NREL Fuel Cell and Hydrogen 

Systems Research

Shaun Onorato and Jennifer Kurtz

Georgia Tech University Webinar

October 16, 2018

NREL/PR-5400-72776
NREL | 2

Hydrogen at a glance

WHAT IS HYDROGEN? 

• One of the most abundant elements in the Universe

• Consists of only one proton and one electron

• Hydrogen is an energy carrier rather than energy source (stores and delivers energy) 

• Found in many substances in nature, but must be extracted for end use

– i.e., Fresh/sea water, biomass, hydrogen sulfide, and fossil fuels

WHY STUDY HYDROGEN? 

• Utilized in fuel cells to generate power using a chemical reaction rather than combustion, producing only water 

and heat as byproducts. 

– Used in vehicles, stationary power, portable power, etc.

HOW HYDROGEN PRODUCTION WORKS

• Hydrogen can be produced using diverse, domestic resources

– Fossil fuels (natural gas and coal), nuclear energy, and other renewable energy sources, such as biomass, 

wind, solar, geothermal, and hydro-electric power—using a wide range of processes.

https://www.energy.gov/eere/fuelcells/hydrogen-production
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Hydrogen Facts

FACTS

• Over ten million metric tons of hydrogen are currently produced in the United States every year (95% of which is 

via centralized reforming of natural gas)

– Other approaches include hydrogen production from water splitting, such as electrolysis, 

photoelectrochemical cells, or solar thermochemical systems. 

• The primary uses of hydrogen today are in the oil refining and ammonia industries.

• Other applications include fuel cell vehicles, metals refining, and synthetic natural gas production.

• Hydrogen can be produced:

– At or near the site of use (distributed production)

– At large facilities and then delivered to the point of use (central production)

– At intermediate scale facilities located in close proximity (25–100 miles) to the point of use (semi-central 

production).

• 1 Kg of Hydrogen (gas) = 1 gallon Gasoline equivalent

https://www.energy.gov/eere/fuelcells/hydrogen-production
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Methods for Making Hydrogen
NREL | 5

Hydrogen Production Pathways

The objective of the U.S. 

Department of Energy 

and the National 

Renewable Energy 

Laboratory is conduct 

R&D into the production 

of economical and 

environmentally friendly 

hydrogen by leveraging a 

diverse set of 

technologies. 

https://www.energy.gov/eere/fuelcells/hydrogen-production-pathways
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Hydrogen Production Methods

https://www.sciencedirect.com/science/article/pii/S0360319914034119
NREL | 7

Potential Hydrogen Demand

Industrial Use

Market potential 

(million metric 

tonne H2 / year)

Refineries & CPI§ 8*

Metals 5

Ammonia 5

Natural Gas 7

Biofuels 4

Light Duty Vehicles 28

Other Transport 3

Total 60

§ CPI: Chemical Processing Industry not including metals, biofuels, or ammonia

* Current potential used due to lack of consistent future projections

Light duty vehicle calculation basis: 190,000,000 light-duty FCEVs from http://www.nap.edu/catalog/18264/transitions-to-alternative-vehicles-and-fuels

1. Global hydrogen Generation Market by Merchant & Captive Type, Distributed & Centralized Generation, Application & Technology- Trends & Forecasts 

(2011-2016)

Total market 

potential: 

60 MMT/yr
NREL | 8

Why Hydrogen?

• Over half of U.S. CO2 emissions come from the industrial 

and transportation sectors

• Hydrogen can enable affordable, reliable, clean, and secure energy across 

sectors

• Large-scale, clean, cross-sector energy

• Energy system flexibility, resiliency, and hybridization

• Economic, security, and environmental benefits

NREL
NREL | 9

H2@Scale

Hydrogen integrated 

with multiple U.S. 

energy sectors 

https://www.energy.gov/eere/fuelcells/h2-scale
NREL | 10

Source: www.caiso.com/Documents/FlexibleResourcesHelpRenewables_FastFacts.pdf

Curtailment

• Integrated renewable-electrolysis systems

have the potential to reduce curtailment in

current and future power systems.

Electricity prices

• The flexibility of renewable-electrolysis

systems enables access to low-cost electricity

for hydrogen production and higher value

markets for renewable electrons.

Electricity markets

• Electrolyzers can participate in different

electricity markets, including energy and

ancillary services for grid balancing and

reliability, as well as capacity for resource

adequacy.

