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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 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS1986

NASA Lewis Evaluation of Regenerative Fuel Cell (RFC) Systems

Evaluation of two regenerative fuel cell (RFC) systems was begun in-house, and under contracts and grants. The passive hydrogen-oxygen RFC offers the possibility of a high-energy density, long-life storage system for geosynchronous Earth orbit missions. The hydrogen-bromine RFC offers the combination of high efficiency and moderate energy density that could ideally suit low Earth orbit missions if successfully developed. Either or both of these systems would be attractive additions to the storage options available to designers of future missions.

Hagedorn, N. H.↗
NASA NTRSDate not supplied

FY20 Regenerative Fuel Cell (RFC) Project Annual Review Presentation

This is the status report for the Game Changing Development (GCD) Regenerative Fuel Cell (RFC) project to be presented at the fiscal year 2020 (FY20) GCD Annual Review. Project to develop hydrogen/oxygen RFC energy storage technology from TRL 3 to TRL 5 for lunar surface applications.

Fuel Cell↗
NASA NTRS2009

Lunar Regenerative Fuel Cell (RFC) Reliability Testing for Assured Mission Success

NASA's Constellation program has selected the closed cycle hydrogen oxygen Polymer Electrolyte Membrane (PEM) Regenerative Fuel Cell (RFC) as its baseline solar energy storage system for the lunar outpost and manned rover vehicles. Since the outpost and manned rovers are "human-rated," these energy storage systems will have to be of proven reliability exceeding 99 percent over the length of the mission. Because of the low (TRL=5) development state of the closed cycle hydrogen oxygen PEM RFC at present, and because there is no equivalent technology base in the commercial sector from which to draw or infer reliability information from, NASA will have to spend significant resources developing this technology from TRL 5 to TRL 9, and will have to embark upon an ambitious reliability development program to make this technology ready for a manned mission. Because NASA would be the first user of this new technology, NASA will likely have to bear all the costs associated with its development.When well-known reliability estimation techniques are applied to the hydrogen oxygen RFC to determine the amount of testing that will be required to assure RFC unit reliability over life of the mission, the analysis indicates the reliability testing phase by itself will take at least 2 yr, and could take up to 6 yr depending on the number of QA units that are built and tested and the individual unit reliability that is desired. The cost and schedule impacts of reliability development need to be considered in NASA's Exploration Technology Development Program (ETDP) plans, since life cycle testing to build meaningful reliability data is the only way to assure "return to the moon, this time to stay, then on to Mars" mission success.

Bents, David J.↗
NASA NTRS2007

Solar Airplanes and Regenerative Fuel Cells

A solar electric aircraft with the potential to "fly forever" has captured NASA's interest, and the concept for such an aircraft was pursued under Aeronautics Environmental Research Aircraft and Sensor Technology (ERAST) project. Feasibility of this aircraft happens to depend on the successful development of solar power technologies critical to NASA's Exploration Initiatives; hence, there was widespread interest throughout NASA to bring these technologies to a flight demonstration. The most critical is an energy storage system to sustain mission power during night periods. For the solar airplane, whose flight capability is already limited by the diffuse nature of solar flux and subject to latitude and time of year constraints, the feasibility of long endurance flight depends on a storage density figure of merit better than 400-600 watt-hr per kilogram. This figure of merit is beyond the capability of present day storage technologies (other than nuclear) but may be achievable in the hydrogen-oxygen regenerative fuel cell (RFC). This potential has led NASA to undertake the practical development of a hydrogen-oxygen regenerative fuel cell, initially as solar energy storage for a high altitude UAV science platform but eventually to serve as the primary power source for NASAs lunar base and other planet surface installations. Potentially the highest storage capacity and lowest weight of any non-nuclear device, a flight-weight RFC aboard a solar-electric aircraft that is flown continuously through several successive day-night cycles will provide the most convincing demonstration that this technology's widespread potential has been realized. In 1998 NASA began development of a closed cycle hydrogen oxygen PEM RFC under the Aeronautics Environmental Research Aircraft and Sensor Technology (ERAST) project and continued its development, originally for a solar electric airplane flight, through FY2005 under the Low Emissions Alternative Power (LEAP) project. Construction of the closed loop system began in 2002 at the NASA Glenn Research Center in Cleveland, Ohio. System checkout was completed, and testing began, in July of 2003. The initial test sequences were done with only a fuel cell or electrolyzer in the test rig. Those tests were used to verify the test apparatus, procedures, and software. The first complete cycles of the fully closed loop, regenerative fuel cell system were successfully completed in the following September. Following some hardware upgrades to increase reactant recirculation flow, the test rig was operated at full power in December 2003 and again in January 2004. In March 2004 a newer generation of fuel cell and electrolyzer stacks was substituted for the original hardware and these stacks were successfully tested at full power under cyclic operation in June of 2004.

