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Results for “integrated hydrogen infrastructure”

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
DOE OSTI2026

Systems-To-Atoms (S2A): enabling hydrogen for climate security

The project addresses a critical gap in hydrogen infrastructure by integrating system-level energy models with atomic-scale material simulations in a unified Systems-to-Atoms (S2A) framework. The motivation stems from the need to develop efficient, cost-effective, and durable hydrogen transport and utilization technologies to support decarbonization of hard-to-electrify sectors such as heavy-duty transportation. Current system models lack awareness of material performance mechanisms, while material-scale models do not account for system-level usage and variability. To bridge this divide, the team developed a co-simulation capability linking techno-economic analyses, reactor/process-flow modeling, and molecular-scale catalysis simulations. Applied to hydrogen delivery in California, the framework enabled comparative evaluations of compressed, cryogenic, and liquid organic hydrogen carrier (LOHC) pathways, highlighting how catalyst operation and unit process efficiency influence overall performance. The results demonstrate that no single material or transport mode is universally optimal; instead, heterogeneous solutions tuned to specific operational contexts deliver better performance. The project delivers a new capability for cross-scale material co-design, advancing hydrogen infrastructure readiness and informing DOE and LLNL missions in climate and energy resilience.

organic↗
DOE OSTI2026

H2@Scale - Validating an Electrolysis System with High Output Pressure: Cooperative Research and Development Final Report, CRADA Number CRD-18-00741

Electrolysis has been a commercially available product for a while and electrolyzers have been a proven capability to provide additional benefits (e.g. controllable load for grid services) in addition to production of hydrogen. The hydrogen output is typically compressed for storage and dispensing. Compression adds cost and decreases system reliability. Honda’s electrolyzer systems have been developed to include electrochemical compression to leverage the production system itself for at least partial compression. In this project, the team will evaluate Honda’s PEM based electrochemical compression system. The system is capable of compressing hydrogen up to 70 MPa electrochemically. Validation testing is the next step to accelerate this technology into the marketplace, as the validation will provide needed data under a variety of operation conditions and controls. These operating conditions and controls are based on over a decade of NLR research and development with low-temperature electrolysis. The validation testing will include preparing NLR’s site for third party evaluation, benchmark testing of Honda’s stack and system, and simulating operation connected to renewables or in a grid service profile. NLR’s Energy System Integration Lab will be the location for the electrolyzer validation research and integrated into the Hydrogen Infrastructure Test & Research Facility (HITRF). This will build into the existing retail style hydrogen fueling station for a fully integrated experimental setup.

08 HYDROGEN↗
DOE OSTI2024

Energy Systems Integration Facility (ESIF): World-Class Systems Integration Capabilities and Research

The Energy Systems Integration Facility (ESIF), located at the National Renewable Energy Laboratory (NREL) South Table Mountain campus, is a world-renowned user facility for research and development of modern, advanced, and clean energy technologies. ESIF is distinguished by its continuously evolving, highly integrated systems that span throughout the building, connecting research capabilities across multiple laboratories and test areas. The primary ESIF research systems include: [1] data, cyber, and control networks, [2] research electrical distribution buses (REDB), [3] thermal integration infrastructure, and [4] hydrogen systems. The data, cyber, and control networks provide monitoring, control, communication, automation, visualization, and time series data storage and tagging capabilities for research projects and ESIF systems, including facility safety functions. The REDB system consists of four dedicated AC and DC electrical power networks that can connect devices located across the facility through versatile, automatic circuit configuration to support complex power electronics experiments up to the megawatt-scale. The thermal integration infrastructure consists of three temperature-conditioned water loops that provide heating and cooling interfaces and capabilities for thermal energy research. The hydrogen systems provide megawatt-scale hydrogen production, drying, compression, high-pressure storage, and delivery to laboratory end uses, including hydrogen fuel cell vehicle fueling. The ESIF research systems interconnect and extend throughout the various lab areas of the facility to create elaborate networks composed of diverse technologies for cutting-edge research. The ESIF capabilities are operated and stewarded by the ESIF Research Operations group, who also actively upgrade and advance the systems to ensure they remain ahead of anticipated research - enabling the success of many pioneering energy integration projects. The poster, created by members of the ESIF Research Operations team, highlights and summarizes the four core integrated systems at ESIF. The poster was first presented at the internal NREL Energize Forum on May 13th, 2024, and received the "Best Poster" award.

