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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 127 records · Page 7

High-pressure hydrogen decompression in sulfur crosslinked elastomers

High-pressure storage and cyclic (de)pressurization of hydrogen gas is known to result in degradation and failure of gas canisters, hoses, linings, and O-rings as the relatively small hydrogen molecule can readily permeate most materials. Hence, identifying material compositions that are less susceptible to hydrogen-induced damage is of significant importance to the hydrogen energy infrastructure. Here, we use classical atomistic molecular dynamics simulations to study hydrogen exposed ethylene-propylene-diene monomer (EPDM) rubber, an elastomer typically used in O-rings. We make chemical modifications to the model by adjusting the crosslink density and report on gas solubility, diffusivity, and molecular restructuring in response to rapid decompression. Our simulations indicate that increases in crosslink density can reduce volumetric expansion during decompression and result in smaller free volume pore sizes. However, these favorable properties for sealing materials come with a tradeoff. At pressure, crosslinks introduce extra free volume, providing potential sites for gas localization, the precursor to cavitation-induced failure.

08 HYDROGEN↗

Optical Fiber Sensors Capable of Monitoring Hydrogen in the Subsurface Hydrogen Storage Environment

Subsurface hydrogen storage is a cost-effective and environmentally friendly storage option in a large quantity. Hydrogen would be stored in subsurface storage reservoirs at high temperature/pressure under very humid condition. Monitoring hydrogen concentration in those harsh storage environments is crucial to ensure the integrity and safety of the hydrogen storage infrastructure. Thus, this project focuses on the development of optical fiber hydrogen sensors capable of monitoring hydrogen in the harsh environments that are representative of underground storage conditions. The optical fiber hydrogen sensor developed at NETL consists of a palladium-based sensing film with a filter layer which minimizes the environmental impacts on hydrogen sensing. The developed sensor has demonstrated significant improvement on hydrogen sensing at 80℃ under high humidity condition (99% RH) without the baseline drift. The hydrogen sensor also showed negligible cross-sensitivity to CO2 and CH4 which would be present as a cushion gas inside the underground hydrogen storage reservoir. Moreover, the sensor has demonstrated the stable monitoring of hydrogen concentration at high pressure (1000 psi) and 80 ℃ in the presence of biological samples. The optical fiber hydrogen sensor developed would enable reliable monitoring of hydrogen concentration in subsurface hydrogen storage facilities.

Kim, Daejin↗

Hydrogen technology for maritime applications: A review of challenges, opportunities, and lessons from the port authority of New York and New Jersey

The maritime industry faces increasing demand for energy security, operational efficiency, and environmental performance improvements. Hydrogen technology, considered a potential energy carrier, is being explored for port operations, including cargo-handling equipment, heavy-duty vehicles, and stationary power systems. This review evaluates the feasibility, challenges, and potential benefits of hydrogen integration within port infrastructure, using the Port Authority of New York and New Jersey as a representative case study. Drawing on case studies, technical reports, and policy analyses, this study examines the infrastructural, regulatory, and operational factors influencing large-scale deployment, emphasizing supply chain development, storage requirements, and refueling infrastructure. By situating hydrogen within broader maritime energy transition efforts, this review provides an evidence-based assessment of its role in port operations and energy diversification strategies. In conclusion, the findings outline key barriers to adoption and emphasize the need for coordinated efforts among stakeholders to determine hydrogen's role alongside other emerging energy technologies.

08 HYDROGEN↗

Techno-Economic Analysis of Repurposing Natural Gas Transmission Pipeline Networks to Accommodate Hydrogen Blends