Bents, David J.↗
NASA NTRS2026

Mathematical Model of a Regenerative Fuel Cell for System Optimization

This thesis developed a system-level optimization model of a regenerative fuel cell (RFC) system for long-duration, off-world energy storage applications. Prior RFC design studies have typically been limited to reduced parameter sets and simplified constraints due to computational limitations relative to the number of relevant degrees of freedom. As a result, important nonlinear interactions between subsystems have not been fully captured. This work began to address that gap by developing a higher-fidelity, nonlinear optimization framework that incorporates a broader set of design variables and coupled constraints, enabling a multidimensional model that captures the coupled behavior of RFC subsystems and demonstrates the feasibility of applying optimization to such systems. An expanded system-level optimization approach was established that captures interactions between electrochemical performance, structural requirements, and storage design. This enabled a more comprehensive evaluation of trade-offs than conventional formulations. The model integrates four coupled subsystems: a fuel cell, an electrolyzer, reactant gas, and high-pressure storage tanks, and was formulated to accommodate a wide range of mission parameters, including operational time and required output power. It incorporates constraints on available solar array power, reactant mass balance between production and consumption, and pressure-dependent storage requirements. To enable reliable convergence, the optimization problem was reformulated to reduce dimensionality and improve numerical stability, with subsystem models organized for efficient evaluation. Problem dimensionality was reduced by consolidating lower-level design variables into higher-level representative quantities, and subsystem behavior was evaluated within the optimization loop. A multi-start initialization strategy was employed to mitigate sensitivity to local minima and improve solution quality, while nonlinear relationships were solved using robust numerical methods. The results showed that convergence was achieved across a range of required output power values. Specific energy reached a maximum at a critical mission power level, where the electrolyzer power matched the available solar input and operated near its voltage and current density limits. Beyond this point, further increases in required power resulted in less mass-efficient operation, increasing total system mass and reducing overall performance. The developed model represents an advancement in RFC system-level optimization by enabling analysis of a broader and more tightly coupled design space than previous considerations. While convergence behavior and computational cost remain challenges, the methods introduced improve solvability and allow inclusion of additional design variables with minimal loss of physical fidelity. However, the numerical results should not be interpreted as definitive design recommendations, as the model includes simplifying assumptions and omits several higher-order effects. Future work should extend this framework by incorporating additional subsystems and loss mechanisms, such as thermal management, parasitic power consumption, and reactant losses, to improve fidelity and ensure more representative design conclusions.

