Publications

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The HyRAM software toolkit provides a basis for conducting quantitative risk assessment and consequence modeling for hydrogen infrastructure and transportation systems. HyRAM is designed to facilitate the use of state-of-the-art science and engineering models to conduct robust, repeatable assessments of hydrogen safety, hazards, and risk. HyRAM includes generic probabilities for hydrogen equipment failures, probabilistic models for the impact of heat flux on humans and structures, and computationally and experimentally validated first-order models of hydrogen release and flame physics. HyRAM integrates deterministic and probabilistic models for quantifying accident scenarios, predicting physical effects, and characterizing hydrogen hazards (thermal effects from jet fires, overpressure effects from deflagrations), and assessing impact on people and structures. HyRAM is developed at Sandia National Laboratories for the U.S. Department of Energy to increase access to technical data about hydrogen safety and to enable the use of that data to support development and revision of national and international codes and standards. HyRAM is a research software in active development and thus the models and data may change. This report will be updated at appropriate developmental intervals. This document provides a description of the methodology and models contained in the HyRAM version 3.0. HyRAM 3.0 includes the new ability to model cryogenic hydrogen releases from liquid hydrogen systems, using a different property calculation method and different equations of state. Other changes include modifications to the ignition probability calculations, component leak frequency calculations, and addition of default impulse data.

Design and analysis of practical reactors utilizing solid feedstocks rely on reaction rate parameters that are typically generated in lab-scale reactors. Evaluation of the reaction rate information often relies on assumptions of uniform temperature, velocity, and species distributions in the reactor, in lieu of detailed measurements that provide local information. This assumption might be a source of substantial error, since reactor designs can impose significant inhomogeneities, leading to data misinterpretation. Spatially resolved reactor simulations help understand the key processes within the reactor and support the identification of severe variations of temperature, velocity, and species distributions. In this work, Sandia's pressurized entrained flow reactor is modeled to identify inhomogeneities in the reaction zone. Tracer particles are tracked through the reactor to estimate the residence times and burnout ratio of introduced coal char particles in gasifying environments. The results reveal a complex mixing environment for the cool gas and particles entering the reactor along the centerline and the main high-speed hot gas reactor flow. Furthermore, the computational fluid dynamics (CFD) results show that flow asymmetries are introduced through the use of a horizontal gas pre-heating section that connects to the vertical reactor tube. Computed particle temperatures and residence times in the reactor differ substantially from the idealized plug flow conditions typically evoked in interpreting experimental measurements. Furthermore, experimental measurements and CFD analysis of heat flow through porous refractory insulation suggest that for the investigated conditions (1350 °C, <20 atm), the thermal conductivity of the insulation does not increase substantially with increasing pressure.

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Hydrogen Fueling Infrastructure Research and Station Technology (H2FIRST) is a project initiated by the DOE in 2015 and executed by Sandia National Laboratories and the National Renewable Energy Laboratory to address R&D barriers to the deployment of hydrogen fueling infrastructure. One key barrier to the deployment of fueling stations is the land area they require (i.e. "footprint"). Space is particularly a constraint in dense urban areas where hydrogen demand is high but space for fueling stations is limited. This work presents current fire code requirements that inform station footprint, then identifies and quantifies opportunities to reduce footprint without altering the safety profile of fueling stations. Opportunities analyzed include potential new methods of hydrogen delivery, as well as alternative placements of station technologies (i.e. rooftop/underground fuel storage). As interest in heavy-duty fueling stations and other markets for hydrogen grows, this study can inform techniques to reduce the footprint of heavy-duty stations as well. This work characterizes generic designs for stations with a capacity of 600 kg/day hydrogen dispensed and 4 dispenser hoses. Three base case designs (delivered gas, delivered liquid, and on-site electrolysis production) have been modified in 5 different ways to study the impacts of recently released fire code changes, colocation with gasoline refueling, alternate delivery assumptions, underground storage of hydrogen, and rooftop storage of hydrogen, resulting in a total of 32 different station designs. The footprints of the base case stations range from 13,000 to 21,000 ft² . A significant focus of this study is the NFPA 2 requirements, especially the prescribed setback distances for bulk gaseous or liquid hydrogen storage. While the prescribed distances are large in some cases, these setback distances are found to have a nuanced impact on station lot size; considerations of the delivery truck path, traffic flow, parking, and convenience store location are also important. Station designs that utilize underground and rooftop storage can reduce footprint but may not be practical or economical. For example, burying hydrogen storage tanks underground can reduce footprint, but the cost savings they enable depend on the cost of burial and the cost land. Siting and economic analysis of station lot sizes illustrate the benefit of smaller station footprints in the flexibility and cost savings they can provide. This study can be used as a reference that provides examples of the key design differences that fueling stations can incorporate, the approximate sizes of generic station lots, and considerations that might be unique to particular designs.

