow), led 15 years of research addressing the issue of algal H2 photoproduction. This project resulted in greatly increased rates and yields of algal hydrogen production; increased understanding of the H2 metabolism in the green alga, Chlamydomonas reinhardtii; expanded our knowledge of other physiological aspects relevant to sustained algal photosynthetic H2 production; led to the genetic identification, cloning and manipulation of algal hydrogenase genes; and contributed to a broader, fundamental understanding of the technical and scientific challenges to improving the conversion efficiencies in order to reach the U.S. Department of Energy’s Fuel Cell Technologies Office’s targets. Some of the tangible results are: (i) 64 publications and 6 patents, (ii) international visibility to NREL, (iii) reinvigoration of national and international biohydrogen research, and (iv) research progress that helped stimulate new funding from other DOE and non-DOE programs, including the AFOSR and the DOE Office of Science.

08 HYDROGEN↗
DOE OSTI2024

Impact of Technology Improvements on the Cost of Hydrogen Produced using SOEC Technology at Large Scale

National Energy Technology Laboratory (NETL) provides system-level process, cost, and market analyses on solid oxide cell (SOC) based technologies. Specifically, techno-economic analyses (TEA), market assessments, and other technology evaluations serve to guide the U.S. Department of Energy (DOE) Office of Fossil Energy and Carbon Management (FECM) Reversible Solid Oxide Fuel Cell (R-SOFC) Program technology goals and objectives. These studies are key to describing how the technologies contribute to improving domestic energy infrastructure in a clean, efficient manner. This effort focuses on hydrogen generation technologies, which have received recent attention due to their potential role in economy-wide decarbonization. In particular, the study is part of a series of investigations at NETL that seek to understand the techno-economic impacts of including SOC technology in energy production, hydrogen production, and/or storage configurations. The objective of this study is to establish a detailed TEA to assess the effectiveness of incremental technology improvements needed for solid oxide electrolysis cell (SOEC) technology to achieve the U.S. DOE’s Hydrogen Shot goal of hydrogen production at less than $1 per kilogram. To take advantage of the benefits of economies of scale, the SOEC hydrogen facilities are sized to produce ≈250,000 metric tons of hydrogen annually with an electrolysis load of one gigawatt (direct current). Some additional critical assumptions include stacks that operate near the thermo-neutral voltage of 1.28 V to avoid adverse thermal gradients, all necessary steam and heat is generated by electric boilers and heaters to enable green hydrogen production, and an air sweep is used to control the oxygen concentration in the air electrode exhaust stream. System efficiency and levelized costs of hydrogen (LCOH) for each case are presented.

Hackett, Gregory↗
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.↗
DOE OSTI2011

Co-Production of Electricity and Hydrogen Using a Novel Iron-based Catalyst

The primary objective of this project was to develop a hydrogen production technology for gasification applications based on a circulating fluid-bed reactor and an attrition resistant iron catalyst. The work towards achieving this objective consisted of three key activities: Development of an iron-based catalyst suitable for a circulating fluid-bed reactor; Design, construction, and operation of a bench-scale circulating fluid-bed reactor system for hydrogen production; Techno-economic analysis of the steam-iron and the pressure swing adsorption hydrogen production processes. This report describes the work completed in each of these activities during this project. The catalyst development and testing program prepared and iron-based catalysts using different support and promoters to identify catalysts that had sufficient activity for cyclic reduction with syngas and steam oxidation and attrition resistance to enable use in a circulating fluid-bed reactor system. The best performing catalyst from this catalyst development program was produced by a commercial catalyst toll manufacturer to support the bench-scale testing activities. The reactor testing systems used during material development evaluated catalysts in a single fluid-bed reactor by cycling between reduction with syngas and oxidation with steam. The prototype SIP reactor system (PSRS) consisted of two circulating fluid-bed reactors with the iron catalyst being transferred between the two reactors. This design enabled demonstration of the technical feasibility of the combination of the circulating fluid-bed reactor system and the iron-based catalyst for commercial hydrogen production. The specific activities associated with this bench-scale circulating fluid-bed reactor systems that were completed in this project included design, construction, commissioning, and operation. The experimental portion of this project focused on technical demonstration of the performance of an iron-based catalyst and a circulating fluid-bed reactor system for hydrogen production. Although a technology can be technically feasible, successful commercial deployment also requires that a technology offer an economic advantage over existing commercial technologies. To effective estimate the economics of this steam-iron process, a techno-economic analysis of this steam iron process and a commercial pressure swing adsorption process were completed. The results from this analysis described in this report show the economic potential of the steam iron process for integration with a gasification plant for coproduction of hydrogen and electricity.