Blending hydrogen into natural gas infrastructure could supplement natural gas supply and increase resilience for applications such as ammonia production, peaking and load-following power plants, and heating. The United States has an extensive network of natural gas pipelines, but the feasibility of employing this infrastructure to transport hydrogen is unclear. We analyze the costs associated with repurposing three distinct natural gas transmission pipelines in different locations within the United States to carry blends of hydrogen up to 100% via three different pipeline network modification methods and compare against the cost of building a new dedicated hydrogen pipeline. We conduct a sensitivity analysis on the hoop stress limit of the existing pipe, techno-economic parameters, emissions, and relative capacity. The results show that the capital costs required to upgrade a pipeline can vary from tens of millions to billions of dollars depending on the length and capacity of the existing pipeline section, whether the existing pipeline already operates at or below its maximum allowable operating pressure, whether future demand is expected to increase or decrease, the network modification method selected, and pipe material costs. The delivered cost of energy to end users is impacted less by the levelized cost of transporting hydrogen blends than by the cost of the natural gas and hydrogen fuels being transported. The emissions impact of blending hydrogen into natural gas transmission networks scales proportionally with the amount of energy displaced with low-emission hydrogen (such as from natural gas with carbon capture and sequestration or electrolysis powered by nuclear, renewable, or geothermal electricity), therefore low blend ratios (e.g., < 20% vol. hydrogen) will result in low emissions impacts. Factors such as permitting and right-of-way costs, the proximity of the pipeline to hydrogen demand and production, and the compatibility of and/or retrofitting costs of end-use gas-fueled technologies will likely be greater drivers in determining whether converting a particular natural gas pipeline to carry hydrogen makes economic sense.

08 HYDROGEN↗

Codes and Standards Assessment for Hydrogen Blends into the Natural Gas Infrastructure

Energy utilities are evaluating emerging energy technologies to reduce reliance on carbon as an energy carrier. Hydrogen has been identified as a potential substitute for carbon-based fuels that can be blended into other gaseous energy carriers, such as natural gas. However, hydrogen blending into natural gas has important implications on safety which need to be evaluated. Designers and installers of systems that utilize hydrogen gas blending into natural gas distribution systems need to adhere to local building codes and engage with the authority having jurisdiction (AHJ) for safety and permitting approvals. These codes and standards must be considered to understand where safety gaps might be apparent when injecting hydrogen into the natural gas infrastructure. This report generates a list of relevant codes and standards for hydrogen blending on existing, upgraded, or new pipelines. Additionally, a preliminary assessment was made to identify the codes and standards that need to be modified to enable this technology as well as potential gaps due to the unique nature and safety concerns of gaseous hydrogen.

03 NATURAL GAS↗

Maritime Fuel Cell Generator Project [FY2019]

The objective of this project is the demonstration, and validation of hydrogen fuel cells in the marine environment. The prototype generator can be used to guide commercial development of a fuel cell generator product. Work includes assessment and validation of the commercial value proposition of both the application and the hydrogen supply infrastructure through third-party hosted deployment as the next step towards widespread use of hydrogen fuel cells in the maritime environment.

08 HYDROGEN↗

Effects of hydrogen partial pressure on crack initiation and growth rate in vintage X52 steel

There is an increasing interest in ensuring compatibility of existing natural gas infrastructure with conveyance of hydrogen, especially for vintage (pre-1970s) pipeline steels. While hydrogen is known to affect the fatigue and fracture resistance of these materials, there is a lack of data on its effects on crack initiation at low hydrogen partial pressure. To address this gap, the current work presents a series of fatigue tests on vintage API Grade X52 steel in pure nitrogen, air and gaseous hydrogen at partial pressures of 1 and 207 bar. Circumferential notch tension (CNT) specimens with direct current potential difference (DCPD) measurements are used to get S–N curves for crack initiation and failure, and compact tension (CT) tests to assess crack growth rates. Results indicate that air accelerates crack initiation, low hydrogen partial pressure affects the crack growth rate, and higher pressures have the largest impact on both. Surprisingly, crack initiation is faster in air than at 1 bar hydrogen partial pressure. The CNT tests also reveal that the orientation of the banded microstructure has no effect on the crack initiation site, but it influences its growth behavior. Moreover, fractography shows that hydrogen also promotes instances of quasi-cleavage and intergranular fracture, linked to embrittlement of the material. Here, these results demonstrate that, while hydrogen may impact the entirety of the fatigue process, its effects on the early stages of damage accumulation become relevant only at larger pressures. More comprehensive studies of crack initiation in hydrogen atmospheres will be critical to future codes and standards for hydrogen infrastructure.

