FY 2015 Progress Report for the DOE Hydrogen and Fuel Cells Program

This report summarizes comments from the Peer Review Panel at the 2011 DOE Hydrogen and Fuel Cells Program Annual Merit Review, held on May 9-13, 2011, in Arlington, Virginia. It covers the program areas of hydrogen production and delivery; hydrogen storage; fuel cells; manufacturing R&D; technology validation; safety, codes, and standards; education; market transformation; and systems analysis.

The Florida Hydrogen Initiative (FHI) was a research, development and demonstration hydrogen and fuel cell program. The FHI program objectives were to develop Florida?s hydrogen and fuel cell infrastructure and to assist DOE in its hydrogen and fuel cell activities The FHI program funded 12 RD&D projects as follows: Hydrogen Refueling Infrastructure and Rental Car Strategies -- L. Lines, Rollins College This project analyzes strategies for Florida's early stage adaptation of hydrogen-powered public transportation. In particular, the report investigates urban and statewide network of refueling stations and the feasibility of establishing a hydrogen rental-car fleet based in Orlando. Methanol Fuel Cell Vehicle Charging Station at Florida Atlantic University ? M. Fuchs, EnerFuel, Inc. The project objectives were to design, and demonstrate a 10 kWnet proton exchange membrane fuel cell stationary power plant operating on methanol, to achieve an electrical energy efficiency of 32% and to demonstrate transient response time of less than 3 milliseconds. Assessment of Public Understanding of the Hydrogen Economy Through Science Center Exhibits, J. Newman, Orlando Science Center The project objective was to design and build an interactive Science Center exhibit called: ?H2Now: the Great Hydrogen Xchange?. On-site Reformation of Diesel Fuel for Hydrogen Fueling Station Applications ? A. Raissi, Florida Solar Energy Center This project developed an on-demand forecourt hydrogen production technology by catalytically converting high-sulfur hydrocarbon fuels to an essentially sulfur-free gas. The removal of sulfur from reformate is critical since most catalysts used for the steam reformation have limited sulfur tolerance. Chemochromic Hydrogen Leak Detectors for Safety Monitoring ? N. Mohajeri and N. Muradov, Florida Solar Energy Center This project developed and demonstrated a cost-effective and highly selective chemochromic (visual) hydrogen leak detector for safety monitoring at any facility engaged in transport, handling and use of hydrogen. Development of High Efficiency Low Cost Electrocatalysts for Hydrogen Production and PEM Fuel Cell Applications ? M. Rodgers, Florida Solar Energy Center The objective of this project was to decrease platinum usage in fuel cells by conducting experiments to improve catalyst activity while lowering platinum loading through pulse electrodeposition. Optimum values of several variables during electrodeposition were selected to achieve the highest electrode performance, which was related to catalyst morphology. Understanding Mechanical and Chemical Durability of Fuel Cell Membrane Electrode Assemblies ? D. Slattery, Florida Solar Energy Center The objective of this project was to increase the knowledge base of the degradation mechanisms for membranes used in proton exchange membrane fuel cells. The results show the addition of ceria (cerium oxide) has given durability improvements by reducing fluoride emissions by an order of magnitude during an accelerated durability test. Production of Low-Cost Hydrogen from Biowaste (HyBrTec?) ? R. Parker, SRT Group, Inc., Miami, FL This project developed a hydrogen bromide (HyBrTec?) process which produces hydrogen bromide from wet-cellulosic waste and co-produces carbon dioxide. Eelectrolysis dissociates hydrogen bromide producing recyclable bromine and hydrogen. A demonstration reactor and electrolysis vessel was designed, built and operated. Development of a Low-Cost and High-Efficiency 500 W Portable PEMFC System ? J. Zheng, Florida State University, H. Chen, Bing Energy, Inc. The objectives of this project were to develop a new catalyst structures comprised of highly conductive buckypaper and Pt catalyst nanoparticles coated on its surface and to demonstrate fuel cell efficiency improvement and durability and cell cost reductions in the buckypaper based electrodes. Development of an Interdisciplinary Hydrogen and Fuel Cell Technology Academic Program ? J. Politano, Florida Institute of Technology, Melbourne, FL This project developed a hydrogen and fuel cell technology academic program at Florida Institute of Technology in Melbourne, Florida. Design and Development of an Advanced Hydrogen Storage System using Novel Materials ? E. Stefanakos, University of South Florida The goal of this project was to design and develop novel conducting polymeric nanomaterials for on-board hydrogen storage. The project approach was to examine synthesis of polyaniline solid state hydrogen storage materials. Advanced HiFoil ? Bipolar Plates ? J. Braun, M. Fuchs, EnerFuel, Inc. The goal of this project was to provide a durable, low cost bipolar plate for high temperature proton exchange membrane fuel cells. The project results produced a durable, low cost bipolar plate with very high in-plane thermal conductivity.