Controllable electrolyzers addressing renewable 

generation challenges

The “Duck” Curve

Renewables over-generate power in times of low demand and 

under-generate during times of high demand causing grid 

resiliency issues. Lack of energy storage solutions result in 

curtailment of renewables. 
NREL | 11

% Variable Renewable Energy

(of annual energy)

System Size (GW)

0.001 0.01 0.1 1 10 100 1000

25

50

75

100

Credit: B. Kroposki, NREL

8

0

5

2

3

Alaska 

Village

Ireland Cont. USA

4

2

Denmark*

3

5

Maui

1

4

CA*

Relatively 

Easy

Much 

Harder

WWSIS

CA 50%

Lanai

ERGIS

REF

54

DOE 2050 Goals

35% Wind (404 GW)

19% PV (632 GW)

Deep 

Decarbonization

1400 GW wind

900 GW Solar

78

* Part of a larger synchronous AC 

power system

2

0 Germany*

Extremely 

Difficult

Note: % VRE in 2015

WWSIS = Western Wind and 

Solar Integration Study

ERGIS = Eastern Renewable 

Generation Integration Study

REF = Renewable Electricity 

Futures Study

Actual Operating

System

Modeled System

What is at scale?
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Real-World H2@Scale Examples 

750,000 tonne/year ammonia plant using 

by-product hydrogen opens in Freeport, TX

(2018; Yara, BASF)

Integration of 10-MW of electrolysis with 

Rheinland Refinery Complex (Germany)

(2018; Shell)

Google Maps 2018 Google Maps 2018
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Steam-Methane Reforming

• The most economical and common form of H2

production today (in the United States) is by 

steam-methane reformation

• High-temperature steam (700°C–1,000°C) is used 

to produce H2 from a methane source (i.e., 

natural gas) 

• Reacts with steam under 3–25 bar pressure in the 

presence of a catalyst to produce H2, CO, and CO2

• Endothermic

Steam-methane reforming reaction

CH4 + H2O (+ heat) → CO + 3H2

Water-gas shift reaction

CO + H2O → CO2 + H2 (+ small amount of heat)

https://www.energy.gov/eere/fuelcells/hydrogen-production-natural-gas-reforming

NREL
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Electrolysis

Process of using electricity to split water into hydrogen and 

oxygen

• Types:

• Proton exchange membrane (PEM) (H+ transport)

• Solid oxide (O2-transport) 

• Alkaline (OH-transport)

• Tied to renewable and/or non-greenhouse-gas-emitting 

forms of electricity for green H2 production

• Primarily wind and nuclear

• Temperature range: 20°C–100°C

• Efficiency range: 60% – 70%

• R&D needs:

• Cost reduction, increased efficiency, and integrated 

compression 

• High temperature electrolysis for future R&D 

https://www.energy.gov/eere/fuelcells/hydrogen-production-electrolysis

Anode Reaction: 2H2O → O2 + 4H+ + 4eCathode Reaction: 4H+ + 4e- → 2H2
NREL | 15

Electrolysis Efficiency

NREL

https://www.hydrogen.energy.gov/pdfs/review17/tv031_hovsapian_2017_o.pdf

• Electrolysis efficiency increases with higher temperature

• High temperature electrolysis is an emerging and potentially breakthrough technology

• Innovations and R&D are needed for high temperature electrolysis. Scalability, novel materials, durability, and 

reliability remain a challenge.
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Key Focus Areas and End Uses

STORE

Improved Bulk Storage Technologies
NREL | 17

Hydrogen Production

>240MW

U.S. Snapshot and States with Growing Interest

More than

CA

HI, OH, SC, NY, CT, MA, CO, UT, 

TX, MI, and others with interest

• Up to 200 stations planned

• Over 35 public stations open

• 12–25 stations planned in the Northeast 

• 4 non-retail stations operating
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Hydrogen Stations

• 700 bar (10,000 psi) gaseous 

onboard storage chosen by 

the original equipment 

manufacturers (OEMs) for 

commercial passenger cars

• 350 bar (5,000 psi) gaseous 

was chosen for buses and lift 

trucks (i.e., forklifts)

• SAE J2601 standard dictates 

the protocols for fills

Source: https://www.energy.gov/eere/fuelcells/dispensing-hydrogen-fuel-vehicles

350 bar 700 bar

NREL

https://www.weh.us/refueling-systems-hydrogen.html/
NREL | 19

Material Handling

More than 20,000 fuel cell forklifts utilized 

across the United States

• Amazon, BMW, Fed-Ex, H-E-B, Kroger, 

Nissan, UPS, Walmart, Wegmans, 

Whole Foods warehouses

• Over 12 million refueling

• Targeting airport and warehouse tugs

NREL NREL
NREL | 20

Fuel Cell Bus and Heavy Duty

FCEBs in operation by year

2010 – 13

2017 – 25

2018 – 34 (estimate) https://www.nrel.gov/hydrogen/fuel-cell-bus-evaluation.html

NREL

NREL

NREL
NREL | 21

Fuel Cell Bus and Heavy Duty

“Toyota’s Heavy-Duty Fuel Cell Truck Finally Hits the Road”

