Progress Report for Hydrogen, Fuel Cells, and Infrastructure Technologies Program

Table of contents :
Cover……Page 1
Acknowledgement……Page 2
Title Page……Page 3
Table of Contents……Page 4
Section I. Introduction……Page 10
Section II. Hydrogen Production and Delivery……Page 28
II.A.1 Biological Water Gas Shift Development……Page 30
II.A.2 Maximizing Photosynthetic Efficiencies and H2 Production in Microalgal Cultures……Page 36
II.A.3 Efficient Hydrogen Production Using Enzymes of the Pentose Phosphate Pathway……Page 42
II.A.4 Biohydrogen Production from Renewable Organic Wastes……Page 47
II.A.5 Photobiological Algal H2 Production……Page 51
II.B.1 H2 Production by Catalytic Reforming of Pyrolysis Vapors……Page 58
II.B.2 Supercritical Water Partial Oxidation……Page 68
II.B.3 Biomass-Derived Hydrogen from a Thermally Ballasted Gasifier……Page 72
II.B.4 Techno-Economic Analysis of Hydrogen Production by Gasification of Biomass……Page 77
II.C.1 Production of Hydrogen by Superadiabatic Decomposition of Hydrogen Sulfide……Page 80
II.C.2 Thermal Dissociation of Methane Using a Solar-Coupled Aerosol Flow Reactor……Page 85
II.C.3 Thermocatalytic CO2-Free Production of Hydrogen From Hydrocarbon Fuels……Page 92
II.C.4 Novel Catalytic Fuel Processing Using Micro-Channel Steam Reforming and Advanced Separatio………Page 96
II.C.5 ITM Syngas and ITM H2: Engineering Development of Ceramic Membrane Reactor Systems for Con………Page 101
II.C.6 Integrated Ceramic Membrane System for Hydrogen Production……Page 106
II.C.7 Low Cost Hydrogen Production Platform……Page 111
II.C.8 Effects of Fuel Constituents on Fuel Processor Catalysts……Page 115
II.C.9 Separation Membrane Development……Page 120
II.C.10 Defect-Free Thin Film Membranes For H2 Separation and Isolation……Page 124
II.C.11 DFMA Cost Estimates of Fuel-Cell/Reformer Systems at Low/Medium/ High Production Rates……Page 129
II.D.1 Photoelectrochemical Systems for Hydrogen Production……Page 134
II.D.2 Photoelectrochemical Hydrogen Production……Page 139
II.D.3 Photoelectrochemical Hydrogen Production Using New Combinatorial Chemistry Derived Materials……Page 145
II.D.4 Combinatorial Discovery of Photocatalysts for Hydrogen Production……Page 153
II.D.5 Low Cost, High Efficiency Reversible Fuel Cell Systems……Page 157
II.D.6 High-Efficiency Steam Electrolyzer……Page 161
II.D.7 Enabling Science for Advanced Ceramic Membrane Electrolyzers……Page 165
II.D.8 Hydrogen Production Through Electrolysis……Page 170
II.E.1 Development of a Turnkey Commercial Hydrogen Fueling Station……Page 175
II.E.2 Autothermal Cyclic Reforming Based Fueling System……Page 179
II.E.3 Development of a Natural Gas to Hydrogen Fuel Station……Page 184
II.E.4 Distributed Hydrogen Fueling Systems Analysis: Cost and Performance Comparison of Stationa………Page 188
II.E.5 Technical Analysis: Integrating a Hydrogen Energy Station into a Federal Building……Page 193
II.F.1 Hydrogen Technical Analysis……Page 198
II.F.2 Hydrogen Infrastructure Studies……Page 203
Section III. Hydrogen Storage……Page 208
III.A.1 Hydrogen Composite Tank Program……Page 210
III.A.2 Hydrogen Storage Using Lightweight Tanks……Page 214
III.A.3 Hydrogen Storage in Insulated Pressure Vessels……Page 219
III.A.4 Advanced Thermal Hydrogen Compression……Page 222
III.A.5 Development of a Compressed Hydrogen Gas Integrated Storage System for Fuel Cell Vehicles……Page 227
III.A.6 Low Permeation Liner for Hydrogen Gas Storage Tanks……Page 232