Rod Borup is a Team Leader in the fuel cell program at Los Alamos National Lab in Los Alamos, New Mexico. He received his B.S.E. in Chemical Engineering from the University of Iowa in 1988 and his Ph.D. from the University of Washington in 1993. He has worked on fuel cell technology since 1994, working in the areas of hydrogen production and PEM fuel cell stack components. He has been awarded 12 U.S. patents, authored over 40 papers related to fuel cell technology, and presented over 50 oral papers at national meetings. His current main research area is related to water transport in PEM fuel cells and PEM fuel cell durability. Recently, he was awarded the 2005 DOE Hydrogen Program R&D Award for the most significant R&D contribution of the year for his team's work in fuel cell durability and was the Principal Investigator for the 2004 Fuel Cell Seminar (San Antonio, TX, USA) Best Poster Award. Jeremy Meyers is an Assistant Professor of materials science and engineering and mechanical engineering at the University of Texas at Austin, where his research focuses on the development of electrochemical energy systems and materials. Prior to joining the faculty at Texas, Jeremy workedmore » as manager of the advanced transportation technology group at UTC Power, where he was responsible for developing new system designs and components for automotive PEM fuel cell power plants. While at UTC Power, Jeremy led several customer development projects and a DOE-sponsored investigation into novel catalysts and membranes for PEM fuel cells. Jeremy has coauthored several papers on key mechanisms of fuel cell degradation and is a co-inventor of several patents. In 2006, Jeremy and several colleagues received the George Mead Medal, UTC's highest award for engineering achievement, and he served as the co-chair of the Gordon Research Conference on fuel cells. Jeremy received his Ph.D. in Chemical Engineering from the University of California at Berkeley and holds a Bachelor's Degree in Chemical Engineering from Stanford University. Bryan Pivovar received his B.S. in Chemical Engineering from the University of Wisconsin in 1994. He completed his Ph.D. in Chemical Engineering at the University of Minnesota in 2000 under the direction of Profs. Ed Cussler and Bill Smyrl, studying transport properties in fuel cell electrolytes. He continued working in the area of polymer electrolyte fuel cells at Los Alamos National Laboratory as a post-doc (2000-2001), as a technical staff member (2001-2005), and in his current position as a team leader (2005-present). In this time, Bryan's research has expanded to include further aspects of fuel cell operation, including electrodes, subfreezing effects, alternative polymers, hydroxide conductors, fuel cell interfaces, impurities, water transport, and high-temperature membranes. Bryan has served at various levels in national and international conferences and workshops, including organizing a DOE sponsored workshop on freezing effects in fuel cells and an ARO sponsored workshop on alkaline membrane fuel cells, and he was co-chair of the 2007 Gordon Research Conference on Fuel Cells. Minoru Inaba is a Professor at the Department of Molecular Science and Technology, Faculty of Engineering, Doshisha University, Japan. He received his B.Sc. from the Faculty of Engineering, Kyoto University, in 1984 and his M.Sc. in 1986 and his Dr. Eng. in 1995 from the Graduate School of Engineering, Kyoto University. He has worked on electrochemical energy conversion systems including fuel cells and lithium-ion batteries at Kyoto University (1992-2002) and at Doshisha University (2002-present). His primary research interest is the durability of polymer electrolyte fuel cells (PEFCs), in particular, membrane degradation, and he has been involved in NEDO R&D research projects on PEFC durability since 2001. He has authored over 140 technical papers and 30 review articles. Kenichiro Ota is a Professor of the Chemical Energy Laboratory at the Graduate School of Engineering, Yokohama National University, Japan. He received his B.S.E. in Applied Chemistry from the University of Tokyo in 1968 and his Ph.D. from the University of Tokyo in 1973. He has worked on hydrogen energy and fuel cells since 1974, working on materials science for fuel cells and water electrolysis. He has published more than 150 original papers, 70 review papers, and 50 scientific books. He is now the president of the Hydrogen Energy Systems Society of Japan, the chairman of the Fuel Cell Research Group of the Electrochemical Society of Japan, and the chairman of the National Committee for the Standardization of the Stationary Fuel Cells. ABSTRACT TRUNCATED« less