Circumferential notch tension↗

Overview of International Activities in Hydrogen System Safety in IEA Hydrogen TCP Task 43

Safety and reliability have long been recognized as key issues for the development, commercialization, and implementation of new technologies and infrastructure, and hydrogen systems are no exception to this rule. Reliability engineering, quantitative risk assessment (QRA), and knowledge exchange each play a key role in proactive addressing safety - before problems happen - and help us learn from problems if they happen. Many international research activities are focusing on both reliability and risk assessment for hydrogen systems. However, the element of knowledge exchange is sometimes less visible. To support international collaboration and knowledge exchange, the International Energy Agency (IEA) convened a new Technology Collaboration Program, "Task 43: Safety and Regulatory Aspects of Emerging Large Scale Hydrogen Energy Applications" started in June 2022. Within Task 43, Subtask E focuses on Hydrogen Systems Safety. This paper discusses the structure of the Hydrogen Systems Safety subtask and the aligned activities and introduces opportunities for future work.

HYDROGEN↗

DCFC + Hydrogen Station Design Optimization [Slides]

Both direct current fast charging (DCFC) and Hydrogen stations are working to create successful long-term business models; however, analyses for DCFC and hydrogen fueling infrastructure are almost always performed separately. This work provides a detailed exploration of the benefit of integrating DCFC and hydrogen stations to lower the total system cost from load balancing and equipment cost sharing. To achieve this we have adapted the REopt optimization framework to simultaneously optimize the design and operation of integrated DCFC and H2 fueling station. Results indicate that 1) combining hydrogen fueling and DCFC stations can significantly reduce lifetime costs compared to separated stations. 2) Co-location with additional site load reduces DCFC costs, however, integration of DCFC with hydrogen provides an even greater cost reduction. 3) Adding PV to combined stations further reduces the lifetime station cost. 4) Capital investments in station combination today can help reduce the cost of operating DCFC tomorrow and 5) product diversification acts as a hedge against variability and enables a more dynamic response to market changes.

08 HYDROGEN↗

Roundtable on Foundational Science for Carbon-Neutral Hydrogen Technologies (Technology Status Document)

This document summarizes the status of carbon-neutral hydrogen production, storage and transport, and utilization. The state of the art in the implementation, limitations, and challenges of these technologies are summarized. Sources of hydrogen are broadly categorized as hydrcoarbons or water and the processes used to convert these sources to hydrogen as catalytic, thermochemical, or electrochemical. Catalytic steam methane reforming of methane is the dominant process today. Other processes have smaller production volumes and the technology is less mature, but are being deployed at increasing rates, most notably water electrolyzers for hydrogen fueling stations. Efficient transport and storage of hydrogen is one of the major challenges facing a hydrogen-based energy economy. This arises in part from its low volumetric energy density necessitating very high pressures or cryogenic temperatures to store sufficient amounts for practical applications. High-pressure compressed hydrogen cylinders are the incumbent hydrogen storage technology for applications such as light-duty fuel cell electric vehicles, for example. The storage of hydrogen in materials or in chemicals is being pursued to address the issues associated with compression, such as parasitic energy loss and weight, size, and cost of storage containers. The complex nature of the chemical and physical processes involved in the uptake, storage, and release of hydrogen has slowed the discovery of suitable hydrogen storage materials. Both small and large-scale storage face the challenge of embrittlement of the storage media by hydrogen. There is a myriad of uses of hydrogen offering the promises of improving the efficiency of various applications and reducing or eliminating CO 2 emissions. These range from direct electrochemical conversion to electricity to power vehicles and grid-level stationary applications to combustion to production of chemicals and commodities. One of the most impactful applications in terms of reduction of CO 2 emissions is fuel cell passenger vehicles and heavy-duty vehicles such as class 8 trucks. The challenges facing widespread deployment of fuel cells, beyond the major hurdle of the lack of a hydrogen distribution infrastructure, are cost and durability, primarily related to the precious metal cathode catalyst and its durability. The other uses of hydrogen from conversion to hydrocarbons, polymer upcycling, and upgrading of bio-oils are at varying stages of maturity and also face fundamental challenges associated with catalytic processes and materials.

