A Brief History of Fuel Cells in Space Applications: Past, Present, and Future

by Haboon Osmond, FCHEA, with special thanks to Ian Jakupca, NASA GRC - LEX

Fuel cells and electrolyzers have long been used in the United States to explore the last frontier: space. This article will highlight the past, present, and future use cases.

Interestingly, the relationship between liquid hydrogen and space travel predates the founding of the National Aeronautics and Space Administration (NASA). In 1957, nearly one year before NASA’s beginning, the U.S. Air Force was working on a proposal to develop a new space booster powered by hydrogen that could place sizeable payloads in geosynchronous Earth orbit (GEO). The proposal would, in turn, create the Centaur Upper Stage Rocket, which helped the United States to eclipse the Soviet Union in the twenty-year Space Race. 

The first applications of fuel cells in the United States were developed specifically for the aerospace sector. In 1962, General Electric developed the first polymeric ion exchange membrane (IEM) fuel cell fuel cell for NASA’s Gemini V spacecraft, generating both power and drinking water.  A few years later, hydrogen helped land humans on the Moon with the alkaline fuel cell technology powering the Command and Service Module (CSM)! Apollo 11, the monumental spaceflight, was powered by three 1420 W (2,300 W emergency peak) alkaline fuel cells. Starting in the 1970s, the use of fuel cells in NASA spacecraft was extensive as it powered the Space Shuttle Orbiters. For example, the now-retired United States Space Shuttle was powered by three fuel cells from 1981 to 2011, producing a nominal 7 kW of power yet rated for 12 kW long durations and up to 16 kW for 20 minutes.

When the Space Shuttle retired, fuel cells were no longer needed to provide power to spaceships. Currently, fuel cells are not used on modern spacecraft because the short-term energy needs of current missions can be satisfied using batteries. 

To understand more about NASA’s history in fuel cells for space applications, please see the following articles:

Spacecraft Systems Become More Troublesome

Gemini 5 Fact Sheet

Currently, NASA is researching fuel cells capable of powering a lunar lander, future lunar habitats, and potential space cities on the Moon and Mars. As part of these activities, NASA is considering alkaline, proton-exchange membrane (PEM), and solid oxide fuel cells and electrolysis systems in future space missions. NASA presented at the 2023 Department of Energy Annual Merit Review with an overview presentation available here.

However, the potential use of such technologies in future missions necessitates safety standards for fuel cell use in space applications. Although there is much activity by many players working to develop standards for fuel cells in aerospace applications, there is currently no standard for qualifying fuel cells for space applications due to issues such as vibration requirements and electromagnetic interference requirements. There is a NASA standard NASA STD-6016-C: Standard Materials and Processes Requirements for Spacecraft; however, it does not yet cover fuel cell and electrolysis systems.

Fuel cells present much potential to power modern spacecraft. With proper safety standards, fuel cells will allow humankind to continue to boldly explore our final frontier.

ASME Update

by Karen Quackenbush, FCHEA

ASME recently published ASME TGP-1-2023: Guidelines to ASME Standards in Hydrogen Value Chains. ASME shared that the intent of this guidance document is to summarize existing standards in hydrogen value chains and identify relevant standards for specific hydrogen applications. The document is available through ASME here.

ASME also approved a new Code Case for Electrolyzer Cell Stack Assemblies. The Code Case is expected to be published very shortly. The Code Case provides rules that may be used to fabricate gasketed electrochemical cell stacks in compliance with Section VIII, Division 1. While Code Cases are not mandatory, compliance may be required by an authority having jurisdiction during the permitting process. Feedback on the Code Case will be considered by ASME as they develop a mandatory appendix on this subject in a future edition of ASME BPVC Section VIII. 

The rules in this Code Case cover the minimum requirements for design, fabrication, assembly, inspection, testing, and documentation of planar geometry gasketed electrochemical cell stacks (ECS) within the Scope described in U-1 for electrolysis. Electrolyzer cell stack assemblies with a maximum allowable working pressure greater than 15 psi, and a cell stack diameter greater than 6 inches fall within the scope of the new rules.

Once the Code Case is published, FCHEA will add it to our Regulatory Affairs Matrix and the searchable codes and standards database available at  https://h2tools.org/codes-standards.

DOE’s Hydrogen and Fuel Cell Technologies Office and the National Renewable Energy Laboratory to Host an Electrolyzer Installation Workshop on September 26–27

by Haboon Osmond, FCHEA

On September 26-27, 2023, HFTO will host a virtual workshop on electrolyzer installations. To support the future growth of large-scale electrolyzer installations, the U.S. Department of Energy’s Hydrogen and Fuel Cell Technologies Office (HFTO), in collaboration with the National Renewable Energy Laboratory, is hosting a two-day Electrolyzer Installation Workshop to share and discuss lessons learned and best practices for electrolyzer installations. The workshop will include discussions of key challenges and cost drivers associated with installing large-scale electrolyzer systems, and opportunities to reduce costs and streamline processes. The workshop will also include discussions of water and electrical requirements, safety, siting, standards, and cost analysis. 