The project's objective was to develop a model or framework for DOE to use in managing research and development programs to the stage at which they are commercialized by the private sector, principally by using the 40 kW fuel cell program as a case study. A concurrent study objective was to develop a framework for DOE decisions regarding the 40 kW fuel cell program itself. The general model for commercialization id discussed; conclusions of the study are presented; and the implicaions of these conclusions for immediate action by DOE are detailed. It is concluded that the fuel cell has sufficiently attractive characteristics to make a significant contribution to energy policy if costs can be brought down to a level competitive with conventional technologies. (WHK)

The Department of Energy Hydrogen and Fuel Cells Program Plan outlines the strategy, activities, and plans of the DOE Hydrogen and Fuel Cells Program, which includes hydrogen and fuel cell activities within the EERE Fuel Cell Technologies Program and the DOE offices of Nuclear Energy, Fossil Energy, and Science.

This report summarizes comments from the Peer Review Panel at the 2009 DOE Hydrogen Program Annual Merit Review, held on May 18-22, 2009, in Arlington, Virginia. It covers the program areas of hydrogen production and delivery; hydrogen storage; fuel cells; education; safety, codes, and standards; technology validation; systems analysis; and manufacturing R&D.

<div class="section abstract"><div class="htmlview paragraph">One of the most critical elements in engineering a hydrogen fuel cell vehicle is the design of the on-board hydrogen storage system. Because the current compressed-gas hydrogen storage technology has several key challenges, including cost, volume and capacity, materials-based storage technologies are being evaluated as an alternative approach. These materials-based hydrogen storage technologies include metal hydrides, chemical hydrides, and adsorbent materials, all of which have drawbacks of their own. To optimize the engineering of storage systems based on these materials, it is critical to understand the impacts these systems will have on the overall vehicle system performance and what trade-offs between the hydrogen storage systems and the vehicle systems might exist that allow these alternative storage approaches to be viable.</div><div class="htmlview paragraph">To gain a better understanding of the interactions that exist between various materials-based hydrogen storage systems and the vehicle system as well as the engineering challenges that exist when integrating one of these systems with a vehicle, the National Renewable Energy Laboratory (NREL) developed a vehicle-level model designed to be sensitive to these issues. The Hydrogen Storage Simulation Model (HSSIM) was developed under the Hydrogen Storage Engineering Center of Excellence (HSECoE) as a specialized tool that could be used to assist in the design and engineering of materials-based hydrogen storage systems being considered by the HSECoE. This tool is designed to not only allow for understanding key trade-offs, but also to have a seamless integration with the HSECoE fuel cell and detailed hydrogen storage system models and to evaluate progress towards the U.S. Department of Energy's hydrogen storage technical targets. This model has been integrated with a fuel cell model developed by Ford Motor Company in a HSECoE common modeling framework developed by United Technologies Research Center and other HSECoE partners.</div><div class="htmlview paragraph">This paper focuses on the development, structure, and validation of the vehicle model HSSIM and summarizes its integration within the framework. HSSIM and the framework are then used to obtain trade-offs for various specific materials-based storage system designs. This includes hydrogen storage sizing analyses, mass compounding analyses, range versus volume studies, and vehicle and component performance analyses, such as acceleration rates and fuel cell and energy storage interactions.</div></div>

