Search Results (322)

In electricity–hydrogen coupling systems (EHCSs), the uncertainty of renewable energy generation (REG) tends to impact electrolyzers (ELs) in the following ways: (1) input powers of ELs are prone to fluctuations; (2) ELs are forced to operate under variable load states. Consequently, both impacts will reduce the service life of ELs. In this paper, considering the start–stop characteristics and combined operation modes of multiple ELs, a two-stage multi-time-scale energy allocation strategy (MSEAS) is proposed to mitigate the impacts of REG uncertainty and optimize the energy allocation for EHCSs. First, five refined operating states of ELs, such as shutdown, cold standby, low-load, variable-load and overload, are formulated as mixed-integer constraints and embedded into the system-level energy optimization model. Second, to mitigate power fluctuations caused by REG, a day-ahead optimization is employed to plan the power allocations of ELs, lithium batteries, fuel cells, and the grid with a 1 h time step; and then an intra-day rolling optimization is employed to adjust the operating states and power outputs of the above units with a 4 h window and 15 min step. Third, by enabling multiple ELs to flexibly operate in a combined mode, power-sharing mode and switching mode, the proposed MSEAS can refine the operation powers of ELs and reduce their start-up frequency. Comparative case studies are conducted in the off-grid and grid-connected operation tests, and the relevant results verify that the proposed MSEAS can effectively prevent the frequent start–stop of ELs, which contributes to extending the service life of ELs and reducing the system operating cost. Full article

Hydrogenation reactor shells are safety-critical thick-section pressure-bearing components in petrochemical hydroprocessing equipment. Long-term exposure to elevated temperature, high pressure, and hydrogen-bearing media requires not only adequate strength, but also toughness, tempering stability, hydrogen-damage resistance, and through-thickness property uniformity. 12Cr2Mo1V steel, a Chinese Cr-Mo-V reactor steel closely related to vanadium-modified 2.25Cr-1Mo-0.25V steels, is widely used for large-shell forgings because its alloy design supports bainitic transformation, carbide stability, and elevated-temperature performance. This review critically synthesizes studies on 12Cr2Mo1V shell forgings, related Cr-Mo-V reactor steels, and heavy free-forged products. The discussion is organized around alloy design, ingot-derived defect inheritance, defect closure during free forging, bainite–grain–carbide evolution during forging and heat treatment, and the resulting strength, toughness, and hydrogen-service performance. Particular emphasis is placed on the process–defect–microstructure–property linkage in super-thick sections. The review shows that free forging is not merely a forming route, but a decisive metallurgical operation for densification, strain penetration, and precursor-structure conditioning. Future work should integrate casting, free forging, and heat treatment with multiscale characterization and data-enhanced predictive quality control. To further reduce descriptive comparison, this review summarizes standardized quantitative indicators for evaluating forging-route design, heat-treatment response, and prediction-method reliability. Full article

With the rapid development of clean and low-carbon energy systems, non-metallic pipelines have become increasingly important in urban gas distribution, water supply, and emerging energy-transport applications, including hydrogen service. As a critical joining technology that governs system integrity and long-term operational safety, electrofusion welding requires a comprehensive and mechanism-oriented understanding beyond empirical process control. In this study, a review is conducted on research published over the past decade in the field of electrofusion welding of non-metallic pipelines, with emphasis on fundamental technical issues including the formation and evolution of temperature fields, characteristics of the molten fusion zone and defect development, and thermo-mechanical coupling with residual stress generation. Based on a synthesis of the literature, the review clarifies the global research landscape, core research communities, and underlying knowledge structure. The results indicate a clear transition of the field from empirically driven parameter optimization toward a mechanism-based and process-controllable paradigm centered on temperature field evolution, fusion zone development, and thermo-mechanical behavior. Current research hotspots converge on HDPE material adaptability, welding process regulation, and the long-term reliability of welded joints. Building on these insights, future research directions are discussed, including mechanism-driven process design, intelligent defect identification based on multi-source data, and full-life reliability assessment under service conditions. This review provides a theoretical framework to support process optimization and engineering application of electrofusion welding in non-metallic pipeline systems. Full article

