Analysis Solutions for Quality Control of Hydrogen

Significance of the Topic

Hydrogen is emerging as a key energy carrier for fuel cells and renewable energy storage. High‐purity hydrogen is essential to protect fuel cell catalysts and maintain performance. In addition, safe handling, transport and storage in carriers such as liquid hydrogen, ammonia or organic hydrides, and reliable materials for pipelines and tanks are critical for a mature hydrogen economy.

Objectives and Study Overview

This white paper presents a comprehensive suite of analytical solutions for quality control across the hydrogen value chain. It covers:

• Trace impurity analysis in fuel‐cell grade hydrogen.
• Spectroscopic methods for low‐level gases and hydrocarbons.
• Total organic carbon monitoring in ammonia carriers.
• High‐resolution structural and mechanical evaluation of hydrogen storage materials.
• Catalyst performance and degradation studies.

Methodology and Instrumentation

The study applies a range of advanced analytical techniques:

• Gas chromatography with barrier discharge ionization detector (GC‐BID) for ppt–ppm level gases.
• Gas chromatography–mass spectrometry (GC‐MS) for inorganic gases and light hydrocarbons.
• Fourier transform infrared spectroscopy (FTIR) for high‐resolution CO quantification.
• Total organic carbon (TOC) analyzers for ammonia solution purity.
• Microfocus X-ray computed tomography (CT) for corrosion and defect imaging.
• Electron probe microanalysis (EPMA) and X-ray photoelectron spectroscopy (XPS) for catalyst surface state.
• Thermomechanical analysis (TMA) and precision universal testing for polymer tank components.
• Ultrasonic optical flaw detection for non-destructive inspection of bonded interfaces.

Key Results and Discussion

Trace impurity analysis by GC‐BID achieved detection limits below 0.1 ppm for CO and sub-ppm quantification of O₂, N₂, CH₄ and other gases, meeting ISO 14687-2019 requirements. GC‐MS with PLOT columns and extracted‐ion monitoring resolved 12 components in mixed gas, even in the presence of water. FTIR at 0.25 cm⁻¹ resolution produced linear CO calibration (r = 0.999). TOC analysis in 2 % ammonia water showed sub-µg/L stability with R² = 0.9999. Microfocus X-ray CT tracked corrosion in copper pipes, quantifying shape changes after two and five months’ exposure. CT‐based 3D data improved finite‐element predictions: simulation models built from CT microstructure data predicted tensile modulus within 7 % of measured values, versus 40 % error using idealized geometry. EPMA and XPS revealed catalyst oxidation states and elemental distributions in MEAs, elucidating performance degradation. TMA characterized polymer expansion from –150 °C to 80 °C, while DCB fracture tests and ultrasonic imaging detected delamination in CFRP tank materials.

Benefits and Practical Applications

• Ensures compliance with fuel cell hydrogen purity standards to prolong catalyst life.
• Enables real‐time monitoring of reformer and catalyst performance in hydrogen production.
• Supports design validation and life prediction of hydrogen tanks and piping through non-destructive inspection.
• Improves accuracy of composite material simulations for safer, lighter storage vessels.
• Provides rapid, multi-component analysis workflows for industrial QA/QC.

Future Trends and Applications

Emerging needs include online, in situ gas purity sensors integrated into refueling stations, miniaturized GC‐BID modules for onboard monitoring in FCVs, and AI-driven defect analysis in CT and ultrasonic data. Digital twins combining CT‐informed models with fatigue data will enable predictive maintenance of hydrogen infrastructure. Advances in TOC and FTIR cell design will allow continuous carrier fuel purity surveillance.

Conclusion

The described analytical portfolio addresses critical quality control challenges throughout the hydrogen value chain. By combining high‐sensitivity gas analysis, precise TOC monitoring, advanced structural imaging and mechanical testing, it is possible to ensure safety, performance and reliability in a developing hydrogen energy society.

Used Instrumentation

• Nexis GC-2030 with BID-2030
• GC-MS QP2020 NX
• FTIR IRXross
• TOC-L Total Organic Carbon Analyzer
• inspXio SMX-225CT FPD HR Plus
• EPMA-8050G
• AXIS Supra+ XPS
• TMA-60 Thermomechanical Analyzer
• AGX-V2 Precision Universal Tester
• MIV-X Ultrasonic Optical Flaw Detector
• TRViewX Digital Video Extensometer
• CGT-7100 Transportable Gas Analyzer

Reference

• ISO 14687-2019: Fuel cell hydrogen – Product specifications.
• SIP Energy Carriers, JST News April 2019, “Effective Use of Hydrogen Energy with the Power of Formic Acid.”