Hydrogen production has become an emerging technology and offered a pathway to sustainable energy utilization in transportation systems. In this paper, we propose a coordinated planning of the electricity network and hydrogen refueling and production station planning strategy for hydrogen fuel cell electric vehicles (FCEVs). In the proposed system structure, a hydrogen supply chain for FCEVs mainly composes hydrogen refueling stations (HRSs), hydrogen production stations (HPSs), hydrogen storage, and hydrogen delivery network. To enhance the system's flexibility, hydrogen delivery combines both gas pipeline delivery and truck logistics delivery. In the mathematical models, the synergistic effect and coupling relationship of the electricity network, gas network, and transportation network are presented. To ensure the efficiency and effectiveness of the hydrogen refueling system, a quality of service (QoS) and reliability assessment method is presented. The proposed methodology is verified in case studies. It is found out that compared with the single delivery methods, the proposed multi-network coordinated planning has the lowest total cost with less unserved energy. Besides, through QoS and reliability assessment, enough hydrogen reserves can be maintained to cope with contingencies.

Goal of the fuel cell program is to increase energy efficiency and economic effectiveness through development and commercialization of fuel cell systems which operate on fossil fuels in multiple end use sectors. DOE is participating with the private sector in sponsoring development of molten carbonate fuel cells and solid oxide fuel cells for application in the utility, commercial, and industrial sectors. Commercialization of phosphoric acid fuel cells is well underway. Besides the introduction, this document is divided into: goal/objectives, program strategy, technology description, technical status, program description/implementation, coordinated fuel cell activities, and international activities.

The purpose of this project was to investigate and evaluate the attractiveness of using a magnesium chemical hydride slurry as a hydrogen storage, delivery, and production medium for automobiles. To fully evaluate the potential for magnesium hydride slurry to act as a carrier of hydrogen, potential slurry compositions, potential hydrogen release techniques, and the processes (and their costs) that will be used to recycle the byproducts back to a high hydrogen content slurry were evaluated. A 75% MgH2 slurry was demonstrated, which was just short of the 76% goal. This slurry is pumpable and storable for months at a time at room temperature and pressure conditions and it has the consistency of paint. Two techniques were demonstrated for reacting the slurry with water to release hydrogen. The first technique was a continuous mixing process that was tested for several hours at a time and demonstrated operation without external heat addition. Further work will be required to reduce this design to a reliable, robust system. The second technique was a semi-continuous process. It was demonstrated on a 2 kWh scale. This system operated continuously and reliably for hours at a time, including starts and stops. This process could be readily reduced to practice for commercial applications. The processes and costs associated with recycling the byproducts of the water/slurry reaction were also evaluated. This included recovering and recycling the oils of the slurry, reforming the magnesium hydroxide and magnesium oxide byproduct to magnesium metal, hydriding the magnesium metal with hydrogen to form magnesium hydride, and preparing the slurry. We found that the SOM process, under development by Boston University, offers the lowest cost alternative for producing and recycling the slurry. Using the H2A framework, a total cost of production, delivery, and distribution of $4.50/kg of hydrogen delivered or $4.50/gge was determined. Experiments performed at Boston University have demonstrated the technical viability of the process and have provided data for the cost analyses that have been performed. We also concluded that a carbothermic process could also produce magnesium at acceptable costs. The use of slurry as a medium to carry chemical hydrides has been shown during this project to offer significant advantages for storing, delivering, and distributing hydrogen: • Magnesium hydride slurry is stable for months and pumpable. • The oils of the slurry minimize the contact of oxygen and moisture in the air with the metal hydride in the slurry. Thus reactive chemicals, such as lithium hydride, can be handled safely in the air when encased in the oils of the slurry. • Though magnesium hydride offers an additional safety feature of not reacting readily with water at room temperatures, it does react readily with water at temperatures above the boiling point of water. Thus when hydrogen is needed, the slurry and water are heated until the reaction begins, then the reaction energy provides heat for more slurry and water to be heated. • The reaction system can be relatively small and light and the slurry can be stored in conventional liquid fuel tanks. When transported and stored, the conventional liquid fuel infrastructure can be used. • The particular metal hydride of interest in this project, magnesium hydride, forms benign byproducts, magnesium hydroxide (“Milk of Magnesia”) and magnesium oxide. • We have estimated that a magnesium hydride slurry system (including the mixer device and tanks) could meet the DOE 2010 energy density goals. During the investigation of hydriding techniques, we learned that magnesium hydride in a slurry can also be cycled in a rechargeable fashion. Thus, magnesium hydride slurry can act either as a chemical hydride storage medium or as a rechargeable hydride storage system. Hydrogen can be stored and delivered and then stored again thus significantly reducing the cost of storing and delivering hydrogen. Further evaluation and development of this concept will be performed as follow-on work under another project. However, since the cost of reducing magnesium from magnesium oxide makes up 85% of the cost of the slurry, if hydrogen can be stored many times in the slurry, then the cost of storing hydrogen can be spread over many units of hydrogen and can be significantly reduced from the costs of a chemical hydride system. This may be the most important finding of this project. If the slurry is used to carry a rechargeable hydride, the slurry can be stored in a conventional liquid fuel tank and delivered to a release system as hydrogen is needed. The release system will contain only the hydride needed to produce the hydrogen desired. This is in contrast to conventional designs proposed for other rechargeable hydride systems that store all the hydride in a large and heavy pressure and heat transfer vessel.

