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Sunday, April 10, 2022

Hydrogen vs Fossil Fuels: The Fight of the Century


    "Huge amounts of uncounted emissions of highly warming greenhouse gas methane are being released by "super-emitters" all over the world, satellite observations reveal. 
    Scientists have only recently worked out how to detect methane emissions from space, but what they have seen since has taken them by surprise. The greenhouse gas, which is 80 times more potent than carbon dioxide, is leaking from gas pipelines, oil wells, fossil fuel processing plants and landfills all over the world. It is frequently released through negligence and improper operations; the emissions, in many cases, are not accounted for in mandatory greenhouse gas inventories. 
    'We see quite a lot of those super-emitters,' Ilse Aben, senior scientist at the Netherlands Institute for Space Research (SRON) told Space.com. 'These are large emissions, and we see a lot of them on the global scale — much more than we had expected."
 
Source: "Satellites discover huge amounts of undeclared methane emissions", Tereza Pultarova, Space.com, published Nov 15, 2021. 

The above excerpt, as alarming as it sounds, is only part of the existential threat that greenhouse gas (GHG) emissions represent. Every life form on earth is being affected by GHG emissions, and the effects are growing by the day.

We are being stalked by an extinction-level monster of our own making. It has been increasing environmental temperatures, raising sea levels, driving ocean acidification, causing more severe weather patterns, increasing wildfires, worsening droughts in some regions, and giving rise to more flooding in others.

Consider the GHG emissions estimates shown at the top of this post from the U.S. Environment Protection Agency (EPA). 92% of U.S. carbon dioxide emissions come from the burning of fossil fuels; and 37% of methane emissions come from coal mining, natural gas and petroleum systems (e.g. leaks). Note that this latter figure is likely much higher due to unreported emissions based on recent satellite data.

But Wait, There’s More

When I was recruited by NASA in 1985 it seemed like a world away from the coal-fired power plant where I had previously worked. I would go on to develop power and propulsion technologies and systems for various rockets, aerospace vehicles, and spacecraft over the next several decades.

However, my first assignment was designing combustion experiments for basic research on the space shuttle. The principal investigator on one of those experiments was an internationally renowned combustion expert from Princeton University. When we started observing unexpected soot formation during one of the tests, he made the following remarks (paraphrased from memory):
"Soot is an interesting topic. There is a soot particle size above which the respiratory system in a healthy person filters it before reaching the lungs. At a smaller size, the soot particle is inhaled into the lungs but can also be exhaled out. Between those two size thresholds are soot particles that don't get filtered and can't be exhaled. These become trapped in the lungs. Diesel soot falls into this category. That's why the exhaust outlets of diesel vehicles are generally positioned so high..."
The casual manner in which he delivered this information stunned me. Stammering in response, I asked "You mean to tell me that diesel soot I've breathed in during my life so far, and all that I'll inhale the rest of my life, may be permanently trapped in my lungs?" "That's right", he matter-of-factly responded.   


We’ve Played This Game Before (Many Times)

Public safety always takes a back seat to profit. It doesn't matter what industry, which company, or who is involved. If there are vested interests making substantial revenue from a product that results in severe health risks, heavy lobbying and campaign contributions will always delay accountability for decades.

It seems to be a consistent pattern of our species that we sacrifice our own collective well being in the name of industrial progress. Asbestos, coal dust, dioxins, lead, mercury, nuclear radiation exposure, oil spills, particulate emissions, PCBs, pharmaceuticals, plastic waste, sulfur emissions, VOCs, … the list goes on and on. GHGs are just another variation on the theme.

Previous cycles of this form of tragedy of the commons have resulted in untold disease and death since the dawn of the industrial revolution. This time, however, the impact is global in reach and catastrophic in consequence for all of us.

In This Corner Weighing in at One Atomic Mass Unit...

After my brief stint in low gravity combustion research, I began developing, testing and deploying liquid hydrogen technologies and systems starting in the mid-1980s. This would become a core part of my career for the next 35 years, and continues to be so.

Most of those liquid hydrogen projects were related to aerospace, defense and energy systems. More recently, this has expanded to transportation vehicles and infrastructure systems. In the early days, the hydrogen community was very concentrated and technically proficient. This has changed considerably in the last few years as mentioned in a previous post.

Transitioning to hydrogen represents one of the fundamental solutions to the GHG emission problem, along with addressing the plethora of public health impacts of fossil fuel usage. Large scale electrolysis plants are coming online at a rapid clip to cleanly produce hydrogen from water using renewable energy resources.