08 HYDROGEN↗

Characterizing Hydrogen Storage Potential in U.S. Underground Gas Storage Facilities

Abstract Underground hydrogen storage is a long‐duration energy storage option for a low‐carbon economy. Although research into the technical feasibility of underground hydrogen storage is ongoing, existing underground gas storage (UGS) facilities are appealing candidates for the technology because of their ability to store and deliver natural gas. We estimate that UGS facilities in the United States (U.S.) can store 327 TWh (9.8 MMT) of pure hydrogen. A complete transition to hydrogen storage would reduce the collective working‐gas energy of UGS facilities by ∼75%; however, most (73.2%) UGS facilities could maintain current energy demand using a 20% hydrogen‐natural gas blend. U.S. UGS facilities can buffer 23.9%–44.6% of the high and low hydrogen demand projected for 2050, respectively, which exceeds the current percentage of natural gas demand buffered by storage. Thus, transitioning UGS infrastructure to hydrogen could substantially reduce the number of new hydrogen storage facilities needed to support a hydrogen economy.

08 HYDROGEN↗

2024 Sustainable Aviation Energy Conference: 5 Key Messages From the Alternative Fueling (Energy) Infrastructure Workshop

At the 2024 Sustainable Aviation Energy Conference, more than 100 aviation leaders gathered in Dallas, Texas, to discuss collaboration and research needed to clear the path to widespread adoption of sustainable aviation technologies. During open workshops, participants from state and federal agencies; airports; aircraft and engine manufacturers; liquid fuel producers; and other stakeholder groups brainstormed the biggest barriers and opportunities for realizing a sustainable aviation ecosystem. This fact sheets presents five key messages and discussion points that emerged during a workshop on alternative fueling (energy) infrastructure.

advanced air mobility↗

Efficient and Safe Hydrogen Refueling of Fuel Cell Vehicles from an Emergency Chemical Hydride Storage Source

Zero-emissions hydrogen fuel cell electrical vehicles (FCEVs) have become more popular in recent years. However, the limited availability of hydrogen fueling stations is considered a critical barrier to sustainable adoption of hydrogen FCEV. To enable the widespread deployment and commercialization of hydrogen FCEV, the availability of hydrogen refueling stations needs to improve. One of the consequences of the lack of hydrogen refueling infrastructure is that consumers can suffer from “range anxiety”, meaning consumers would get anxious of running out of fuel during long-distance trip [4]. A practical solution is to provide a compact emergency hydrogen refueler that can be used if the consumer runs out of hydrogen before reaching the nearest hydrogen refueling station. A safe, compact, and user-friendly hydrogen refueler would give consumers the flexibility they need to feel comfortable using their hydrogen FCEV when planning a long-distance trip. Offering this product would alleviate range anxiety, and it would make Hydrogen FCEV a more attractive alternative to gasoline vehicles. The emergency hydrogen refueler consists of a lithium hydride bed that reacts with liquid water to produce hydrogen gas and lithium hydroxide.

08 HYDROGEN↗

Learnings From the 2022 NREL Partner Forum: Research Needs for Energy Infrastructure

During the 2022 Partner Forum at the National Renewable Energy Laboratory (NREL), stakeholders and experts from across aviation came to the whiteboard to outline common goals, align interests, understand technologies, and discuss steps for safely and seamlessly decarbonizing aviation. Attendees identified challenges, strategies, and needed research on aviation fuels, infrastructure, and aircraft. Initial insights, strategies, and high-level suggestions from a focused infrastructure workshop are summarized below, including potential barriers and synergies for achieving bold decarbonization goals.

advanced air mobility↗

Modeling Freight Traffic Demand and Highway Networks for Hydrogen Fueling Station Planning: A Case Study of U.S. Interstate 75 Corridor

The use of hydrogen as an alternative transportation fuel has gained much interest in recent years. Hydrogen can be utilized in electric vehicles equipped with hydrogen powertrains (including hydrogen internal combustion engines or fuel cells). Given that most of the freight in the U.S. is transported via diesel trucks, transition to hydrogen fuel would help achieve significant environmental benefits as well as accelerate the decarbonization of the freight transportation sector. This paper presents the methodology and results of a case study on modeling freight traffic demand and highway networks based on publicly available data for the Interstate 75 freight corridor. The purpose of this study is to prepare input traffic and network data that can support the planning of a hydrogen fueling station infrastructure. In particular, the data can be used for siting and characterizing an optimized framework of hydrogen fueling stations from candidate diesel stations along the Interstate 75 corridor. The methodologies developed and presented in this paper may be readily expanded and applied to any transport corridor given the data availability. This paper is the first in a series that will build out a comprehensive model to optimize a consolidated national hydrogen refueling infrastructure eco-system targeted at commercial vehicles.