On-site hydrogen refueling stations (HRS) face significant operational challenges due to the stochastic nature of hydrogen demand, creating a severe supply–demand mismatch. Under traditional pressure-based hysteresis control, this volatility forces Proton Exchange Membrane (PEM) electrolyzers into frequent start–stop cycles, accelerating degradation and reducing efficiency. In response, this study introduces an automated control framework integrating macroscopic gas-state modeling with deep-learning-based demand prediction. First, a real-gas thermodynamic model was established. Monte Carlo simulations of 100 random filling scenarios identified a robust design benchmark of 4.5 kg per vehicle. A low filling stability coefficient (5.02%) confirmed that individual thermodynamic fluctuations are negligible, validating a traffic-flow-driven demand approach. Next, a deep Long Short-Term Memory (LSTM) network was developed to forecast short-term demand. Trained on an 8784 h dataset exhibiting “double-peak” traffic patterns, the model achieved high precision on the unseen test set, yielding a Root Mean Square Error (RMSE) of 6.75 kg and a normalized RMSE (nRMSE) of 0.0987, explaining 82% of the demand variance. Finally, an LSTM-informed demand-following control strategy was formulated to enable proactive, thermally bounded operation alongside a novel “Hot Standby” mechanism. Maintaining a minimal 3.0 kg/h holding current during idle periods sustains stack temperatures above 60 °C, effectively mitigating thermal stress. Comparative simulations over 1464 h demonstrated that the proposed framework reduces detrimental cold start–stop cycles by 98.4% (from 61 to 1) and suppresses power output fluctuations by 40.7% compared to the traditional baseline. These results confirm that data-driven control significantly enhances operational stability, facilitates grid integration, and extends core equipment service life. Full article

This study investigates pulsed gas metal arc welding (pGMAW) of API 5L X65 pipeline steel for sour service applications where H₂S exposure is anticipated. Mechanized pGMAW in the 5G downhill position was employed to fabricate girth welds using ER70S-6 filler wire with Ar-20%CO₂ shielding. Comprehensive characterization, including optical microscopy, tensile testing, fractography, EBSD, and fracture toughness evaluation via SENT specimens, was conducted on specimens tested in both air and H₂S-precharged sour conditions. Microstructural analysis revealed ferritic–pearlitic base metal, weld metal with acicular ferrite and bainitic constituents, and a transformed HAZ gradient. Tensile testing demonstrated severe hydrogen embrittlement in sour conditions, with elongation dropping from 22% in air to 4% after H₂S exposure, accompanied by a transition from ductile cup–cone fracture to quasi-cleavage morphology. EBSD showed texture sharpening toward ⟨101⟩ fiber post-deformation, with a broader orientation spread under sour conditions, indicating heterogeneous strain localization. Fracture toughness testing revealed approximately a 50% reduction in CTOD values under sour exposure, with the weld centerline exhibiting greater degradation (0.50 mm to 0.27 mm) compared to the HAZ (0.92 mm to 0.47 mm). Fractography confirmed hydrogen-assisted cracking features, including shallow dimples, cleavage facets, and secondary cracking. These findings establish critical baseline data for engineering a critical assessment of pGMAW-welded X65 pipelines in sour service. Full article

Integrating green hydrogen systems into hybrid microgrids introduces nonlinear dynamics that compromise control stability during operational transitions. The performance of the advanced control loops depends on the latency and reliability provided by the communication infrastructure. This paper proposes a Software-Defined Networking (SDN) architecture integrated with an adaptive Quality of Service (AQoS) framework to support time-critical data flows in a hybrid microgrid with green hydrogen integration. An emulated network topology in GNS3, with OpenDaylight as the SDN controller and Open vSwitch as the forwarding plane, reproduces IEC 61850 traffic patterns, including GOOSE, control set-points and MMS. These traffic classes coordinate key microgrid components, including electrolysers, fuel cells and battery storage. Experimental results show that the SDN-AQoS framework reduces latency variance by 60% compared to unmanaged SDN configurations and delivers 49.4% higher throughput than traditional TCP/IP networks under congestion. The SDN-AQoS configuration achieves a median latency of 9.68 ms, keeping 97.5% of the measurements below the 20 ms safety threshold for electrolyser control. This level of reliability represents a substantial improvement over the plain TCP/IP at 90%, unmanaged SDN at 66.7% and static QoS policing at 60%. QoS rules are configured through the RESTCONF interface and remain fixed during each experiment while enabling the future integration of reinforcement learning agents for autonomous QoS adaptation. At the same time, this framework supports the bounded communication delay required to sustain frequency control and electrolyser safety coordination in low-inertia hydrogen microgrids during network congestion. The physical layer impact of these communication improvements remains a subject of future hardware-in-the-loop validation. Full article