These renewable resources can be from overgeneration capacity; dedicated microgrids; and/or from regions where solar, wind, water, or geothermal energy far exceed the regional electrical demand. The latter case represents a lucrative opportunity for some regions to be primary exporters of hydrogen to the regions with high electrical demand but limited renewable resources (e.g. the recent trade agreement involving Australia exporting liquid hydrogen to Japan).

When hydrogen is fed to a fuel cell for electrical generation, water vapor is the only emission. When burned in a turbine or engine, water vapor and NOx are the only emissions. Note the NOx is a byproduct of all high temperature combustion processes and can be reduced by a variety of methods.

Hydrogen released into water or air readily combines with available oxygen and hydroxides to form water vapor. Preferable to releasing it, however, leaked or vented hydrogen can be used in fuel cells for auxiliary power. It can also be recaptured and compressed or liquefied to minimize waste. If release of hydrogen in air is absolutely necessary for a given system operation, it can also be flared to mitigate unwanted local concentrations.

Made from water with renewable energy. Returned to water in a fuel cell or combustion process. Hydrogen is the infinity fuel for our sustainable future. In future posts, I'll delve more deeply into the details of our shared path to the liquid hydrogen era.


Matt Moran is the Managing Member at Moran Innovation LLC, and previous Managing Partner at Isotherm Energy. He's been developing power and propulsion systems for more than 40 years; and first-of-a-kind liquid, slush and gaseous hydrogen systems since the mid-1980s. Matt was also the Sector Manager for Energy & Materials in his last position at NASA where he worked for 31 years. He's been a cofounder in seven technology based start-ups; and provided R&D and engineering support to many industrial, government and research organizations. Matt has three patents and more than 50 publications including the Cryogenic Fluid Management report series. More about him can be found here.

Sunday, April 3, 2022

LH2 Era Outline for Upcoming Posts

Hydrogen Energy and Renewables Architecture (HyERA)™



Following up on my previous post, below is a draft outline of planned topics to address in upcoming posts on the transition to the liquid hydrogen era. Any feedback or other suggested topics of interest to address are welcome and appreciated: info@moraninnovation.com.

  1. Introduction
    • The infinity fuel (why hydrogen?)
    • Zero plus twenty (why cryogenic liquid?)
    • Energy in a bottle (storage, carrier, fuel)
  2. Evolution
    • Jet engines & aircraft (1930-1960)
    • Rocket stages (1960-today)
    • Other liquid hydrogen history
  3. Fundamentals
    • Cryogenics (properties, materials, basics)
    • Thermodynamics (temperature and pressure)
    • Managing LH2 (production, storage, transfer)
  4. State-of-the-Art
    • Tankage (vacuum jacket, single wall, insulation)
    • Components (valves, piping, sensors)
    • Operations (fill, vent, pressurize, drain)
  5. Safety
    • Hazards (physiological, phase change, ignition)
    • Design (best practices, reviews, standards)
    • Operations (planning, training, fail safes)
  6. Advancements
    • New materials (composites, insulation)
    • Cryo-refrigeration (zero boil-off, liquefaction)
    • Sensors & controls (gauging, leaks, monitor)
  7. Applications
    • Energy (production, storage, distribution)
    • Fuel (land, sea, air, space)
    • Heat (industrial, residential, CHP)
  8. Systems
    • Engineering (model, design, verify & validate)
    • Integration (subsystems, interfaces, test)
    • Deployment (commission, dynamics, learning)
  9. Strategy
    • Plan (NGOs, requirements, Conops)
    • Develop (innovation, prototyping, trades)
    • Launch (IP management, partners, growth)
  10. Conclusion
    • Summary (takeaways, gaps, path forward)
    • Challenges (techno-economic, vested interests)
    • Sustainable Future (transition, vision, legacy)
In my next post I'll start to answer the question: Why hydrogen?



Matt Moran is the Managing Member at Moran Innovation LLC, and previous Managing Partner at Isotherm Energy. He's been developing power and propulsion systems for more than 40 years; and first-of-a-kind liquid, slush and gaseous hydrogen systems since the mid-1980s. Matt was also the Sector Manager for Energy & Materials in his last position at NASA where he worked for 31 years. He's been a cofounder in seven technology based start-ups; and provided R&D and engineering support to many industrial, government and research organizations. Matt has three patents and more than 50 publications including the Cryogenic Fluid Management report series. More about him can be found here.