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Additional fueling stations need to be constructed in the U.S. to enable the wide-spread adoption of fuel cell electric vehicles. A wide variety of private and public stakeholders are involved in the development of this hydrogen fueling infrastructure. Each stakeholder has particular needs in the station planning, development, and operation process that may include evaluation of potential sites and requirements, understanding the components in a typical system, and/or improving public acceptance of this technology. Publicly available templates of representative station designs can be used to meet many of these stakeholder needs. These 'Reference Stations' help reduce the cost and speed the deployment of hydrogen stations by providing a common baseline with which to start a design, enabling quick assessment of the suitability of a particular site for a hydrogen station, and identifying contributors to poor economics and research and development areas for certain station designs.

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The Alternative Fuels Risk Assessment Models (A1tRAM) toolkit combines Quantitative Risk Assessment (QRA) with simulations of unignited dispersion, ignited turbulent diffusion flames, and indoor accumulation with delayed ignition of fuels. The models of the physical phenomena need to be validated for each of the fuels in the toolkit. This report shows the validation for methane which is being used as a surrogate for natural gas. For the unignited dispersion model, seven previously published experiments from credible sources were used to validate. The validation looked at gas concentrations with respect to the distance from the release point. Four of these were underexpanded jets (i.e. release velocity equal to or greater than local speed of sound) and the other three subsonic releases. The methane plume model in AltRAM matched both varieties well, with higher accuracy for the underexpanded releases. For the jet flame model, we compared the heat flux and thermal radiation data reported from five separate turbulent jet flame experiments to the quantities calculated by A1tRAM. Four of the five datasets were for underexpanded diffusion jets flames. While the results still match well enough to give a good estimate of what is occurring, the error is higher than what was seen with the plume model. For the underexpanded flames A1tRAM provided reasonable approximations, which would lead to conservative risk assessments. Some modeling errors can be attributed to environmental effects (i.e. wind) since most large scale flame experiments are conducted outdoors. A1tRAM has been shown to be a reasonably accurate tool for calculating the concentration or flame properties of natural gas releases. Improvements could still be made for the plume of subsonic releases and radiative heat fluxes to reduce the conservative nature of these predictions. These models can provide valuable information for the risk assessment of natural gas infrastructure.

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Hydrogen is increasingly being used in the public sector as a fuel for vehicles. Due to the high density of hydrogen in its liquid phase, fueling stations that receive deliveries of and store hydrogen as a liquid are more practical for high volume stations. There is a critical need for validated models to assess the risk at hydrogen fueling stations with cryogenic hydrogen on-site. In this work, a cryogenic hydrogen release experiment generated controlled releases of cryogenic hydrogen in the laboratory. We measured the maximum ignition distance, flame length and the radiative heat flux and developed correlations to calculate the ignition ditance and the radiative heat flux. We also measured the concentration and temperature fields of releases under unignited conditions and used these measurements to validate a model for these cryogenic conditions. This study provides critical information on the development of models to inform the safety codes and standards of hydrogen infrastructure.

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Laboratory measurements were made on the concentration and temperature fields of cryogenic hydrogen jets. Images of spontaneous Raman scattering from a pulsed planar laser sheet were used to measure the concentration and temperature fields from varied releases. Jets with up to 5 bar pressure, with near-liquid temperatures at the release point, were characterized in this work. This data is relevant for characterizing unintended leaks from piping connected to cryogenic hydrogen storage tanks, such as might be encountered at a hydrogen fuel cell vehicle fueling station. The average centerline mass fraction was observed to decay at a rate similar to room temperature hydrogen jets, while the half-width of the Gaussian profiles of mass fraction were observed to spread more slowly than for room temperature hydrogen. This suggests that the mixing and models for cryogenic hydrogen may be different than for room temperature hydrogen. Results from this work were also compared to a one-dimensional (streamwise) model. Good agreement was seen in terms of temperature and mass fraction. In subsequent work, a validated version of this model will be exercised to quantitatively assess the risk at hydrogen fueling stations with cryogenic hydrogen on-site.