Hydrogen energy, as an important green energy source, is a crucial guarantee for achieving carbon neutrality and peak carbon emission. The anion exchange membrane (AEM) electrolysis cell combines the advantages of alkaline electrolysis cell and proton exchange membrane electrolysis cell and can employ non-precious metal catalysts combined with renewable energy, which is expected to break through the bottleneck of high production cost of green hydrogen. AEM water electrolysis combines the advantages of alkaline and proton exchange membrane water electrolysis for hydrogen production. It has the characteristics of high electrolysis efficiency, fast response rates, and low cost, and its considered one of the most promising renewable green energy hydrogen production technologies at present. AEM is a key component that provides OH^– ion conduction and blocks gas crossover, which directly affects the performance and service life of the AEM electrolysis water system. However, current AEMs face issues of low ion conductivity and poor stability. This review introduces the role of AEM in electrolytic cells, the performance requirements and evaluation parameters that high-performance AEM should meet, and focuses on the transport mechanism and influencing factors of OH^– in AEM. Furthermore, this review provides an overview of the structural composition of AEM, as well as common cationic groups and polymer backbone types. The degradation mechanism of various cationic groups and the characteristics of polymer main chains were elaborated, with a focus on the strategies for designing the stability of cationic functional groups, the methods for modifying and preparing polymer main chains, and the performance of AEMs. Finally, the future challenges and potential research directions of AEM membranes are discussed. It is suggested that high-performance AEMs meeting practical application needs should be developed through strategies such as crosslinking, block copolymerization, side chain grafting, and composite membrane technology, based on the design of alkali-resistant and stable AEM membranes. These insights provide reference and guidance for the further development of AEMs. Full article

Self-healing materials have attracted increasing attention as a strategy to enhance durability, extend service life, and reduce maintenance in advanced material systems. Among these, cellulose-based self-healing materials represent a sophisticated intersection between sustainable macromolecular chemistry and adaptive materials science. This review provides a synthesis of recent advancements in the field, systematically categorizing materials derived from cellulose raw materials. We evaluate the fundamental chemical strategies employed to achieve autonomous repair, distinguishing between extrinsic mechanisms—utilizing cellulose-based micro/nano-capsules to sequester healing agents—and intrinsic mechanisms governed by dynamic covalent chemistry (Schiff-base, boronic ester, Diels–Alder) and supramolecular interactions (hydrogen bonding, metal–ligand coordination, and host–guest assemblies). The analysis highlights how cellulose’s hierarchical structure and abundant surface functionality are leveraged to overcome the traditional trade-off between mechanical toughness and healing efficiency. Particular emphasis is placed on the transition from simple structural hydrogels to sophisticated multifunctional systems. These include ultra-stretchable strain and pressure sensors for e-skin applications, biocompatible and injectable matrices for chronic wound management and stem cell delivery, and advanced anti-freezing eutectogels for performance in extreme environments. Furthermore, we explore the integration of cellulose into traditional sectors, such as self-healing concrete utilizing microbe-induced calcification and smart, eco-friendly coatings for corrosion protection. Finally, we discuss critical challenges, including environmental stability, scalability, and the development of standardized evaluation protocols, providing a roadmap for the next generation of bio-derived, sustainable and intelligent materials. Full article