Trucks.com 10/12/2017

“Nikola to Start Fuel Cell Truck Field Tests in Late 2018”

Trucks.com 11/09/2017

• Target market for FCEV technology

• Range, performance, and efficiency 
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Commercial Fuel Cell Electric Vehicles (FCEVs)

Toyota Mirai (2016–Present)

Power: 114 kW (153 hp)

Torque: 335 Nm (247 lbf⋅ft)

Fuel Economy: 66 mpg-e combined

Range: 312 miles

H2 Capacity: 5 Kg

Buy/Lease: $349/month for 36 mos. and 3 years/$15K in H2 fuel or 

$58,365 with 3 years/$15K H2 fuel

Honda Clarity FCV (2017–Present)

Power: 103 kW (174 hp)

Torque: 335 Nm (221 lbf⋅ft)

Fuel Economy: 68 mpg-e combined

Range: 366 miles

H2 Capacity: 5.46 Kg

Lease Only: $369/month for 36 mos. and 3 years/$15K in H2 fuel

Hyundai Nexo (2018 Pre-Production 2019 Release)

Power: 135 kW (160 hp)

Torque: 395 Nm (291 lbf⋅ft)

Fuel Economy: 60 mpg-e combined

Range: 370 miles

H2 Capacity: 6.3 Kg

Lease: $369/month for 36 mos. and 3 years/$15K in H2 fuel

https://automobiles.honda.com/clarity-fuel-cell

https://www.hyundainews.com/models/hyundai-nexo-2019-nexo/overview

https://ssl.toyota.com/mirai/fcv.html

Honda 2018

Hyundai 2018

NREL
NREL | 23

Commercial Fuel Cell Electric Vehicles (FCEVs)

Mercedes-Benz GLC F-Cell (Anticipated early 2019)

Power: TBD (PHEV with fuel cell hybrid powerplant)

Torque: TBD

Fuel Economy: TBD

Range: 30 miles electric and 271 miles total (hybrid)

H2 Capacity: TBD

Buy/Lease: Available early 2019 for fleets only 

General Motors Colorado ZH2 (2016)

Power: Not disclosed (based on GM FCEV models)

Torque: Not disclosed

Fuel Economy: Not disclosed

Range: Not disclosed

H2 Capacity: Not disclosed

Lease Only: Military demonstration only (TARDEC)

Daimler 2018

https://www.mercedes-benz.com/en/mercedes-benz/vehicles/passenger-cars/glc/the-new-glc-f-cell/

NREL

https://www.motortrend.com/news/gm-u-s-army-unveil-chevrolet-colorado-zh2-fuel-cell-truck/
NREL | 24

California FCEV Deployment

Source: https://www.arb.ca.gov/msprog/zevprog/ab8/ab8_report_2017.pdf

Increasing on-road FCEV 

counts are driving 

increased demand for 

hydrogen fueling
NREL | 25

New Applications and Opportunities

Leverage performance 

and economics of 

automotive fuel cell 

technology advances for 

new applications like a 

carbon-free data center 

with distribution fuel cell 

IT power. 

Daimler media 11/10/17 –

non-transportation fuel 

cell systems 

NREL

Source: https://www.sciencedirect.com/science/article/pii/S1464285917304273
NREL | 26

Have Batteries Won?

• Complex energy issues require multiple technology options where the system 

requirements drive system solutions

• Integrated energy sectors need economically viable, performance based solutions with 

optimization for duration and size

• A portfolio of mobility solutions ensures technologies that meet specific needs and 

operational profiles

Vehicle Energy Needs

Powertrain Cost

FCEV

BEV FCEVs offer extended range, fast 

refueling time, electric drivetrain, 

and scalable. 
NREL Fuel Cell and 

Hydrogen Research
NREL | 28

National Laboratories

The United States Department of Energy National Laboratories and Technology Centers are a system 

of facilities and laboratories overseen by the United States Department of Energy for the purpose of 

advancing science and technology to fulfill the DOE mission.