Saturday, March 26, 2022

Transitioning to the Liquid Hydrogen Era


NASA KSC 24-meter outer diameter liquid hydrogen dewar under construction in 2020 (left) and internal design (right)*

I co-founded my sixth technology based startup in early 2016 after ending a thirty-one year career at NASA. The new company was focused on hydrogen as the sustainable solution to our global challenges in the energy, mobility, food, and water nexus. This was a natural fit for my expertise and experience developing liquid, slush, and gaseous hydrogen systems since the mid-1980s.

My business partner and I spent several years developing hydrogen system designs for various applications in the energy, agriculture, aerospace, and transportation market sectors. It was the classic Venn diagram overlap of our personal passions, unique capabilities, and the most urgent global needs. However, the general feedback at the time was that despite our unique expertise with these systems there was insufficient impetus to transition to widespread hydrogen use.

Historically, the hydrogen community has been small and concentrated. Early work with liquid hydrogen systems and applications was well underway in the U.S. in the 1950s at NBS (now NIST) and NACA (the precursor to NASA). The space industry has been the largest user of liquid hydrogen since the 1960s; supported by the cryogenic liquiefied gas production companies and prime aerospace contractors; and largely funded by the space and defense agencies of a few countries. Over time, an established supply chain of hydrogen technology, component and subsystem providers has developed. Other commodity users of hydrogen also emerged in steel making, food processing, semiconductor fabrication, and various research facilities.

This state of affairs changed dramatically in the past few years with an unprecedented growth in interest and investments in hydrogen systems for transitioning the global economy away from greenhouse gas emitting fuels. Unfortunately, the newfound interest in hydrogen has brought with it newly self-proclaimed experts. Organizations and individuals with little or no hydrogen experience - and who in some cases openly dismissed hydrogen just a few years ago - are now clamoring for related government funding. Startups are attracting large capital investments for hydrogen applications despite often lacking personnel with any significant relevant experience.

As a result, conversations around the transition to hydrogen frequently become mired in strongly held opinions rather than evidence-based reality. Some factions are hyping their own hydrogen system concepts without the requisite knowledge to assess the associated technical and economic feasibility, let alone the risks. At the other end of the spectrum are vehement hydrogen detractors who make hand waving arguments rooted in misinformation. They also often have a vested interest in legacy systems or competing technologies that are threatened by hydrogen.

In upcoming posts, I'll attempt to separate the signal from the noise based on more than 35 years of designing, developing, and deploying hydrogen systems as large as 4732 cubic meters of usable liquid hydrogen with zero boil-off losses*. The goal is to provide a clear-eyed perspective on transitioning to the liquid hydrogen era, and demonstrate that there are no true technology gaps preventing the widespread use of liquid hydrogen. Rather, the remaining challenges relate to experienced systems engineering, capital investments, competitive business models, market acceptance, public policy, and regulatory maturation.

*References:
  1. Fesmire and Swanger, "Overview of the New LH2 Sphere at NASA Kennedy Space Center", DOE/NASA Advances in Liquid Hydrogen Storage Workshop, Aug, 2021.
  2. Moran, "No-Loss Liquid Hydrogen and LNG Systems (Zero Boil-Off)", May 12, 2018. (https://blog.matthewemoran.com/2018/05/no-loss-liquid-hydrogen-and-lng-systems.html)


Matt Moran is the Managing Member at Moran Innovation LLC, and previous Managing Partner at Isotherm Energy. He's been developing power and propulsion systems for more than 40 years; and first-of-a-kind liquid, slush and gaseous hydrogen systems since the mid-1980s. Matt was also the Sector Manager for Energy & Materials in his last position at NASA where he worked for 31 years. He's been a cofounder in seven technology based start-ups; and provided R&D and engineering support to many industrial, government and research organizations. Matt has three patents and more than 50 publications including the Cryogenic Fluid Management report series. More about him can be found here.

Tuesday, March 15, 2022

Cryogenic Fluid Management of Liquid Hydrogen...


Executive Summary


This report provides passive cryogenic fluid management (CFM) insights, methods, equations, and algorithms suitable for performing system designs and trades. The content is intended for engineers, designers, analysts, managers and others who are developing or operating passive CFM systems.

Topics covered are based on cryogenic systems subject matter expertise at Moran Innovation LLC that has been developed over the past 35 years. Each main section concludes with calculation examples to demonstrate how to use the equations presented and interpret the results.