III.B.1 Hydrogen Storage in Carbon Single-Wall Nanotubes……Page 235
III.B.2 Doped Carbon Nanotubes for Hydrogen Storage……Page 240
III.B.3 Hydrogen Storage in Metal-modified Single-Walled Carbon Nanotubes……Page 244
III.C.1 Catalytically Enhanced Hydrogen Storage Systems……Page 248
III.C.2 Complex Hydrides for Hydrogen Storage……Page 253
III.C.3 High-Density Hydrogen Storage Demonstration Using NaAlH4 Based Complex Compound Hydrides……Page 256
III.C.4 Standardized Testing Program for Emergent Chemical Hydride and Carbon Storage Technologies……Page 260
III.C.5 Hydrogen Fueled ICE Scooter with On-Board Metal Hydride Storage……Page 264
III.C.6 Hydride Development For Hydrogen Storage……Page 269
Section IV. Fuel Cells……Page 274
IV.A.1 Atmospheric Fuel Cell Power System for Transportation……Page 276
IV.A.2 Fuel Cell Systems Analysis……Page 279
IV.A.3 Fuel Cell Vehicle Systems Analysis……Page 284
IV.A.4 Cost Analyses of Fuel Cell Stack/Systems……Page 288
IV.B.1 Alkaline Fuel Cell Development……Page 292
IV.B.2 Development of Advanced, Low-Cost PEM Fuel Cell Stack and System Design for Operation on R………Page 294
IV.B.3 Proton Exchange Membrane Fuel Cell Power System on Ethanol……Page 299
IV.B.4 Fuel Cell Distributed Power Package Unit: Fuel Processing Based on Autothermal Cyclic Refo………Page 303
IV.B.5 Research and Development on an Ultra-Thin Composite Membrane For High-Temperature Operatio………Page 306
IV.C.1 Next Millennium Fuel ProcessorTM for Transportation Fuel Cell Power System……Page 309
IV.C.2 Multi-fuel Processor for Fuel Cell Electric Vehicle Applications……Page 314
IV.C.3 Quick-Starting of Fuel Processors……Page 318
IV.C.4 Microchannel Fuel Processor Development……Page 322
IV.C.5 Plate-Based Fuel Processing System……Page 329
IV.C.6 Fuel Processors for PEM Fuel Cells……Page 334
IV.C.7 Evaluation of Partial Oxidation Fuel Cell Reformer Emissions……Page 337
IV.C.8 Catalysts for Autothermal Reforming……Page 341
IV.C.9 Fuel Processing of Diesel Fuel for Auxiliary Power Units……Page 346
IV.C.10 Testing of Fuels in Fuel Cell Reformers……Page 351
IV.C.11 Sulfur Removal from Reformate……Page 357
IV.C.12 Nanoscale Water Gas Shift Catalysts……Page 361
IV.C.13 Water-Gas Shift Catalysis……Page 365
IV.C.14 Transition Metal Carbide Water Gas Shift Catalysts……Page 369
IV.C.15 Development of Novel Water-Gas-Shift Membrane Reactor……Page 373
IV.D.1 R&D of a 50 kW, High Efficiency, High Power Density, CO-Tolerant PEM Fuel Cell Stack System……Page 378
IV.D.2 Development of Comprehensive Computer Models for Simulation of Fuel Cell Systems……Page 382
IV.D.3 High Performance, Matching PEM Fuel Cell Components and Integrated Pilot Manufacturing Pro………Page 388
IV.D.4 Design and Installation of a Pilot Plant for High-Volume Electrode Production……Page 395
IV.D.5 Integrated Manufacturing for Advanced Membrane Electrode Assemblies……Page 399
IV.D.6 Development of High Temperature Membranes and Improved Cathode Catalysts……Page 404
IV.D.7 High-Temperature Membranes……Page 409
IV.D.8 Bacterial Cellulose Membranes……Page 413
IV.D.9 Nano-particulate Porous Oxide Electrolyte Membranes (POEMs) as Proton Exchange Membranes……Page 417
IV.D.10 Low-Platinum Catalysts for Oxygen Reduction at PEMFC Cathodes……Page 422
IV.D.11 Low Platinum Loading Catalysts for Fuel Cells……Page 427
IV.D.12 Development of High-Performance, Low-Pt Cathodes Containing New Catalysts and Layer Struc………Page 432
