India

Correlating hydrogen embrittlement phenomenon with the metallic microstructural features holds the key for developing metals resistant to hydrogen-based failures. In case of fatigue failure of hydrogen charged metals in addition to the hydrogen-based failure mechanisms associated with monotonic loading such as HELP HEDE etc. microstructural features such as grain size type of grain boundary (special/random) fraction of special grain boundaries; their network and triple junctions can play a complex role. The probable sites for fatigue crack initiation in such metals can be identified as the sites of highest hydrogen concentration or accumulated plastic strain. To this end we have developed an experimental framework based on in-situ fatigue crack initiation and propagation studies under scanning electron microscope (SEM) to identify the weakest link in the metallic microstructure leading to failure. In-situ fatigue experiments are performed on carefully designed polycrystalline nickel (99.95% pure) specimens (miniaturised shallow-notched & electro-polished) using a 10 kN fatigue stage inside the SEM. Electron Back Scattering Diffraction (EBSD) map of the notched region surface helps identify the distribution of special/random grain boundaries triple junctions and grain orientation. The specimen surface in the shallow notched region for both the hydrogen charged and un-charged specimens are then carefully studied to correlate the microstructural feature associated with fatigue crack initiation sites. Such correlation of the fatigue crack initiation site and microstructural feature is further corroborated with the knowledge of hydrogen trapping and grain’s elastic anisotropicity to be either the site of high hydrogen concentration accumulated plastic slip or both.

Present work describes the failure analysis of cooling duct of a fighter aircraft. The analyzed chemical composition of cooling duct indicates that it is manufactured from Al-based alloy (AA 3003 or its equivalent). Microstructure of cooling duct displays the presence of two phases namely matrix and insoluble particles. The hardness values at different locations within damaged area of cooling duct reflect nearly same and consistent. The fracture surface of the cooling duct exhibits transgranular features and cracks with little branching. The analyzed hydrogen content in cooling duct is significantly higher (∼ 12 ppm) than the specified one (< 1 ppm). However the alloy used to fabricate cooling duct is not susceptible to typical hydrogen embrittlement. This shows hydrogen pick up during operation. The presence of cracks with branching does reflect features of hydrogen embrittlement. In addition striations indicative of fatigue features are also observed. It thus appears that the cooling duct has failed due to pick up of large amount of hydrogen as well as vibrational fatigue.

Emerging hydrogen energy technologies are creating new avenues for bring hydrogen fuel usage into larger public domain. Identification of possible accidental scenarios and measures to mitigate associated hazards should be well understood for establishing best practice guidelines. Accidentally released hydrogen forms flammable mixtures in a very short time. Ignition of such a mixture in congestion and confinements can lead to greater magnitudes of overpressure catastrophic for both structure and people around. Hence understanding of the permissible level of confinements and congestion around the hydrogen fuel handling and storage unit is essential for process safety. In the present study numerical simulations have been performed for the hydrogen-air turbulent deflagration in a well-defined congestion of repeated pipe rig experimentally studied by [1]. Large Eddy Simulations (LES) have been performed using the in-house modified version of the OpenFOAM code. The Flame Surface Wrinkling Model in the LES context is used for modelling deflagrations. Numerical predictions concerning the effects of hydrogen concentration and congestion on turbulent deflagration overpressure are compared with the measurements [1] to provide validation of the code. Further insight about the flame propagation and trends of the generated overpressures over the range of concentrations are discussed.

Hydrogen (H2) has attained significant benefits as an energy carrier due to its gross calorific value (GCV) and inherently clean operation. Thus hydrogen as a fuel can lead to global sustainability. Conventional H2 production is predominantly through fossil fuels and electrolysis is now identified to be most promising for H2 generation. This review describes the recent state of the art and challenges on ultra-pure H2 production through methanol electrolysis that incorporate polymer electrolyte membrane (PEM). It also discusses about the methanol electrochemical reforming catalysts as well as the impact of this process via PEM. The efficiency of H2 production depends on the different components of the PEM fuel cells which are bipolar plates current collector and membrane electrode assembly. The efficiency also changes with the nature and type of the fuel fuel/oxygen ratio pressure temperature humidity cell potential and interfacial electronic level interaction between the redox levels of electrolyte and band gap edges of the semiconductor membranes. Diverse operating conditions such as concentration of methanol cell temperature catalyst loading membrane thickness and cell voltage that affect the performance are critically addressed. Comparison of various methanol electrolyzer systems are performed to validate the significance of methanol economy to match the future sustainable energy demands.