Main sections and subsections include:
  • Introduction to mission and vehicle drivers, thermophysical properties, thermodynamic behavior, fluid dynamics and heat transfer.
  • Acceleration and thermal environments, and how these environments vary based on mission segment.
  • Tankage for the storage of cryogenic propellants including: material properties; design and sizing; heat loads and insulation; and packaging and integration.
  • Venting of cryogenic tanks and associated implications such as: cryogen losses; liquid level rise in low gravity; and utilization of vent gas for propulsive settling and/or structural cooling.
  • Pressurization and pressure response of tanks including: active pressurization, interfacial heat and mass transfer, self-pressurization, and ullage collapse.
  • Other passive CFM topics including: chilldown and tank filling; tank internal insulation and structures; tank external structures and components; mass and energy balance; and propellant tracking.
  • References section with all sources cited in the footnotes; and an Appendix with instructions on how to access additional online content, and information on Moran Innovation LLC.

Online Access


The report is available online and can be accessed at: www.moraninnovation.com

The online version is a shared document in pdf format with viewer permission granted. Download and print functions are disabled. If you are having difficulty accessing the document, check with the IT department at your organization to ensure online access to shared Google Docs is permitted.




Matt Moran is the Managing Member at Moran Innovation LLC, and previous Managing Partner at Isotherm Energy. He's been developing power and propulsion systems for more than 40 years; and first-of-a-kind liquid, slush and gaseous hydrogen systems since the mid-1980s. Matt was also the Sector Manager for Energy & Materials in his last position at NASA where he worked for 31 years. He's been a cofounder in seven technology based start-ups; and provided R&D and engineering support to many industrial, government and research organizations. Matt has three patents and more than 50 publications including the Cryogenic Fluid Management report series. More about him can be found here.

Monday, December 20, 2021

Moran Innovation 2021 Highlights

NASA KSC LC39B New Liquid Hydrogen Dewar Tank (left: under construction in 2020, right: near completion in 2021)


  • Hydrogen Systems Development: Past, Present and Future. Seminar presentation to LTA Research on the evolution of hydrogen systems in aerospace along with present day state-of-the-art technologies and future hydrogen systems. A publicly available abstract and version of the presentation package can be found here.
  • Densified and No-Loss (Zero Boil-off) Liquid Hydrogen Systems. An overview of these systems along with safety considerations and proven mitigations presented at the Center for Hydrogen Safety Asia-Pacific Conference 2021. The abstract, video and presentations slides can be found here.
  • Liquid Hydrogen Drones and Microgrids. US Air Force funded project to demonstrate extended duration drones and integrated hydrogen energy storage for base operations under subcontract to NEOEx Systems. A $10 million earmark from the 2022 US federal defense appropriation budget will support further development of liquid hydrogen refueling systems.
  • Lunar Human Landing System (HLS). Support to NASA under subcontract to HX5 as a subject matter expert in cryogenic fluid management for the SpaceX HLS development of the first commercial human lander that will safely carry astronauts to the lunar surface.
  • Long Term Liquid Hydrogen Storage. Support to NASA under subcontract to HX5 for the Lockheed Martin Tipping Point testing of more than a dozen cryogenic fluid management technologies, positioning them for infusion into future space systems.
  • Orbital Cryogenic Propellant Transfer. Support to NASA under subcontract to HX5 for the SpaceX Tipping Point large-scale flight demonstration to transfer cryogenic propellant, specifically liquid oxygen, between tanks on a Starship vehicle.
  • New design tools and training courses. Several new software tools for liquid hydrogen systems and cryogenic fluid management were created in 2021. Training courses on these topic areas are also under development and planned for rollout in 2022.
  • Lunar ice mining concept. "Down Under Excavation and Transport (DUET) Lunar Mining System (LuMiS)", Free J., Cannard S., Sciortino J., Rhatigan J., Haberbusch M., Moran M. Submitted to the NASA Break the Ice Challenge and presented at the 2021 Lunar Surface Science Workshop.
  • Other news. See the Moran Innovation website and blog at LH2era.com for more in depth information and news on hydrogen, propulsion, and power systems.


Matt Moran is the Managing Member at Moran Innovation LLC, and previous Managing Partner at Isotherm Energy. He's been developing power and propulsion systems for more than 40 years; and first-of-a-kind liquid, slush and gaseous hydrogen systems since the mid-1980s. Matt was also the Sector Manager for Energy & Materials in his last position at NASA where he worked for 31 years. He's been a cofounder in seven technology based start-ups; and provided R&D and engineering support to many industrial, government and research organizations. Matt has three patents and more than 50 publications including the Cryogenic Fluid Management report series. More about him can be found here.

