Simultaneous H2 Generation and Compression with Intermediate-Temperature Solid-Oxide Membranes

Precision Combustion, Inc. (PCI) proposes to develop and demonstrate simultaneous H2 generation and compression with intermediate-temperature solid-oxide membranes. The innovation is based on a novel cell architecture and materials, and processing techniques recently developed at PCI. Phase I testing of the developed cell architecture indicated a potential for lightweight and compact hardware, presenting several advantages over state of the art, including high gravimetric and volumetric power density, simplified structure, and highly efficient H2 generation and compression. The multi-functional solid-oxide membrane cell is also capable of operating in fuel cell mode for power generation with high fuel utilization, expected to realize a system with a high round trip efficiency. The key innovations that enable this advance are: (i) innovative cell structure with high DP tolerance; (ii) advanced solid oxide membrane materials that operate at intermediate temperatures; (iii) novel cell and membrane fabrication process; and (iv) novel stack design suitable for simultaneous electrolysis and H2 compression. The Ph. II goal will be to generate high-purity H2 via electrolysis at low energy consumption at a larger scale than Ph. I, and with simultaneous compression to pressures for supporting H2 storage. This avoids the need for mechanical compression as well as sweep gases or gas separators which are essential for conventional solid oxide membranes. Our approach also resolves corrosion in high steam environments. A H2 generation and compression sub stack will be demonstrated and delivered to NASA. During Ph. I, Precision Combustion, Inc. (PCI) developed and validated the potential for high purity H2 generation via electrolysis and simultaneous electrochemical compression via a novel, intermediate-temperature solid-oxide membrane. This development addresses a NASA identified shortfall of “producing propellants and mission consumables from extracted in-situ resources.” The novel architecture enables electrolysis operation with high differential pressures, producing pure, dry H2. This avoids the need for complex, inefficient mechanical or low-temperature electrochemical compression. Our multi-functional, structured, solid oxide membrane architecture overcomes the known H2 compression limitations. Our university partner was able to confirm the tolerance of our solid oxide membrane to pressurized operations via button cell testing.  The Phase II goals will be to develop, demonstrate, and deliver a sub-stack capable of producing and compressing H2, based on our design developed in Phase I, for functional testing and validation of capability for meeting NASA target metrics. In Phase II, we will optimize and scale-up the advanced solid oxide cells developed in Ph I, and will confirm cell/stack performance. Sub-stack module will be fabricated and evaluated to demonstrate for 1 LPM H2 generation and compression capability. Phase II objectives are: Optimize, scale-up of the advanced cells and confirm cell performance Confirm suitability of seals at operating temperature and pressure Confirm compression capability as needed to support H2 storage Confirm 500-hour durability under steady state operation Design for structural integrity i.e., vibration tolerance (as required for launch loads) Optimize fabrication for repeatability/QA/QC (fabricate multiple cells with prescribed process) Design, iterate, and fabricate repeat unit and stack assemblies Test sub-stack to confirm functional and performance metrics Develop operational system model; confirm safety via FMEA analysis   Phase II Deliverables: A sub-stack prototype using advanced solid oxide cells will be developed and characterized in Phase II, and will be provided to NASA for ground demonstration at the end of the contract. Performance testing data that address H2 generation efficiency, specific mass and/or volume, energy utilization, and product properties will be included in the Final Report. In addition, operating procedures, FMEA, final and periodic reports will be provided. 

In addition to sustainable, energy-efficient production and compression of hydrogen from Lunar resources (with solid state device, without moving parts), other NASA applications include power generation, regenerative operation, and energy storage (as compressed H2) for In-Situ Resource Utilization (ISRU). This technology can also address the Shortfall for ISRU #1583 “Produce propellants and mission consumables from extracted in-situ resources”. Targeted non-NASA applications include compact and efficient distributed H2 production (from low quality H2O), storage, and compression (or liquefaction) as well as regenerative operation for power generation, via a single system. Synthetic chemicals production with CO2 utilization as well as offsetting renewable energy generation variabilities are another potential non-NASA applications.

This is early/mid-stage (TRL 4) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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