Please click here to learn more about the webinar and view the meeting agenda. To register, please click here.

SAMPE’s Call for Abstracts

by Haboon Osmond, FCHEA 

As the only technical society encompassing all fields of endeavor in materials and processes, the Society for the Advancement of Material and Process Engineering (SAMPE) conference provides the most extensive and applicable programming for the advanced materials and processes industry anywhere in the world. Each conference category includes a variety of programs that engage and educate on ground-breaking technologies, industry advances, and provide opportunity to source solutions for critical challenges.

SAMPE North America is seeking technical paper and ITAR abstract submissions for the SAMPE 2024 Conference and Exhibition in Long Beach, CA on May 20-23, 2024. The deadline for abstracts is October 1, 2023. To submit your abstract, please visit here. 

Conference Tracks:

  • Additive manufacturing

  • Advances in composites manufacturing technology

  • Clean and sustainable energy

  • Composites qualification and certification

  • Design, analysis, and simulation Emergent materials and applications

  • Factory of the future Government programs and projects

  • Joining, assembly, maintenance and repair

  • Materials for extreme environments

  • Sustainable technologies and circular economy

  • Thermoplastic materials and processes

EuroCAE Call for Participation

by Karen Quackenbush, FCHEA

EuroCAE/ SAE WG-80 / AE-7F has announced a new activity: MASPS Hydrogen Fuel Cells for Propulsion.

The scope of this new standard is the usage of hydrogen PEM fuel cells for the generation of electrical power for propulsion systems and for airplane electrical systems that distribute for critical systems (primary power) such as flight controls, hydraulic, pneumatic, and avionic. The standard would cover all equipment, subsystems, and installation aspects that allow the hydrogen PEM fuel cell system to perform its intended function, such as energy buffering elements (batteries, supercaps, flying-wheels, etc.), thermal management systems, flammable and fire zoning, drainage, vent, inerting, etc. Maintenance is also part of the scope.

The standard would also provide an acceptable means for the certification of the hydrogen PEM fuel cell system in applicable uses such as calculations, simulations, analysis, lab, ground, and flight testing.

The rationale for this activity is that there are currently several proposals to use fuel cells for the generation of power onboard aircraft to supply electrical propulsion systems and also for primary power supply for flight controls and avionics. Existing standards regarding fuel cells for aviation were elaborated when the objective of the usage of fuel cells was for secondary or non-critical applications, such as galley power, APU, electric taxi, medevac, etc. None of them considered propulsion or critical systems, including those standards already published by this committee.

Therefore, there is a need to address this kind of application. A survey was carried out to understand the best way to address that issue, and the results pointed out for a new standard dedicated to fuel cells for propulsion as opposed to revising the existing standards. This result was presented in July 2022, and the proposal for a new standard dedicated to hydrogen fuel cells for propulsion was approved. Members and coordination agreed on the viability of starting this activity by mid-2023, with the expected release in 18 months.

If you are interested in participating (actively or observer), please fill this registration form.

For further information, please contact Roel van Benthem, Carlos Mourao, or Esther Hoyas.

The Public Comment Period for CGA G-5, Hydrogen Has Begun

by Haboon Osmond, FCHEA

The public comment period for CGA G-5, Hydrogen has begun. The deadline to submit public comments during this 45-day public review period is Monday, October 30, 2023. 

If you are a CGA member, you can download the current ANS Committee-approved draft of CGA G-5 by clicking here. 

If you would like to submit comments, please use this form. Comments have to be submitted to Kristy Mastromichalis (kmastromichalis@cganet.com) with a copy to ANSI (psa@ansi.org).

Please note that any substantive changes made as a result of accepting public review comments require another consensus body and council vote as well as another public review. If no public comments are received during this public review, this publication will move directly into CGA print production and will undergo a final review in preparation for publication.

If you have any further questions, please contact Kristy Mastromichalis at kmastromichalis@cganet.com.

Hydrogen Certification 101

by Haboon Osmond, FCHEA

The International Partnership for Hydrogen and Fuel Cells in the Economy (IPHE) and the International Energy Agency’s Technology Hydrogen Collaboration Platform (IEA H2 TCP), with support from the International Renewable Energy Agency (IRENA) and contributions from the Hydrogen Council and the International Power-to-X Hub, released the Hydrogen Certification 101 paper. 

In the emerging global hydrogen economy, robust tradeable certification schemes for hydrogen and derivatives will:

  • Enable the implementation of government policies as certification can constitute an integral element of policy measures such as targets, quotas, and tax credits;

  • Evidence of their sustainability attributes, such as carbon footprint – as well as the use of land and water, and social impacts – credibly and consistently internationally;

  • Create transparency for consumers and enable consumer choice;

  • Allow consumers to signal the demand for hydrogen based on its sustainability credentials;

  • Create trust between prospective importers and exporters, fostering global, cross-border trade in hydrogen and derivatives based on their sustainability credentials.