Sunday, October 31, 2021

Densified Liquid Hydrogen and No-Loss (Zero Boil-off) Systems




Conference: Center for Hydrogen Safety (CHS) Asia-Pacific Conference, Nov 30 - Dec 2, 2021 AEST (Nov 29 - Dec 1 PST)

Abstract: Liquid hydrogen (LH2) can be thermodynamically conditioned to increase storage density compared to normal boiling point conditions in a process known as densification. A variety of methods to produce densified hydrogen have been successfully demonstrated using vacuum pumping or cryo-refrigeration. Additional system advantages beyond increased storage capacity include: increased cooling capacity for longer storage times or heat sink functions; greater vehicle payloads and/or range; higher mass flow rates; smaller hydrogen delivery components; and the potential for more efficient oxidizer-fuel ratios for some applications. No-loss LH2 systems have been demonstrated using cryo-refrigeration which enables zero boil-off storage and transfer operations. Gaseous hydrogen can also be liquified or re-liquefied in either continuous or batch processes. Additionally, high pressure and temperature LH2 can be thermodynamically conditioned to colder and lower pressure conditions without venting using cryo-refrigeration. The resulting system can operate for years without any boil-off losses. In the case of all these densified and zero boil-off LH2 systems, a key safety risk is the potential for subatmospheric conditions within the storage vessel and other fluid system components. The associated potential for air in-leakage and structural buckling failures can result in a catastrophic event. Proven mitigation methods are presented to manage this risk.



Video: 






Matt Moran is the Managing Member at Moran Innovation LLC, and previous Managing Partner at Isotherm Energy. He's been developing power and propulsion systems for more than 40 years; and first-of-a-kind liquid, slush and gaseous hydrogen systems since the mid-1980s. Matt was also the Sector Manager for Energy & Materials in his last position at NASA where he worked for 31 years. He's been a cofounder in seven technology based start-ups; and provided R&D and engineering support to many industrial, government and research organizations. Matt has three patents and more than 50 publications including the Cryogenic Fluid Management report series. More about him can be found here.

Saturday, October 9, 2021

Hydrogen Systems Development: Past, Present and Future



Technological evolution often requires decades of incubation and advancement in a variety of fields before large scale commercial adoption is achieved. Hydrogen has followed these trends since its discovery in the late 1700’s and subsequent application for wide ranging industrial uses. Liquid hydrogen (LH2) has been in routine and continuous use in the space program since the early 1960’s. However, many are not aware that its roots in aerospace trace much further back in aviation to the initial jet engine research and development in the late 1930’s; and later with successful flight demonstrations of a liquid hydrogen fueled jet engine in the mid-1950’s.

Modern LH2 systems make use of vacuum jacketed dewars for long term storage on the ground. Flight vehicles have used single wall tanks with foam insulation which significantly reduces mass but is only viable if the consumption rate in flight is greater than the boil-off venting required to meet tank pressure constraints. Composite LH2 tanks of various types (with or without metal inner liners) have been attempted over the years with mixed success and are still under development.

Safety with LH2 is a paramount priority. Key drivers are related to hydrogen’s properties, LH2 cryogenic temperatures, and liquid-vapor phase change within the system. Many legacy standards, codes and guidelines exist for LH2, and many more are in active formulation or revision. The three primary mantras to remember when designing and operating hydrogen systems is: 1) provide ventilation, 2) prevent leaks, and 3) eliminate ignition sources. Understanding the thermodynamic behavior of LH2 systems during various operations is also critical.

The development of future hydrogen systems can be optimized using an adaptive systems approach that treats hydrogen as a critical enabler in an overall system architecture rather than simply a commodity fuel. Selecting architecture options permit trade studies of candidate system concepts that can be assessed on the basis of technical, economic, environmental impact, and other key performance metrics. The end result is the ability to optimize systems for a multitude of hydrogen applications that can then be modeled, simulated, developed, assembled, and put into operation. Further, the proven ability to eliminate boil-off losses in LH2 systems - and provide better performing and sustainable propulsion and power relative to legacy fossil fuel systems - will play a key role in the global transition to hydrogen





Matt Moran is the Managing Member at Moran Innovation LLC, and previous Managing Partner at Isotherm Energy. He's been developing power and propulsion systems for more than 40 years; and first-of-a-kind liquid, slush and gaseous hydrogen systems since the mid-1980s. Matt was also the Sector Manager for Energy & Materials in his last position at NASA where he worked for 31 years. He's been a cofounder in seven technology based start-ups; and provided R&D and engineering support to many industrial, government and research organizations. Matt has three patents and more than 50 publications including the Cryogenic Fluid Management report series. More about him can be found here.