IV.D.13 New Electrocatalysts for Fuel Cells……Page 438
IV.D.14 Electrodes for Polymer Electrolyte Membrane Fuel Cell Operation on Hydrogen/Air and Refor………Page 442
IV.D.15 Nondestructive Study of the Water Transport Mechanism Inside Operating PEM Fuel Cells Usi………Page 447
IV.D.16 Direct Methanol Fuel Cells……Page 450
IV.D.17 Development of Advanced Catalysts for Direct Methanol Fuel Cells……Page 456
IV.D.18 Carbon Composite Bipolar Plates……Page 460
IV.D.19 Cost-Effective Surface Modification for Metallic Bipolar Plates……Page 463
IV.D.20 Scale-Up of Carbon/Carbon Composite Bipolar Plates……Page 467
IV.D.21 Carbon Foam for Fuel Cell Humidification……Page 472
IV.D.22 Carbon Monoxide Sensors For Reformate Powered Fuel Cells……Page 477
IV.D.23 Electrochemical Sensors for PEMFC vehicles……Page 482
IV.D.24 Development of Sensors for Automotive Fuel Cell Systems……Page 485
IV.D.25 Design and Development of New Glass-Ceramic Proton Conducting Membranes……Page 489
IV.D.26 Fuel Cell System Durability……Page 494
IV.E.1 Turbocompressor for PEM Fuel Cells……Page 499
IV.E.2 Development and Testing of a High Efficiency Integrated Compressor/ Expander Based on Toro………Page 503
IV.E.3 Turbocompressor for Vehicular Fuel Cell Service……Page 508
IV.E.4 Motor Blower Technologies for Fuel Cell Automotive Power Systems……Page 512
IV.E.5 Hybrid Compressor/Expander Module……Page 517
IV.F.1 Precious Metal Availability and Cost Analysis for PEMFC Commercialization……Page 522
IV.F.2 Assessment of Fuel Cell Auxiliary Power Systems for Onroad Transportation Applications……Page 526
IV.F.3 Guidance for Transportation Technologies: Fuel Choice for Fuel Cell Vehicles……Page 531
IV.F.4 Fuel Cell R&D and Demonstration……Page 535
IV.F.5 Advanced Underground Vehicle Power and Control Fuel Cell Mine Locomotive……Page 539
Section V. Integrated Hydrogen and Fuel Cell Demonstration/Analysis……Page 544
V.A.1 Analysis of Hydrogen Production Using Ammonia and Ammonia-Borane Complex for Fuel Cell Appl………Page 546
V.A.2 Well-to-Wheels Analysis of Energy and Emission Impacts of Fuel Cell Vehicle Fuels……Page 552
V.A.3 Hydrogen and Fuel Cell Vehicle Evaluation……Page 556
V.A.4 Power Parks System Simulation……Page 559
V.A.5 Process Analysis Work for the DOE Hydrogen Program – 2001……Page 563
V.B.1 Real-World Demonstration of Fuel Cell Vehicles and Refueling Technology……Page 567
V.B.2 Filling Up With Hydrogen 2000……Page 572
V.B.3 Hydrogen Reformer, Fuel Cell Power Plant, and Vehicle Refueling System……Page 576
Section VI. Safety and Codes & Standards……Page 580
VI.A.1 Gallium Nitride Integrated Gas/Temperature Sensors for Fuel Cell System Monitoring for Hyd………Page 582
VI.A.2 Interfacial Stability of Thin Film Hydrogen Sensors……Page 586
VI.A.3 Micro-Machined Thin Film H2 Gas Sensors……Page 590
VI.B.1 Hydrogen Infrastructure Activities Codes and Standards: Hydrogen Codes and Standards Outreach……Page 594
VI.B.2 Codes and Standards Analysis……Page 600
VI.B.3 Hydrogen Codes and Standards……Page 604
VI.B.4 SAE Fuel Cell Codes and Standards Initiative……Page 607
Section VII. Conversion Devices……Page 612
VII.A.1 Reduced Turbine Emissions using Hydrogen-Enriched Fuels……Page 614
VII.B.1 Internal Combustion Engines Research And Development……Page 618
VII.B.2 HCNG Heavy Duty Vehicle Prime Mover……Page 622
Acronyms……Page 628
Appendix A. Draft DOE Technical Targets……Page 634
Index of Primary Contacts……Page 646
Disclaimer……Page 648
Back Cover……Page 649