Electrochemistry↗
NASA NTRS2006

Hydrogen-Oxygen PEM Regenerative Fuel Cell Development at NASA Glenn Research Center

The closed-cycle hydrogen-oxygen PEM regenerative fuel cell (RFC) at NASA Glenn Research Center has demonstrated multiple back to back contiguous cycles at rated power, and round trip efficiencies up to 52 percent. It is the first fully closed cycle regenerative fuel cell ever demonstrated (entire system is sealed: nothing enters or escapes the system other than electrical power and heat). During FY2006 the system has undergone numerous modifications and internal improvements aimed at reducing parasitic power, heat loss and noise signature, increasing its functionality as an unattended automated energy storage device, and in-service reliability. It also serves as testbed towards development of a 600 W-hr/kg flight configuration, through the successful demonstration of lightweight fuel cell and electrolyser stacks and supporting components. The RFC has demonstrated its potential as an energy storage device for aerospace solar power systems such as solar electric aircraft, lunar and planetary surface installations; any airless environment where minimum system weight is critical. Its development process continues on a path of risk reduction for the flight system NASA will eventually need for the manned lunar outpost.

Bents, David J.↗
NASA NTRS2018

Energy Storage for Lunar Surface Exploration

This paper presents the updated results of a previous NASA study funded under the Advanced Exploration Systems (AES) Modular Power Systems (AMPS) project. This work focuses on generating high-level system sizing relationships for two lunar surface locations that serve as bounding conditions for most other locations. Four critical parameters are considered to provide sizing data: specific energy, energy density, specific power, and power density. Given the energy storage requirements or customer power demand for a lunar mission location, the data presented in this paper provides a method to determine the critical parameter values of a Regenerative Fuel Cell (RFC) system in order to perform high-level mission architecture trades.

surface power systems↗
NASA NTRS2008

Lunar RFC Reliability Testing for Assured Mission Success

NASA's Constellation program has selected the closed cycle hydrogen oxygen Polymer Electrolyte Membrane (PEM) regenerative Fuel Cell (RFC) as its baseline solar energy storage system for the lunar outpost and manned rover vehicles. Since the outpost and manned rovers are "human-rated", these energy storage systems will have to be of proven reliability exceeding 99 percent over the length of the mission. Because of the low (TRL=5) development state of the closed cycle hydrogen oxygen PEM RFC at present, and because there is no equivalent technology base in the commercial sector from which to draw or infer reliability information from, NASA will have to spend significant resources developing this technology from TRL 5 to TRL 9, and will have to embark upon an ambitious reliability development program to make this technology ready for a manned mission. Because NASA would be the first user of this new technology, NASA will likely have to bear all the costs associated with its development. When well-known reliability estimation techniques are applied to the hydrogen oxygen RFC to determine the amount of testing that will be required to assure RFC unit reliability over life of the mission, the analysis indicates the reliability testing phase by itself will take at least 2 yr, and could take up to 6 yr depending on the number of QA units that are built and tested and the individual unit reliability that is desired. The cost and schedule impacts of reliability development need to be considered in NASA's Exploration Technology Development Program (ETDP) plans, since life cycle testing to build meaningful reliability data is the only way to assure "return to the moon, this time to stay, then on to Mars" mission success.

Bents, David J.↗
NASA NTRS2017

Thermal Design for Extra-Terrestrial Regenerative Fuel Cell System

The Advanced Exploration Systems (AES) Advanced Modular Power Systems (AMPS) Project is investigating different power systems for various lunar and Martian mission concepts. The AMPS Fuel Cell (FC) team has created two system-level models to evaluate the performance of regenerative fuel cell (RFC) systems employing different fuel cell chemistries. Proton Exchange Membrane fuel cells PEMFCs contain a polymer electrolyte membrane that separates the hydrogen and oxygen cavities and conducts hydrogen cations (protons) across the cell. Solid Oxide fuel cells (SOFCs) operate at high temperatures, using a zirconia-based solid ceramic electrolyte to conduct oxygen anions across the cell. The purpose of the modeling effort is to down select one fuel cell chemistry for a more detailed design effort. Figures of merit include the system mass, volume, round trip efficiency, and electrolyzer charge power required. PEMFCs operate at around 60 C versus SOFCs which operate at temperatures greater than 700 C. Due to the drastically different operating temperatures of the two chemistries the thermal control systems (TCS) differ. The PEM TCS is less complex and is characterized by a single pump cooling loop that uses deionized water coolant and rejects heat generated by the system to the environment via a radiator. The solid oxide TCS has its own unique challenges including the requirement to reject high quality heat and to condense the steam produced in the reaction. This paper discusses the modeling of thermal control systems for an extraterrestrial RFC that utilizes either a PEM or solid oxide fuel cell.