This study investigates hydrogen embrittlement in welded joints of X52 (L360) pipeline steel obtained from an operating natural gas transmission network after 31 years of service, with particular emphasis on production (longitudinal) and girth (circumferential) welds. The aim is to elucidate the influence of microstructural heterogeneity across the pipe wall and within different welded joint types on hydrogen transport, trapping behavior, and fracture mechanisms. The investigation combines X-ray diffraction, electrochemical hydrogen permeation testing, fractographic analysis, and transmission electron microscopy. X-ray diffraction results show that the base metal and girth weld consist predominantly of body-centered cubic ferrite, whereas the production weld additionally contains retained austenite associated with an elevated manganese content. These phase-related differences are consistent with transmission electron microscopy observations of martensite–austenite constituents within the weld microstructure. Electrochemical hydrogen permeation measurements reveal pronounced microstructure-dependent hydrogen transport behavior. The production weld exhibits a significantly lower apparent diffusion coefficient and a markedly higher hydrogen trap density, approximately five times greater than those of the base metal and girth weld, providing a mechanistic explanation for the observed differences in hydrogen uptake behavior. Fractographic analysis demonstrates a transition from ductile microvoid coalescence in the uncharged condition to predominantly brittle fracture following hydrogen charging. This transition is accompanied by a substantial increase in the fraction of brittle fracture zones, reaching approximately 53% in hydrogen-charged specimens. A pronounced gradient in hydrogen embrittlement susceptibility is observed across the pipe wall thickness, with outer-wall specimens consistently exhibiting greater susceptibility than inner-wall specimens. This behavior reflects the combined influence of long-term soil corrosion and hydrogen-assisted degradation. Transmission electron microscopy reveals that plastic deformation governs dislocation generation, while hydrogen significantly modifies dislocation behavior by promoting dislocation pile-ups near martensite–austenite constituents and non-metallic inclusions. These observations indicate strong interactions between hydrogen, dislocations, and microstructural heterogeneities. A clear size-dependent role of non-metallic inclusions is identified. Sub-micron inclusions act primarily as irreversible hydrogen trapping sites that contribute to hydrogen redistribution within the microstructure, whereas larger inclusions serve as preferential crack initiation sites under hydrogen charging conditions. Overall, the results demonstrate that hydrogen embrittlement behavior is governed by the combined effects of microstructural state, welded joint type, and long-term service-induced degradation, resulting in distinct hydrogen transport characteristics and fracture responses across the pipe wall. Full article

Hydrogen energy is an important carrier for achieving China’s “dual carbon” goals, and one of the sources of green hydrogen is to develop better water electrolysis catalysts. This paper reviews the current research status of water electrolysis hydrogen production catalysts, analyzes the role and significance of advanced hydrogen energy catalysts in achieving the “dual carbon” goals, and conducts an in-depth analysis of the difficulties in moving from the laboratory to large-scale application, namely, how to bridge the “four gaps”, including catalyst performance evaluation, long-term application of catalysts, macro-scale preparation, and device integration. It also proposes overall improvement ideas and measures. In this paper, effective improvement methods are proposed for these “four gaps”, which can improve the relevant indicators and service life of water electrolysis hydrogen production catalysts, further promote the large-scale production and industrial application of green hydrogen, and provide a strong guarantee for solving China’s “dual carbon” problems. Full article

This study employs molecular dynamics simulations to investigate hydrogen diffusion and deformation mechanisms in FeCrNi-based austenitic stainless steels, with a focus on the effects of alloying composition, temperature, and hydrogen concentration. Arrhenius analysis reveals that Cr increases, while Ni decreases, the activation energy for hydrogen migration. Alloys with low Cr and Ni contents (6 wt.%) promote FCC→BCC→HCP martensitic transformations, accompanied by stress drops, whereas high Cr or Ni levels (24 wt.%) suppress these transformations and favour dislocation plasticity dominated by cross-slip. High hydrogen concentrations reduce stacking-fault energy, activating dense Shockley partial dislocations in agreement with hydrogen-enhanced localised plasticity. Elevated temperatures and high hydrogen concentrations synergistically promote dislocation-mediated plasticity and facilitate vacancy formation, which can cluster into hydrogen–vacancy complexes and proto-nanovoids, accelerating material failure. These findings advance our understanding of the coupled effects of composition, hydrogen, and temperature on degradation in austenitic stainless steels and provide guidance for tailoring Cr/Ni ratios, controlling hydrogen content, and optimising service temperatures in the design of hydrogen-related structural alloys. Full article

Although austenitic steels have been implemented in direct liquid hydrogen (LH₂) contact for decades, detailed microstructural and mechanical studies are still rare at a temperature of 20 K and inexistent for long-term exposure in LH₂. Therefore, austenitic stainless-steel parts, which were in direct contact with LH₂, from a container for LH₂ transport from the company Linde GmbH that has been in service for over 30 years, was chosen as a material model system for this investigation. In the present work, the possible influence of cryogenic gaseous and liquid H₂ (GH₂ and LH₂) on the micro- and macroscopic as well as mechanical properties of the container was investigated. Monitoring the properties after long-term GH₂ and LH₂-exposed material assesses the durability and the failure characteristics of these austenitic steels. A mean content of 2.5 ppm H was detected in the container walls after the long-term exposure. The microhardness of the long-term GH₂ and LH₂ are similar to an H₂ non-exposed sample. Based on the SEM investigations, no microstructural change could be detected in the material after long-term H₂ exposure and the residual tensile properties are still similar to those of ‘fresh’ non-exposed material. The hydrogen embrittlement (HE) occurred in the container material only after additional thermal H-charging, where the ductility reduced to about 50% at 200 K. Full article