capabilities↗
DOE OSTI2025

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↗
DOE OSTI2026

SimH 2 : an integrated techno-economic modeling framework for hydrogen pipeline infrastructure and network optimization

Large-scale hydrogen (H 2 ) pipeline transport design and network optimization have seldom been reported due to the lack of a cost model accounting for the relationship between transport cost and hydrogen mass flow rate. Here, this work introduced a system-level cost model for hydrogen pipeline transport at supercritical state and integrated it with an existing CO 2 pipeline network tool, SimCCS, for hydrogen-specific pipeline design and optimization. The Intermountain West (I-West) region of the U.S., historically dependent on fossil fuel-based economies, is chosen to demonstrate the capabilities of our H 2 pipeline cost model and transport network optimization platform called SimH 2 . Two scenarios are examined: one where the pipeline is not allowed to pass through disadvantaged communities and the other where it is permitted. The results highlight that incorporating disadvantaged-community constraints lead to longer pipeline routes and increased transport costs, reflecting the trade-offs involved in equitable infrastructure development. It is demonstrated that the newly developed SimH 2 tool not only enables the efficient design of H 2 transportation pipelines but also optimizes the network by accounting for local terrain and the presence of disadvantaged areas.

08 HYDROGEN↗
DOE OSTI2025

Integrated Systems-to-Atoms (S2A) Framework for Designing Resilient and Efficient Hydrogen Infrastructure Solutions

The success of a future clean hydrogen infrastructure will depend on technology performance, operating conditions, and system configuration, which will be integrated to meet specific end-use requirements. We introduce a Systems-to-Atoms framework to cosimulate material, device, and system design for clean hydrogen storage and transport. Here we present a demonstration scenario in which hydrogen is distributed using a liquid organic hydrogen carrier to 700 bar refueling stations. Cross-scale analysis on hydrogen release at the refueling station reveals that while a high reaction pressure (up to 100 bar) may not enhance the catalyst performance, it can lead to system-level cost savings (up to 5% of total refueling station cost) due to savings in downstream gas compression. Further, a typically low-performing dehydrogenation catalyst material (e.g., copper) may be preferred over a high-performing catalyst (e.g., palladium) at different operating conditions when considering overall system affordability and supply chain resilience.

08 HYDROGEN↗
DOE OSTI2024

Sustainable Port Operations: Powered by NREL

Seaports are vital economic hubs that allow the United States to compete on a global scale. But the heavy vehicles and cargo equipment that enable their operations also emit harmful air pollutants and greenhouse gas emissions. For nearly two decades, National Renewable Energy Laboratory (NREL) researchers have worked toward comprehensive seaport decarbonization. They fuse world-class analysis with deep vehicle and transportation systems knowledge to guide strategic deployment of low- and zero-emissions vehicles, charging and refueling infrastructure, and grid improvements. Together, these capabilities can enable sustainable port operations. This fact sheet outlines major seaport and airport decarbonization capabilities across the laboratory, including: fleet research, energy data, and insights for decarbonization; comprehensive hydrogen infrastructure deployment; optimized charging through grid integration; strategic blueprinting for clean, optimized technology deployment; and integrating diversity, equity, inclusion, and accessibility considerations into decarbonization efforts.