thermal modeling↗
NASA NTRS2017

Thermal System Modeling for Lunar and Martian Surface Regenerative Fuel Cell Systems

The Advanced Exploration Systems (AES) Advanced Modular Power Systems (AMPS) Project is investigating different power systems for various lunar and Martian mission concepts. The AMPS Fuel Cell (FC) team has created two system-level models to evaluate the performance of regenerative fuel cell (RFC) systems employing different fuel cell chemistries. Proton Exchange Membrane fuel cells PEMFCs contain a polymer electrolyte membrane that separates the hydrogen and oxygen cavities and conducts hydrogen cations (protons) across the cell. Solid Oxide fuel cells (SOFCs) operate at high temperatures, using a zirconia-based solid ceramic electrolyte to conduct oxygen anions across the cell. The purpose of the modeling effort is to down select one fuel cell chemistry for a more detailed design effort. Figures of merit include the system mass, volume, round trip efficiency, and electrolyzer charge power required. PEMFCs operate at around 60 degrees Celsius versus SOFCs which operate at temperatures greater than 700 degrees Celsius. Due to the drastically different operating temperatures of the two chemistries the thermal control systems (TCS) differ. The PEM TCS is less complex and is characterized by a single pump cooling loop that uses deionized water coolant and rejects heat generated by the system to the environment via a radiator. The solid oxide TCS has its own unique challenges including the requirement to reject high quality heat and to condense the steam produced in the reaction. This paper discusses the modeling of thermal control systems for an extraterrestrial RFC that utilizes either a PEM or solid oxide fuel cell.

thermal modeling↗
NASA NTRS2000

Solar Power System Evaluated for the Human Exploration of Mars

The electric power system is a crucial element of any mission for the human exploration of the Martian surface. The bulk of the power generated will be delivered to crew life support systems, extravehicular activity suits, robotic vehicles, and predeployed in situ resource utilization (ISRU) equipment. In one mission scenario, before the crew departs for Mars, the ISRU plant operates for 435 days producing liquefied methane and oxygen for ascent-stage propellants and water for crew life support. About 200 days after ISRU production is completed, the crew arrives for a 500-day surface stay. In this scenario, the power system must operate for a total of 1130 days (equivalent to 1100 Martian "sols"), providing 400 MW-hr of energy to the ISRU plant and up to 18 kW of daytime user power. A photovoltaic power-generation system with regenerative fuel cell (RFC) energy storage has been under study at the NASA Glenn Research Center at Lewis Field. The conceptual power system is dominated by the 4000- m2 class photovoltaic array that is deployed orthogonally as four tent structures, each approximately 5 m on a side and 100-m long. The structures are composed of composite members deployed by an articulating mast, an inflatable boom, or rover vehicles, and are subsequently anchored to the ground. Array panels consist of thin polymer membranes with thin-film solar cells. The array is divided into eight independent electrical sections with solar cell strings operating at 600 V. Energy storage is provided by regenerative fuel cells based on hydrogen-oxygen proton exchange membrane technology. Hydrogen and oxygen reactants are stored in gaseous form at 3000 psi, and the water produced is stored at 14.7 psi. The fuel cell operating temperature is maintained by a 40-m2 deployable pumped-fluid loop radiator that uses water as the working fluid. The power management and distribution (PMAD) architecture features eight independent, regulated 600-Vdc channels. Power management and distribution power cables use various gauges of copper conductors with ethylene tetrafluoroethylene insulation. To assess power system design options and sizing, we developed a dedicated Fortran code to predict detailed power system performance and estimate system mass. This code also modeled the requisite Mars surface environments: solar insolation, Sun angles, dust storms, dust deposition, and thermal and ultraviolet radiation. Using this code, trade studies were performed to assess performance and mass sensitivities to power system design parameters (photovoltaic array geometry and orientation) and mission parameters (landing date and landing site latitude, terrain slope, and dust storm activity). Mission analysis cases were also run. Power results are shown in this graph for an analysis case with a September 1, 2012, landing date; 18.95 North latitude landing site; two seasonal dusts storms; and tent arrays. To meet user load requirements and the ISRU energy requirement, an 8-metric ton (MT) power system and 4000-m2 photovoltaic array area were required for the assumed advanced CuInS2 thin-film solar cell technology. In this figure, the top curve is the average daytime photovoltaic array power, the middle curve is average daytime user load power, and the bottom curve is nighttime power. At mission day 1, daytime user power exceeds 120 kW before falling off to 80 kW at the end of the mission. Throughout the mission, nighttime user power is set to the nighttime power requirement. In this analysis, "nighttime" is defined as the 13- to 15-hr period when array power output is below the daytime power requirement. During dust storms, power system capability falls off dramatically so that by mission day 900, a daily energy balance cannot be maintained. Under these conditions, the ISRU plant is placed in standby mode, and the regenerative fuel cell energy storage is gradually discharged to meet user loads.