High-pressure hydrogen exposure may induce transport and diffusion–relaxation–controlled changes in elastomeric sealing materials that differ from conventional fluid aging. Hydrogen uptake through solution–diffusion processes can lead to swelling, redistribution of molecular mobility, viscoelastic evolution, and, under certain conditions, cavitation or microvoid formation during decompression, which may affect long-term sealing performance. This review compiles experimental results for commonly used elastomers, including Nitrile Butadiene Rubber (NBR), hydrogenated nitrile butadiene rubber (HNBR), Fluoroelastomer (FKM), Ethylene Propylene Diene Monomer (EPDM), and silicone, and summarizes reported ranges of hydrogen diffusivity, solubility, and permeability under high-pressure conditions. These transport characteristics are compared with mechanical and microstructural observations obtained from Dynamic Mechanical Analysis (DMA), Nuclear Magnetic Resonance (NMR), decompression testing, and micro-computed tomography (µXCT) imaging. Available evidence suggests that hydrogen-induced changes are predominantly governed by physical processes, including swelling, plasticization-like mobility changes, and constraint redistribution, while extensive chemical degradation of the polymer backbone is generally limited under clean hydrogen conditions. Materials with similar conventional mechanical properties may, therefore, exhibit different hydrogen uptake, viscoelastic response, and resistance to decompression damage. Conventional single-point mechanical tests, such as tensile measurements, may not fully capture the time-dependent viscoelastic evolution relevant to sealing performance. This work proposes a multiscale characterization framework integrating transport, viscoelastic, molecular, and microstructural analysis for more reliable evaluation of elastomers in hydrogen service, supporting improved qualification strategies for high-pressure hydrogen systems. Full article

The bottom brick is a critical component of float glass furnace tin baths, serving under harsh conditions including high temperature, tin penetration, hydrogen diffusion and alkali attack. Traditional flint clay-based bottom bricks suffer from high porosity and insufficient service performance. In this study, a high-performance low-cement castable was developed by introducing mullite aggregates to partially replace flint clay. The effects of mullite particle size and addition content on sintering behavior, mechanical properties, thermal shock resistance, refractoriness under load and hydrogen diffusion were systematically investigated. The results demonstrate that, compared with the existing tin bath bottom bricks applied in float glass furnaces, the introduction of 18 wt% mullite with a particle size of 5–3 mm can significantly increase the bulk density, reduce the apparent porosity, enhance the mechanical strength at both room temperature and high temperature, and achieve a higher refractoriness under load and lower hydrogen diffusion capacity. Accordingly, a novel tin bath bottom brick with excellent comprehensive properties for float glass furnaces was successfully developed. Full article

High-pressure gaseous hydrogen storage is widely adopted in the hydrogen energy industry chain due to its simplicity, reliability, and economic viability. However, when these systems are subjected to rapid filling, a series of complex thermodynamic behaviors are induced. These have been identified as a bottleneck restricting the safety and service life of hydrogen storage and transportation equipment. In this paper, a detailed review is conducted on the recent domestic and international research progress regarding the thermodynamic issues encountered during the charging process of storage devices. Research achievements related to the thermodynamics of the process are systematically classified, summarized and discussed. These achievements are analyzed from four aspects: thermodynamic theoretical models, numerical simulation analysis, experimental testing, and thermal management strategies. The thermodynamic mechanism of the charging process is revealed, and the variation laws of thermodynamic responses during charging are sorted out. Key factors affecting the thermodynamic behaviors of charging are clarified, and the implementation effects of different thermal management strategies are elaborated. Finally, based on the future development trend and prominent potential challenges in high-pressure hydrogen storage, the future development directions of the thermodynamics of hydrogen fueling in storage and transportation devices are explored and prospected. Full article