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The development and revision of safety codes and standards for hydrogen infrastructure requires a solid scientific basis, including studies of unignited releases from high pressure systems for various scenarios. Most hydrogen releases are modeled as axisymmetric jets, but real leaks are more likely to be non-axisymmetric jets issuing from high aspect ratio cracks or slots. In the present study, underexpanded hydrogen jets from square and rectangular nozzles with aspect ratios of 1–16 were numerically modeled for stagnation pressures up to 20 MPa. The near and far flow fields were modeled separately using two sequential computational domains to accurately and efficiently capture the flow characteristics. The numerical models were first validated with experimental data from a previous experimental study and literature data. The mass fraction and velocity distributions show that the centerline decay rates increase as the nozzle aspect ratio increases, but this increase is dependent on the pressure. This means that the canonical decay law of round turbulent jets and plumes no longer applies to the slot nozzle jets for high pressures. The radial profiles collapse onto a Gaussian curve in the major axis plane, but neither collapse, nor are they Gaussian in the minor axis plane with peaks away from the jet centerline. Different shock patterns were identified along the major and minor axes and the axis switching phenomenon seen in the literature was also reproduced. The axis switching resulted in significantly wider flattened concentration distributions compared with the axisymmetric jet which may require consideration during safety analyses for non-circular nozzles. A scaling factor taking both the nozzle shape and pressure effects into account was then developed to better scale the centerline decay rates for jets from both the square and rectangular nozzles. The present study demonstrates that the nozzle shape effects on the jet spreading should not be overlooked and proper scaling factors are required to collapse the data and calculate decay rates.

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Apparent char kinetic rates are commonly used to predict pulverized coal char burning rates. These kinetic rates quantify the char burning rate based on the temperature of the particle and the oxygen concentration at the external particle surface, inherently neglecting the impact of variations in the internal diffusion rate and penetration of oxygen. To investigate the impact of bulk gas diffusivity on these phenomena during Zone II burning conditions, experimental measurements were performed of char particle combustion temperature and burnout for a subbituminous coal burning in an optical entrained flow reactor with helium and nitrogen diluents. The combination of much higher thermal conductivity and mass diffusivity in the helium environments resulted in cooler char combustion temperatures than in equivalent N2 environments. Measured char burnout was similar in the two environments for a given bulk oxygen concentration but was approximately 60% higher in helium environments for a given char combustion temperature. To augment the experimental measurements, detailed particle simulations of the experimental conditions were conducted with the SKIPPY code. These simulations also showed a 60% higher burning rate in the helium environments for a given char particle combustion temperature. To differentiate the effect of enhanced diffusion through the external boundary layer from the effect of enhanced diffusion through the particle, additional SKIPPY simulations were conducted under selected conditions in N2 and He environments for which the temperature and concentrations of reactants (oxygen and steam) were identical on the external char surface. Under these conditions, which yield matching apparent char burning rates, the computed char burning rate for He was 50% larger, demonstrating the potential for significant errors with the apparent kinetics approach. However, for specific application to oxy-fuel combustion in CO2 environments, these results suggest the error to be as low as 3% when applying apparent char burning rates from nitrogen environments.

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Spontaneous Raman scattering images of liquid and near liquid methane released through 1 and 1.25 mm diameter orifices were taken using a pulsed planar laser sheet. The methane back pressure was varied between 2 and 6 bar_abs with methane temperatures between 130 and 220 K. Analysis of the Raman images resulted in the planar concentration and temperature fields of the methane jets. The measured methane concentration was compared with empirical relationships for warm gas releases and found to be in agreement in terms of centerline concentration decay rate, self-similarity, and half-width decay rate. Comparisons were then made for anticipated real-world CNG and LNG releases showing similar extents of flammable mass for the two fuel options. Measured images were compared to a cold gas release model, which showed good agreement over the range of methane release temperatures, pressures, and nozzle sizes. The collected measurements provide validation of this cold release model which will be used to model additional scenarios and inform LNG safety codes and standards.

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