ADVANCED PROPULSION SYSTEMS,ENERGY CONSERVATION, C↗
DOE OSTI2025

Utilization of Existing Pipelines in Hydrogen Transport: Literature Review Report

This report critically reviews the flow behavior of hydrogen-natural gas (H 2 -NG) mixtures in pipelines and examines the critical factors of hydrogen integration into existing natural gas infrastructure. It addresses the choking behavior characterized by velocity increase and pressure drop, as well as the effects of flow restrictions and pressure losses during hydrogen transport. Computational and analytical models are used to investigate these effects, and their effects on thermodynamic properties and system performance are evaluated. The study also reviews the energy efficiency and flow dynamics of hydrogen and methane-hydrogen mixtures and optimizes the hydrogen flow rate. In addition, the effects of these mixtures on the flow characteristics are discussed in detail, with special emphasis on the compressibility factor (z factor) and fluid properties based on equations of state for hydrogen-natural gas mixtures. The study also analyzes the mixture ratios and highlights the thermophysical properties, flow dynamics, and hydrogen-blended natural gas application potential. These investigations assess flow stability, material interactions, and operational feasibility of transporting hydrogen mixtures through natural gas pipelines, which contribute to developing sustainable and efficient energy systems.

08 HYDROGEN↗
DOE OSTI2026

SynthEsizing Novel H2 Sensors for Operational Resilience in Pipeline Infrastructure (SENSOR) (CRADA Final Report)

Hydrogen (H₂) is gaining attention as a versatile energy carrier with potential applications across industrial processes, power generation, and transportation. However, its practical deployment, particularly in large-scale distribution systems, faces significant infrastructure challenges. Transporting hydrogen through dedicated pipelines or blending it into existing natural gas networks can lead to serious issues, such as leakage due to the small size of hydrogen molecules and material degradation in pipelines through embrittlement. These technical risks raise safety concerns and could limit the integration of hydrogen into current energy infrastructures. Additionally, using hydrogen-enriched gas mixtures in combustion systems like turbines and engines introduces new performance and compatibility challenges that must be resolved before widespread use becomes feasible.

08 HYDROGEN↗
DOE OSTI2024

ARIES / Flatirons Facility - Hydrogen System Capability Buildout

Under the "Advanced Research on Integrated Energy Systems" (ARIES) initiative, hydrogen system capabilities including a MW-scale electrolyzer, storage system, and MW-scale fuel cell generator will be designed and commissioned at NREL's Flatirons Campus. This hydrogen infrastructure will support H2@Scale goals by enabling integrated systems R&D to study the science of scaling for hydrogen energy systems.The system is designed with flexibility to provide a testbed to demonstrate systems integration, grid services, energy storage, direct renewable hydrogen production, and innovative end use applications (e.g. HD transportation, natural gas blending, etc.).

electrical grid↗
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 OSTI2024

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↗
DOE OSTI2024

Quantitative risk assessment examples for underground hydrogen storage facilities

Hydrogen energy storage can be used to achieve goals of national energy security, renewable energy integration, and grid resilience. Adapting underground natural gas storage facility (UNGSF) infrastructure for underground hydrogen storage (UHS) is one method of storing large quantities of hydrogen that has already largely been proven to work for natural gas. There are currently some underground salt caverns in the United States that are being used for hydrogen storage by commercial entities, but it is still a fairly new concept in that it has not been widely deployed nor has it been done with other geologic formations like depleted hydrocarbon reservoirs. Assessments of UHS systems can help identify and evaluate risks to people both working within the facility and residing nearby. This report provides example risk assessment methodologies and analyses for generic wellhead and processing facility configurations, specifically in the context of the risks of unintentional hydrogen releases into the air. Assessment of the hydrogen containment in the subsurface is also critically important for a safety assessment for a UHS facility, but those geomechanical assessments are not included in this report.