For sustainable and incremental growth mankind is adopting renewable sources of energy along with storage systems. Storing surplus renewable energy in the form of hydrogen is a viable solution to meet continuous energy demands. In this paper the concept of electrochemical hydrogen storage in a solid multi-walled carbon nanotube (MWCNT) electrode integrated in a modified unitized regenerative fuel cell (URFC) is investigated. The method of solid electrode fabrication from MWCNT powder and egg white as an organic binder is disclosed. The electrochemical testing of a modified URFC with an integrated MWCNT-based hydrogen storage electrode is performed and reported. Galvanostatic charging and discharging was carried out and results analyzed to ascertain the electrochemical hydrogen storage capacity of the fabricated electrode. The electrochemical hydrogen storage capacity of the porous MWCNT electrode is found to be 2.47 wt% which is comparable with commercially available AB5-based hydrogen storage canisters. The obtained results prove the technical feasibility of a modified URFC with an integrated MWCNT-based hydrogen storage electrode which is the first of its kind. This is surelya step forward towards building a sustainable energy economy

Compressed natural gas (CNG) is being increasingly used as a clean transportation fuel. However for further reduction in emissions particularly NOx H-CNG mixture with ~ 20 % hydrogen is recommended. Presently most of the H-CNG mixture is produced by blending hydrogen with CNG. For hydrogen production Steam Methane Reforming (SMR) is a major process accounting for more than 90% of hydrogen production by various industries. In this process natural gas is first reformed to syn gas under severe operating conditions (Pressure 20-30 bar temperature 850-950 deg C) followed by conversion of CO to hydrogen in the shift reactor. Other method of hydrogen production such as electrolysis of water is more expensive. Further there are issues of safety with handling of hydrogen its storage and transportation for blending. In order to overcome these problems a single step compact process for the production of H-CNG gaseous mixture through low severity steam methane reforming of natural gas has been developed. It employs a catalyst containing nickel nickel oxide magnesium oxide and silica and has the capability of producing H-CNG mixture in the desired proportion containing 15-20 vol % hydrogen with nil CO production. The process is flexible and rugged allowing H-CNG production as per the demand. The gaseous H-CNG product mixture can directly be used as automobile fuel after compression. The process can help as important step in safe transition towards hydrogen economy. A demonstration unit is being set up at IOC R&D Centre.

Renewable energy has become very popular in recent years. The amount of renewable generation has increased in both grid-connected and stand-alone systems. This is because it can provide clean energy in a cost-effective and environmentally friendly fashion. Among all varieties photovoltaic (PV) is the ultimate rising star. Integration of other technologies with solar is enhancing the efficiency and reliability of the system. In this paper a fuel cell–solar photovoltaic (FC-PV)-based hybrid energy system has been proposed to meet the electrical load demand of a small community center in India. The system is developed with PV panels fuel cell an electrolyzer and hydrogen storage tank. Detailed mathematical modeling of this system as well as its operation algorithm have been presented. Furthermore cost optimization has been performed to determine ratings of PV and Hydrogen system components. The objective is to minimize the levelized cost of electricity (LCOE) of this standalone system. This optimization is performed in HOMER software as well as another tool using an artificial bee colony (ABC). The results obtained by both methods have been compared in terms of cost effectiveness. It is evident from the results that for a 68 MWh/yr of electricity demand is met by the 129 kW Solar PV 15 kW Fuel cell along with a 34 kW electrolyzer and a 20 kg hydrogen tank with a LPSP of 0.053%. The LCOE is found to be in 0.228 $/kWh. Results also show that use of more sophisticated algorithms such as ABC yields more optimized solutions than package programs such as HOMER. Finally operational details for FC-PV hybrid system using IEC 61850 inter-operable communication is presented. IEC 61850 information models for FC electrolyzer hydrogen tank were developed and relevent IEC 61850 message exchanges for energy management in FC-PV hybrid system are demonstrated.