17 National Labs

• 10 Office of Science

• 4 DOE

• 3 NNSA

Golden, CO

https://science.energy.gov/laboratories/
NREL | 29

National economic impact

facilities, renowned 

technology experts

World-class

with industry, 

academia, and 

government

Partnerships

operates as a 

living laboratory

Campus National 

economic 

impact

NREL at a Glance

$872M

annually 1,800

Employees,

early-career researchers 

and visiting scientists

\

nearly

750 National economic impact

plus more than 

400
Title: Content Slide

NREL | 30

NREL advances the science and engineering of energy efficiency, 

sustainable transportation, and renewable power technologies and 

provides the knowledge to integrate and optimize energy systems.

Transforming Energy through Science
Messaging + Blue 

Infographic 

Content

NREL | 31

Bioenergy

Vehicle Technologies

Hydrogen

Sustainable Transportation

Buildings

Advanced Manufacturing

Government Energy Management

Energy 

Efficiency

Solar

Wind 

Water

Geothermal

Renewable

Power

Bioenergy

Vehicle Technologies

Hydrogen

Sustainable 

Transportation

Buildings

Advanced Manufacturing

Government Energy 

Management

Energy 

Efficiency

High-Performance 

Computing 

Data and 

Visualizations

Energy Systems

Integration

NREL’s Science 

Drives 

Innovation
NREL | 32

Curtailed renewable 

electricity

Renewables

Hydrogen production 

via electrolysis

Production

Hydrogen storage 

and distribution via 

liquid, truck, pipeline

Distribution

Hydrogen fueling 

cars, trucks, buses, 

and forklifts

Fueling

Zero-emission 

mobility for people 

and goods

Mobility

Connecting 

Renewables and 

Mobility
NREL | 33

Fuel Cell and Hydrogen Technologies

• Hydrogen production

• Delivery/H2FIRST

• Storage

• Fuel cells

• Fuel cell manufacturing R&D

• Technology validation

• Market transformation

• Safety, codes and standards

• Systems analysis

Major Research Topics

H2FIRST: Hydrogen Fueling Infrastructure Research and Station Technology

NREL
NREL | 34

Hydrogen Production

• Photoelectrochemical (PEC) water splitting

• Photobiological water splitting (concluded)

• Fermentation of biomass 

• Solar thermochemical water splitting

• Renewable electrolysis

• Pathway analysis (H2A)
NREL | 35

Website: https://h2awsm.org

• Advanced high- and low-temperature electrochemical conversion

• Direct photoelectrochemical solar water splitting

• Direct solar thermochemical water splitting

Comprising more than 80 unique, world-class capabilities/expertise in 

materials theory/computation, synthesis, characterization & analysis

Materials Theory/Computation Advanced Materials Synthesis Characterization & Analytics

Conformal ultrathin TiO2 ALD 

coating on bulk nanoporous

gold

Core Labs

TAP reactor for 

extracting quantitative 

kinetic data

Stagnation flow reactor 

to evaluate kinetics of 

redox material at high-T

LAMMPS classic molecular 

dynamics modeling relevant to H2O 

splitting

Bulk & interfacial 

models of aqueous 

electrolytes

High-throughput spray 

pyrolysis system for 

electrode fabrication

LLNL

SNL

SNL

INL

Accelerating discovery and development of innovative materials critical to 

advanced technologies for sustainable H2 production, including:

NREL

LLNL

HydroGEN: Advanced Water Splitting Materials (AWSM)
NREL | 36

Photoelectrochemical (PEC) H2 Production: New World Record

• Inverted metamorphic multijunction (IMM) 

PEC device enables more ideal bandgaps

• Grown by organometallic vapor phase epitaxy

• Incorporates buried p/n GaInP2 junction and

AlInP passivation layer 

Technology Solar-to-Hydrogen Efficiency

16.4%

Benchmarked under 

outdoor sunlight at NREL

Si wafer handle 16.4% STH

epoxy

Au 

contact/refl

ector

III-V tandem 5

μm

top surface

10 μm

Growth 

direction

p-GaInP2

p-n InGaAs

graded buffer

1 μm

SEM TEM

IMM device cross sections
Energy Systems Integration Facility (ESIF)

Offices High Performance

Data Center 

Labs

H2

Production, 

Compression, 

Storage
NREL | 38

ESIF Layout
NREL | 39

National Fuel Cell Technology Center (NFCTEC)