To advance global cooperation on the certification of hydrogen and derivatives, the Hydrogen Certification 101 paper:

  • provides clarity and precision on terminology and concepts used in hydrogen certification;

  • describes the purposes and functionalities of hydrogen certification schemes;

  • offers basic information on certification scheme design;

  • and lays out the concept of mutual recognition of certification schemes for hydrogen and derivatives.

To learn more, please click here.

H2Tech September: Safety Article

by Haboon Osmond, FCHEA 

The September issue of H2Tech, the first publication devoted to the technology driving the hydrogen economy, includes a top story that focuses on advancing safety in the H2 value chain.

The article overviews the challenges of using hydrogen fuel and offers best practices to specify tubing that ensures safe, long-lasting, and effective refueling station designs.  

To read the article, please click here. 

Center of Hydrogen Safety’s Hydrogen Laboratories: Safety Considerations Webinar

by Haboon Osmond, FCHEA

On September 14, the Center for Hydrogen Safety (CHS) hosted a webinar designed to equip hydrogen laboratory researchers, industry practitioners, students, principal investigators, and administrators with the essential knowledge to work safely with hydrogen gas. CHS delved into the intricacies of hydrogen-related hazards, best practices, and safety considerations that are crucial for maintaining a secure and productive laboratory environment.

The webinar discussed the following objectives:

  • Understanding Best Practices for Hydrogen Handling: Gain a comprehensive understanding of the best practices for safely working with hydrogen gas. Learn about proper storage, transportation, and handling techniques to minimize risks.

  • Fostering a General Laboratory Safety Culture: Explore the importance of establishing a robust safety culture within laboratory settings. Understand how to integrate hydrogen-specific safety measures into the broader safety framework of your research organization.

  • Identifying, Preventing, and Mitigating Hydrogen Hazards: Develop skills to identify potential hydrogen-related hazards and implement effective preventive measures. Learn how to mitigate risks through proper engineering controls, protocols, and emergency response planning.

  • Design Considerations for Hydrogen Laboratories and Equipment: Delve into the critical aspects of designing hydrogen laboratories and experimental equipment and how selection can contribute to a safer working environment.

  • Overview of Safety and Emergency Planning: Acquire insights into safety and emergency planning specific to hydrogen laboratories. Learn how to develop emergency response procedures, evacuate lab spaces, and handle potential incidents involving hydrogen.

Larry Moulthrop and Gary Stottler were the webinar presenters.

For further information or to purchase a recording of the webinar, please visit here.

Summaries of FCHEA’s WG meetings

by Haboon Osmond, FCHEA

Production Working Group Meetings Summary 

FCHEA’s Production Working Group met on August 15. The group discussed updates and impact of federal policies, RCS developments, as well as recent ASME activities.

The Working Group also met on September 12. In addition to discussing information dissemination on hydrogen and fuel cell policies and RCS updates, Flexitallic, an FCHEA member, presented to the working group. Flexitallic gave an overview of its products (e.g., spiral wound gaskets, gaskets, Thermiculite), involvement in hydrogen (e.g., feedstocks, production & storage, transport & distribution, and applications), and its history with fuel cells & electrolysis. The market of environmental attributes and working group updates were discussed as well.

Power Working Group Meetings Summary

FCHEA’s Power Working Group met on August 8.  In addition to discussing information dissemination on hydrogen and fuel cell policies and RCS updates such as an ASME report, the meeting touched on working group updates.  

Distribution Working Group Meetings Summary

FCHEA’s Distribution Working Group met on September 7. In addition to discussing information dissemination on hydrogen and fuel cell policies and RCS updates, GKN Hydrogen, an FCHEA member, presented to the working group. GKN Hydrogen presented an overview of its robust supply chain, technologies, power-to-power architecture & micro solutions & MW-scale solutions, hydrogen storage, system and install arrangement, distributed hydrogen applications, and project benefits. The meeting closed with working group updates.

Transportation Working Group Meetings Summary

FCHEA’s Transportation Working Group met on August 1. In addition to discussing information dissemination on hydrogen and fuel cell policies and RCS updates, the meeting discussed working group updates and walk-in items.

The Working Group also met on September 5. In addition to discussing information dissemination on hydrogen and fuel cell policies and RCS updates, ANGI/Gilbarco, an FCHEA member, presented to the working group. ANGI gave an overview of its activities. ANGI has expanded its activities to cover hydrogen refueling stations. ANGI has a dispenser ready for market and undergoing the certification process, and it should be ready for customers by the end of 2023. The meeting closed with working group updates.

If your company is an FCHEA member and you or your colleagues want to be added to any of our Working Group, Committee, or Task Force rosters, please contact Haboon Osmond at hosmond@fchea.org..