The presentation will provide an overview of the U.S. Department of Energy's (DOE) Hydrogen, Fuel Cell, and Infrastructure Technologies program with a focus on DOE's work to develop a unified domestic program and agenda for hydrogen codes and standards. This program involves the DOE, key standards development and model code development organizations, industry and industry associations, other federal agencies, and national laboratories. The paper will describe the objectives, approach, and major elements of this collaborative effort. Recent accomplishments and on-going activities will also be discussed.

This report summarizes the hydrogen and fuel cell R&D activities and accomplishments of the DOE Hydrogen Program for FY2009. It covers the program areas of hydrogen production and delivery; fuel cells; manufacturing; technology validation; safety, codes and standards; education; and systems analysis.

Systems based on hypo-eutectic Mg–Mg2Ni alloys for medium to large scale hydrogen storage and delivery

Hydrogen delivery through liquid organic hydrides: Considerations for a potential technology

Efficient hydrogen storage is critical for advancing hydrogen-based technologies. This study investigates the effects of pressure and surface area on hydrogen storage in three carbon-based materials: graphite, graphene oxide, and reduced graphene oxide. Hydrogen adsorption–desorption experiments under pressures ranging from 1 to 9 bar revealed nonlinear storage capacity responses, with optimal performance at around 5 bar. The specific surface area plays a pivotal role, with reduced graphene oxide and exhibiting a surface area of 70.31 m2/g, outperforming graphene oxide (33.75 m2/g) and graphite (7.27 m2/g). Reduced graphene oxide achieved the highest hydrogen storage capacity, with 768 sccm and a 3 wt.% increase over the other materials. In assessing proton-exchange fuel cell performance, this study found that increased hydrogen storage correlates with enhanced power density, with reduced graphene oxide reaching a maximum of 0.082 W/cm2, compared to 0.071 W/cm2 for graphite and 0.017 W/cm2 for graphene oxide. However, desorption rates impose temporal constraints on fuel cell operation. These findings enhance our understanding of pressure–surface interactions and underscore the balance between hydrogen storage capacity, surface area, and practical performance in carbon-based materials, offering valuable insights for hydrogen storage and fuel cell applications.