Fiber-reinforced pressure vessels are increasingly becoming the cornerstone of the hydrogen economy and play a key role in the transport, storage and use of hydrogen for mobile and stationary applications. AZL Aachen GmbH, in collaboration with a consortium of 25 leading industrial companies, has successfully completed a 12-month research and development project entitled ‘Trends & Design Factors for Hydrogen Pressure Vessels’.
The 550-page report, which was presented to the 40 participants at the last project meeting in November, provides a comprehensive overview of the market and technology trends associated with the development of pressure vessels made from thermosets and thermoplastics. The project looks at the impact of materials, complex design considerations and advanced manufacturing technologies, providing insights into business and technology. Companies along the entire value chain of pressure vessels were involved: Resins, fibers, linings, production systems, container manufacturers, hydrogen system integrators and OEMs.
In the first phase of the project, regulations, requirements and safety standards were examined in detail and examples of modern hydrogen pressure vessels were presented. Key aspects included manufacturing processes, supply chains and production technologies as well as a comprehensive patent analysis. In addition, the study examined winding patterns, design strategies, material models and software tools used in the development of pressure vessels.
The second phase of the project involved extensive technical studies. Warden Schijve, Design Leader at AZL, explained the process: “Our team of experts developed CAE models for 12 different layouts of a two meter long, 350 liter Type IV pressure vessel designed for 700 and 350 bar applications. These models included different resin and fiber types, layup variations and hub designs to evaluate the impact on mechanics, weight, cost and carbon footprint. We also investigated hybrid fiber combinations and dome reinforcements with patch technologies. Detailed modeling of the process chain provided further insights into the cost structures and carbon footprint.”
The results reveal initial future trends: Through the targeted use of advanced material combinations, coordinated designs and manufacturing techniques, it is possible to significantly reduce the weight and cost of the containers while maintaining the necessary safety standards. Compared to state-of-the-art containers, hydrogen-over-tank weight efficiencies could be improved from the usual 6 to 7% to over 11%. These developments could strengthen the competitiveness of hydrogen technology in various mobility and energy sectors in the future.
“The knowledge gained in the project provides a strong basis for new technologies to meet the hydrogen economy’s requirements for safe and cost-effective pressure vessels,” comments Celal Beysel, Chairman of the Board at FLOTEKS Plastik San. Tic. A.Ş.
Floteks, a Tier 1 supplier of plastic components, has launched numerous R&D initiatives for the design and development of Type IV vessels in recent years. In 2023, the company became a member of the AZL working group for composite pipes and vessels and joined the AZL partner project ‘Trends and Design Factors for Hydrogen Pressure Vessels’. Celal Beysel adds: “We are pleased to announce that Floteks 2024 has established a new company called Pressura, which will focus on the production of Type IV pressure vessels for buses and trucks.”
Companies and organizations seeking detailed insights or opportunities for collaboration are welcome to contact the AZL. AZL Aachen GmbH serves as an innovation partner for the development of hydrogen tanks, prototypes and tests and is dedicated to the promotion of composite technologies.
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