08 HYDROGEN↗
NASA NTRS2003

Detecting Near-Surface Water and Hydrate Minerals on Mars from a Rover, Penetrator, or Borehole: The HYDRA Instrument

One of the major goals of near term NASA Mars exploration is to identify exact locations of near-surface water or hydrated minerals on Mars. Evidence for the existence of recent nearsurface water on Mars underscores the need for developing instrumentation that can identify water or hydrated minerals very near the surface. Further encouraging evidence of surface and near-surface water and hydrate minerals on Mars comes from neutron spectrometer measurements aboard Mars Odyssey. Preliminary results show very large regions of high hydrogen content poleward of 60 deg. latitude, as well as interesting features closer to the equator. However, spatial resolution from orbit is very poor, approx. 400 km. The next logical step is to use in-situ or near-surface investigations to map in detail some of the most interesting features. Relatively simple instrumentation based on He-3 gas proportional counters were shown to be highly successful on the Lunar Prospector mission in identifying even low levels of enhanced hydrogen abundances. Here we discuss HYDRA, a water- and hydrate-sensing instrument currently being developed under the NASA Mars Instrument Development Program (MIDP). HYDRA is based on Lunar Prospector technology, and is intended as a rover body-mounted instrument, or an instrument on an aerobot, penetrator, hard lander on the surface of Mars, or for borehole stratigraphy applications. Our proposed instrument would be ideal for such platforms as it would be small (less than 7 cm diameter by 10 cm long), low mass (less than 500 g), low power (less than 1W), and have a low data volume per measurement. We use neutron spectrometry (a) because of its proven ability to uniquely detect and quantify hydrogen abundance, and (b) because the resources required by this approach (weight, power, size, telemetry bandwidth, and measurement time) are extremely low. This compact neutron spectrometer package, comprised of two small He-3 gas proportional counters, offers superior sensitivity, extensive flight heritage, and inherent ruggedness. These tubes have survived approx. 1500 g's of acceleration in penetrator tests. In a landed application, HYDRA would help address many topics of interest to the Mars Exploration and Astrobiology communities: (a) nature and origin of stratified deposits; (b) water cycle(s) and temporal changes; (c) early water oceans, aquifers, precipitation; (d) current extent/location/state of water; (e) polar cap processes and temporal changes; (f) where extremeophiles could survive on Mars; (g) paleoclimate surface signatures and modeling; (h) strategies for future Mars exploration.

R C Elphic↗
NASA NTRS1987

A computer program for performance prediction of tripropellant rocket engines with tangential slot injection

For the development of a Heavy Lift Launch Vehicle (HLLV) several engines with different operating cycles and using LOX/Hydrocarbon propellants are presently being examined. Some concepts utilize hydrogen for thrust chamber wall cooling followed by a gas generator turbine drive cycle with subsequent dumping of H2/O2 combustion products into the nozzle downstream of the throat. In the Space Transportation Booster Engine (STBE) selection process the specific impulse will be one of the optimization criteria; however, the current performance prediction programs do not have the capability to include a third propellant in this process, nor to account for the effect of dumping the gas-generator product tangentially inside the nozzle. The purpose is to describe a computer program for accurately predicting the performance of such an engine. The code consists of two modules; one for the inviscid performance, and the other for the viscous loss. For the first module, the two-dimensional kinetics program (TDK) was modified to account for tripropellant chemistry, and for the effect of tangential slot injection. For the viscous loss, the Mass Addition Boundary Layer program (MABL) was modified to include the effects of the boundary layer-shear layer interaction, and tripropellant chemistry. Calculations were made for a real engine and compared with available data.

Dang, Anthony↗
NASA NTRS1984

Particle excitation, airglow and H2 vibrational disequilibrium in the atmosphere of Jupiter

The extreme ultraviolet EUV emission produced by particle excitation of the hydrogen atmospheres of Jupiter and Saturn is examined using model calculations to determine the nature of the energy deposition process and the effect of such processes on atmospheric structure. Tasks ranging from examination of phenomenologically related processes on Saturn and Titan to analysis of experimental laboratory data required to allow accurate modeling of emissions from hydrogenic atmospheres are investigated. An explanation of the hydrogen H Ly(alpha) bulge in Jupiter's emission from the equatorial region is presented. It is proposed that Saturn, rather then Titan is the major source of the extended hydrogen cloud. The atomic hydrogen detected at the rings of Saturn may originate predominantly from the same source. A cross calibration is obtained between the Pioneer 10 EUV photometer and the Voyager EUV spectrometers, thus providing a direct measure of the temporal morphology of Jupiter between a minimum and a maximum in solar activity. Atomic and molecular data required for the research program are analyzed. An extrapolation of conditions in the upper atmospheres of Jupiter and Saturn produces a predicted condition at Uranus in terms of excitation and hydrogen escape rates that may be observed at Voyager-Uranus encounter.

Shemansky, D. E.↗
NASA NTRS1985

Two-dimensional kinetics computer program for orbit transfer vehicles

Future Orbit Transfer Vehicles (OTV) presently under consideration require rocket engines delivering a high specific impulse. This high performance can be obtained with large area ratio thrust chambers using oxygen with either hydrogen or hydrocarbon fuels. In the projected nozzles, the combustion products are expanded to low pressure and temperature levels at high Mach number, a domain which has not been experienced with existing rocket engines. In order to assist in the design and evaluation of OTV engines, modifications have recently been incorporated in the Two-Dimensional-Kinetics (TDK) computer program. These modifications include the treatment of shock waves induced by the wall curvature, and shocks which are attached to the wall. The reflection of a shock wave at the flow axis is also treated in an appropriate manner and multiple shock reflections are allowed. A Boundary Layer Module (BLM) has also been incorporated into the TDK computer program in order to provide an automated treatment of the rigorous JANNAF rocket engine performance prediction procedure.

Nickerson, G. R.↗