08 HYDROGEN↗
DOE OSTI2024

Hydrogen Sustainable Infrastructure Guidelines (H2SIG)

Infrastructure interacts with major global challenges inclusive of climate change, resilience, equity and social justice, environmental protection and biodiversity, public health, and economic recovery. This effort directly addresses how to apply sustainability assessments to the unique aspects of hydrogen (H2) infrastructure projects using the Envision® sustainability framework developed by the Institute for Sustainable Infrastructure (ISI). Envision is a flexible system of criteria and performance objectives to aid decision makers and help project teams identify sustainable approaches during planning, design and construction of infrastructure projects that will continue throughout the project’s operations, maintenance, and end-of-life phases. The goal of this work is to support those interested in conducting sustainability assessments for hydrogen infrastructure projects. Through this work the team has developed hydrogen-specific guidelines and best practices to assist project developers, investors and regulators in straightforward application of the Envision framework to systematically enhance clarity and increase objectivity across hydrogen projects. Subject matter experts from 20 different organizations (industry, non-profits, municipalities, emissions regulators, national labs) were engaged through 7 focus groups to discuss the H2-prioritized Envision requirements and elements to be included in the guidelines. In addition to these guidelines, the team conducted case studies as a way of demonstrating and informing the guidelines and providing examples or ideas for implementing sustainability in future projects. Through this study, the authors found that hydrogen infrastructure projects can incorporate many sustainable practices including reducing GHG emissions affecting climate change, reducing air pollutant emissions affecting the health of communities, synergistically handling waste byproducts, integrating into existing infrastructure, incorporating renewable energy, and addressing equity and environmental justice. Additionally, hydrogen infrastructure projects could benefit from 2-way communication engagement and collaborative planning with stakeholders, educational awareness of hydrogen technology, tracking and reporting on water use and water quality, and including monetized environmental and social benefits in life-cycle cost estimates. This document is the final technical report for the Hydrogen Sustainability Assessment Methods for Project Development project. While the main focus of the report is to provide guidelines for applying sustainability to hydrogen infrastructure, there are sections within the appendix providing completed project tasks and methodology.

08 HYDROGEN↗
DOE OSTI2026

System-of-systems optimization of hydrogen infrastructure for heavy-duty freight corridors: The interstate 10 case study

Medium and heavy-duty freight transportation requires hydrogen energy infrastructure that is cost-effective, operationally reliable, spatially coherent, and resilient to demand variability along major corridors. This paper presents an integrated hydrogen corridor planning framework using Oak Ridge National Laboratory's OR-AGENT that couples freight-driven, route-resolved hydrogen demand modeling with optimized station siting, sizing, and station-level techno-economic analysis. The framework is demonstrated for the Interstate 10 freight corridor and the Houston-to-Los-Angeles region. Hydrogen demand is derived from high-resolution origin–destination freight data, duty-cycle characterization, and physics-based energy consumption modeling. Candidate refueling sites are selected from existing heavy-duty diesel fueling locations and optimized subject to onboard storage and station capacity constraints. Resulting station throughputs are evaluated using established techno-economic models for electrolytic hydrogen production and dispensing infrastructure. Results show that a regional, portfolio-level aggregation, average dispensed electrolytic hydrogen cost of $6.87–$7.26/kg is currently feasible, and is strongly influenced by demand density and utilization.

Sujan, Vivek [ORNL] (ORCID:0000000269882342)↗
DOE OSTI2024

Increasing Reliability and Safety of Hydrogen Components - Reliability Data Collection

Come learn about the new Hydrogen Component Reliability Database (HyCReD) and participate in discussions on hydrogen component reliability data collection, collaboration, and analysis. Funded by the U.S. Department of Energy's Office of Energy Efficiency and Renewable Energy under the Hydrogen and Fuel Cell Technologies Office, HyCReD is a collaborative project between the National Renewable Energy Laboratory, the University of Maryland, and hydrogen stakeholders to improve safety reliability for hydrogen facilities by integrating risk reduction methodologies and component reliability data taxonomies that support hydrogen infrastructure failure rate analysis.

component↗