Uddin, Majbah↗

Gulf of Mexico Offshore Wind Transmission - Literature Review and Gaps Analysis: Environmental Considerations, Community Readiness, and Infrastructure

The ability to effectively and efficiently connect offshore wind energy resources to end users in the Gulf of Mexico, requires coordinated transmission planning to ensure that electric transmission facilities can adequately support future offshore development. The Gulf of Mexico has substantial wind resources in both shallow shelf waters and deeper waters off the shelf where fixed bottom and floating wind technologies would be most appropriate. Most interest in offshore wind development to date has been in the central and western portions of the Gulf of Mexico (Louisiana and Texas) in federal and state waters. As a companion study to other federal activities in the offshore wind transmission space, including the Atlantic Offshore Wind Transmission Literature Review and Gaps Analysis, the Atlantic Offshore Wind Transmission Study, the West Coast Offshore Wind Transmission Literature Review and Gaps Analysis, the West Coast Offshore Wind Transmission Study, and the Advancing Offshore Wind Energy in the United States: U. S. Department of Energy Strategic Contributions Toward 30 Gigawatts and Beyond Report, this literature review and gaps analysis for offshore wind transmission in the Gulf of Mexico builds off previous literature reviews and supports the role of federal leadership to facilitate offshore wind energy. The overarching goal of this document is to identify gaps and lay the groundwork to inform coordinated transmission planning, ocean co-use, existing energy infrastructure, and siting associated with offshore wind energy development in the Gulf of Mexico. There are unique regional considerations for offshore wind transmission, which are summarized herein based on a review and assessment of publicly available information.

08 HYDROGEN↗

Transport Affordable Clean Hydrogen Energy via Existing Pipeline Infrastructure (CRADA 573)

Our Nation’s vast network of oil pipelines span over 230,000 miles connecting remote energy producing regions to distant markets. The COVID-19 pandemic’s influence on oil prices intensified technical and economic vulnerabilities afflicting the Trans-Alaska Pipeline System (TAPS, operating below 25% capacity) that may soon resurface as energy demand shifts to low carbon sources. Through the opportunity afforded by the Arctic Advanced Manufacturing Program, I’ve toured the great State of Alaska learning about its culture, unique energy challenges, business ecosystem, research institutions, and regulatory agencies. With encouragement and support from dedicated Alaskans and my professional mentors, I’ve founded Mighty Pipeline for the purpose of developing and commercializing proprietary technology and hardware to convert oil pipelines into clean hydrogen energy transmission systems. Leveraging the advanced technical capabilities of Pacific Northwest National Laboratory, we’ve demonstrated proof-of-concept (TRL = 3) and are seeking pre-pilot development project opportunities to conduct hardware and system level tests. If we successfully achieve technical and regulatory milestones, Mighty Pipeline’s technology could be available to help facilitate bulk clean hydrogen energy export this decade.

08 HYDROGEN↗

Autonomous Fueling System for Heavy-Duty Fuel Cell Electric Trucks

The motivation for this project stemmed from the challenges associated with rapidly refueling heavy-duty hydrogen fuel cell electric trucks (FCETs). Current manual refueling processes for fast refueling involve large, heavy equipment (e.g., hoses three times heavier than standard) and pose ergonomic risks and potential for equipment damage. The goal was to develop and test an autonomous fueling system to improve ergonomics, enhance safety, increase equipment durability through design improvements, and potentially speed up the fueling process. This project aimed to add to the understanding of autonomous systems in the context of heavy-duty hydrogen refueling, evaluating the technical effectiveness of potential concepts. A successfully developed system would benefit the public by facilitating the adoption of zero-emission heavy-duty transport, reducing reliance on manual labor for a physically demanding task, and potentially improving the safety and efficiency of hydrogen refueling infrastructure. The major accomplishment during the project's active period was the completion of the system-level architecture task. This involved establishing a detailed list of system requirements covering interfaces, environmental conditions, regulatory compliance, industry standards, safety, security, performance capabilities, and optional features. Five key use cases for the autonomous system were also identified. However, due to internal restructuring at Nikola, the necessary resources could not be allocated to continue the project. Consequently, Nikola opted to discontinue the project. The award was mutually terminated by Nikola and the DOE.

08 HYDROGEN↗