• Independent, secure analysis

• Industry collaboration and 

benchmarking

• Confirmation of component 

and system technical targets

• Technology validation

• Evaluation, optimization, and 

demonstration in integrated 

energy systems and realworld operation

• Security of proprietary data
NREL | 40

Hydrogen Dispensing

Average dispensing 

per station 

>50 kg/day

Average price is 

$16.31/kg

https://www.nrel.gov/hydrogen/infrastructure-cdps-retail.html
NREL | 41

Capital Cost – H2 Retail Stations

• Progress – 2009 

100 kg/day stations 

>$20,000 kg/day

• <$3,000/kg for 

1,000 kg/day 

station = $3 million 

Source: NREL, https://www.nrel.gov/docs/fy13osti/56412.pdf
NREL | 42

NREL Electrolyzer Experimental Setup

• Stack test bed at NREL’s Energy 

Systems Integration Laboratory 

(ESIL)

– Fully controllable AC-DC 

power supplies capable of 

4,000 ADC and 250 VDC 

(1 MW)

– All balance of plant 

equipment

– Flexible platform with 

growing capability to test 

multiple electrolyzers at 

one time

– Individual cell monitoring

– Production to research 

hydrogen station

Image of electrolyzer hardware-in-the-loop, NREL

NREL
NREL | 43

Electrolyzers as Controllable Loads

Real time dynamic operation

• Validating performance and 

benefits

• Verifying the communications 

and controls

• Optimizing balance of plant 

components

• Quantifying stack 

characterization and 

degradation

• Evaluating use case scenarios 

of electrolyzers providing grid 

services with hydrogen 

production

Image of electrolyzer hardware-in-the-loop, NREL

NREL
NREL | 44

Renewable Hydrogen Production via Electrolysis

Electrolyzers can provide grid services and renewably generated 

hydrogen for mobility with fast response time as a controllable load.

Source: NREL 
NREL | 45

Electrolyzers Avoid Curtailed Renewable Generation with 

Hydrogen Production

Electrolyzers are operated at nearly steady state until PV generation, then the electrolyzer 

network operates during PV transients to dampen impacts of variable generation on a distribution 

feeder, utilize what would have been curtailed PV generation, and produce high-value hydrogen. 

Source: NREL 
NREL | 46

Hydrogen Infrastructure Research at NREL

Hydrogen Infrastructure Testing and Research Facility

Fully integrated system 

capable of experiments on 

advanced components and 

subsystems and innovative 

component/system concepts. 
NREL | 47

Dispensing, compression and storage, safety, control/operational strategies, production and delivery, outreach
NREL | 48

Benchmarking Dispenser Reliability

Major dispenser components:

Breakaway

Hose

Nozzle

Block/Bleed Valves

Filters
NREL | 49

Component Reliability Based On Temperature

• Gather statistical failure data for dispenser components

• Number of fill events to failure

• Mass of hydrogen dispensed to failure

• Sensitivity of component failures to controlled and uncontrolled variables

• Inform industry with results to improve future component performance

TTHH2= -40°C, -20°C, 0°C TTaaaaaaaaaaaaaa RRHH
NREL | 50

Component Reliability Based On Use

Nozzle freeze lock project objectives: 

• Repeatable characterization in varying 

ambient conditions for temperature and 

humidity, diagnosis of cause, and 

recommended mitigation strategies for nozzle 

freeze lock events

Hose reliability project objectives: 

• Replicate failures seen in the field

• Develop accelerated lifetime testing

• Identify methods for early prediction of 

failure

• Identify solutions for improved reliability
NREL | 51

Improving Hydrogen Compression

70MPa H2 Output

Combined PEM 

Electrolysis and 

Compression 

System

Electrochemical compression project

objectives: 

• Benchmark and validate system

• Identify potential market opportunities 

for project partner

Compressor reed valve lifetime project

objectives: 

• Design a test apparatus capable of attaining 

valve failures representative of field operation
NREL | 52

Safety, Codes and Standards

• Guidance on safe operation, handling, and use 

• Safety testing and sensors 

• Vehicle, equipment, and building codes and standards

Top and middle photos by Keith Wipke, NREL; bottom photo by Dennis Schroeder
www.nrel.gov

This work was authored by the National Renewable Energy Laboratory, operated by Alliance for Sustainable 

Energy, LLC, for the U.S. Department of Energy (DOE) under Contract No. DE-AC36-08GO28308. Funding 

provided by U.S. Department of Energy Office of Energy Efficiency and Fuel Cell Technologies Office. The 

views expressed in the article do not necessarily represent the views of the DOE or the U.S. Government. 

The U.S. Government retains and the publisher, by accepting the article for publication, acknowledges that 

the U.S. Government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or 

reproduce the published form of this work, or allow others to do so, for U.S. Government purposes.

Thank you

NREL/PR-5400-72776