Blending hydrogen into natural gas pipelines is a recent alternative adopted for hydrogen transportation as a mixture with natural gas. In this paper hydrogen embrittlement of steel pipelines originally designed for natural gas transportation is investigated. Solubility permeation and diffusion phenomena of hydrogen molecules into the crystalline lattice structure of the pipeline material are followed up based on transient evolution of internal pressure applied on the pipeline wall. The transient regime is created through changes of gas demand depending on daily consumptions. As a result the pressure may reach excessive values that lead to the acceleration of hydrogen solubility and its diffusion through the pipeline wall. Furthermore permeation is an important parameter to determine the diffusion amount of hydrogen inside the pipeline wall resulting in the embrittlement of the material. The numerical obtained results have shown that using pipelines designed for natural gas conduction to transport hydrogen is a risky choice. Actually added to overpressure and great fluctuations during transients that may cause fatigue and damage the structure also the latter pressure evolution is likely to induce the diffusion phenomena of hydrogen molecules into the lattice of the structure leading to brittle the pipe material. The numerical simulation reposes on solving partial differential equations describing transient gas flow in pipelines coupled with the diffusion equation for mass transfer. The model is built using the finite elements based software COMSOL Multiphysics considering different cases of pipe material; API X52 (base metal and nutrided) and API X80 steels. Obtained results allowed tracking the evolution with time of hydrogen concentration through the pipeline internal wall based on the pressure variation due to transient gas flow. Such observation permits to estimate the amount of hydrogen diffused in the metal to avoid leakage of this flammable gas. Thus precautions may be taken to prevent explosive risks due to hydrogen embrittlement of steel pipelines among other effects that can lead to alter safe conditions of gas conduction.

The effect of hydrogen on short crack propagation under cyclic loading in SA508 Grade 3 Class I low alloy steel is investigated. This low alloy steel is used in manufacturing of pressure vessel installed in Indian nuclear power plants. During operation these pressure vessels are subjected to continuous supply of pressurized hot water at 600 K and hence are susceptible to hydrogen embrittlement. In past research has been conducted on the effect of hydrogen embrittlement on long fatigue crack propagation in this material but the mechanistic understanding and correlation of hydrogen embrittlement with microstructural features in the material can be understood well by studying the effect of hydrogen embrittlement on short fatigue crack propagation. Short fatigue cracks are of the order of 10 µm to 1 mm and unlike long cracks these short cracks strongly interact with the microstructural features in the material such as grain/phase boundaries. The effect of hydrogen embrittlement on short crack propagation is studied by artificial hydrogen charging of the material through electrochemical process. The single edge notch tension (SENT) specimens with an initial notch of the order of 85 to 90 µm are used to study the short crack propagation. The short cracks in hydrogen charged samples initiated from the notch at lower number of loading cycles as compared to the uncharged notched samples for the same value of applied stress range (Δσ). After initiation the short fatigue crack in hydrogen charged samples propagated at higher rate as compared to uncharged samples. This dissimilarity in crack propagation behavior is due to the difference in the interaction of short fatigue crack with the microstructural features for a hydrogen charged and uncharged samples.

Hydrogen is the most efficient energy carrier. Hydrogen can be obtained from different sources of raw materials including water. Among many hydrogen production methods eco-friendly and high purity of hydrogen can be obtained by water electrolysis. However In terms of sustainability and environmental impact PEM water electrolysis was considered as most promising techniques for high pure efficient hydrogen production from renewable energy sources and emits only oxygen as byproduct without any carbon emissions. Moreover the produced hydrogen (H₂) and oxygen (O₂) directly used for fuel cell and industrial applications. However overall water splitting resulting in only 4% of global industrial hydrogen being produced by electrolysis of water mainly due to the economic issues. Nowadays increased the desire production of green hydrogen has increased the interest on PEM water electrolysis. Thus the considerable research has been completed recently in the development of cost effective electrocatalysts for PEM water electrolysis. In this present review we discussed about the recent developments in the PEM water electrolysis including high performance low cost HER and OER electrocatalysts and their challenges new and old related to electrocatalysts and PEM cell components also addressed. This review will contribute further research improvements and a road map in order to support in developing the PEM water electrolyser as a commercially feasible hydrogen production purpose.