Kerslake, Thomas W.↗
NASA NTRS1997

Operation of the 25kW NASA Lewis Research Center Solar Regenerative Fuel Cell Tested Facility

Assembly of the NASA Lewis Research Center(LeRC)Solar Regenerative Fuel Cell (RFC) Testbed Facility has been completed and system testing has proceeded. This facility includes the integration of two 25kW photovoltaic solar cell arrays, a 25kW proton exchange membrane (PEM) electrolysis unit, four 5kW PEM fuel cells, high pressure hydrogen and oxygen storage vessels, high purity water storage containers, and computer monitoring, control and data acquisition.

Solar Regenerative Fuel Cell electrolyzer↗
NASA NTRS2017

Regenerative Fuel Cell Power Systems for Lunar and Martian Surface Exploration

This paper presents the preliminary results of a recent National Aeronautics and Space Administration (NASA) study funded under the Advanced Exploration Systems (AES) Modular Power Systems (AMPS) project. This study evaluated multiple surface locations on both the Moon and Mars, with the goal of establishing a common approach towards technology development and system design for surface power systems that use Regenerative Fuel Cell (RFC) energy storage methods. One RFC design may not be applicable to all surface locations; however, AMPS seeks to find a unified architecture, or series of architectures, that leverages a single development approach to answer the technology need for RFC systems. Early system trades were performed to select the most effective fuel cell and electrolyzer architectures based on current state-of-the-art technology, whereas later trades will establish a detailed system design to enable a near-term ground (non-flight) demonstration. This paper focuses on the initial trade studies, presents the selected fuel cell and electrolyzer architectures for follow-on system design studies, and suggests areas for further technology investment.

lunar and Mars exploration↗
NASA NTRS2022

Aerospace Regenerative Fuel Cell Fluidic Component Design Challenges

A discrete regenerative fuel cell (RFC) system is currently under development at the NASA Glenn Research Center and Johnson Space Center. The objective of this activity is to produce an energy storage system with a higher specific energy (W·hr/kg) than the state-of-the-art battery technologies then test that system within an environment simulating the temperatures and pressures expected over a full lunar day cycle on the lunar surface. The system is designed to be as flight-like as possible given resource and commercially available technology limitations. The RFC system is comprised of a fuel cell power system, a high pressure electrolysis system, fluidic and electronic balance of plant systems, avionics, power management and distribution system, and software. This technical memorandum discusses components and subsystems that present challenges in developing flight ready RFCs. To remedy identified issues, functional application test plans are presented for components and subsystems primarily constructed with commercially available options due to the budget and schedule constraints of this ground technology demonstration project.

fuel cell↗