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13 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Precursor Processing Development for Low Cost, High Strength Carbon Fiber for Composite Overwrapped Pressure Vessel Applications

Carbon fiber (CF) is central to produce lightweight, high pressure, composite overwrapped pressure vessels (COPVs), which are used for on-board storage of hydrogen for fuel cell vehicles. In 2015, carbon fiber cost accounted for 62% of the cost of a hydrogen storage system, as COPVs were manufactured with T700S CF at $\$ $29.40/kg CF. The high cost of hydrogen storage, largely attributed to the carbon fiber cost, limits the application of fuel cells in vehicles. Therefore, our team endeavored to develop fiber processing to demonstrate carbon fiber tensile properties similar to T700S with a production cost potential of $\$ $12.60/kg or less. Here, the overarching goal of the project was the development of low cost, high strength carbon fiber for composite overwrapped pressure vessels. Within the project, our team investigated a new low-cost, high-volume, high quality polyacrylonitrile (PAN)-based precursor terpolymer for the production of carbon fiber precursors, methods for increasing water and energy use efficiency in wash-water/solvent separation, and ultimately developed a multifilament spinning and conversion process for the production of hollow carbon fibers from a segmented arc spinneret utilizing a solution spinning method.

08 HYDROGEN↗
DOE OSTI2022

Comparison of Side-on Peak Overpressure Predictions and Measurements for Type IV Composite Overwrapped Pressure Vessel Catastrophic Failure

This development of empirical data to support realistic and science-based input to safety regulations and transportation standards is a critical need for the hazardous material (HM) transportation industry. Current regulations and standards are based on the TNT equivalency model. However, real world experience indicates that use of the TNT equivalency model to predict composite overwrapped pressure vessel (COPV) potential energy release is unrealistically conservative. The purpose of this report is to characterize and quantify rupture events involving damaged COPV’s of the type used in HM transportation regulated by the Department of Transportation (DOT). This was accomplished using a series of five tests; 2 COPV tests for compressed natural gas (CNG), 2 COPV tests for hydrogen, and 1 COPV test for nitrogen. Measured overpressures from these tests were compared to predicted overpressures from a TNT equivalence model and blast curves. Comparison between the measurements and predictions shows that the predictions are generally conservative, and that the extent of conservatism is dominated by predictions of the chemical contribution to overpressure from fuel within the COPVs.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Smart Composite Pressure Vessels (SCPV) with Integrated Health Monitoring

The U.S. Department of Energy (DOE) is promoting and developing more energy efficient and environmentally friendly technologies that will enable America to use less petroleum. Hydrogen fuel cells – which directly convert the chemical energy in hydrogen to electricity with only water and heat as byproducts – are a very attractive solution that can enable this to happen. To date, DOE's efforts have culminated in commercial demonstration of on-board vehicular hydrogen storage systems that can allow for a driving range of greater than 300 miles. This requires storing 5 Kgs of hydrogen onboard a light vehicle. In order to store this quantity of hydrogen, the hydrogen gas needs to be stored in a composite overwrapped pressure vessel (COPV) at a very high internal pressure. The objective of the program was to demonstrate continuous and predictable health-monitoring of composite pressure vessels. A higher confidence in the operational safety of the vessels will lead to reduced burst factor of safety imposed by regulatory standards and hence will help reduce the structural wall thickness that drives the cost of the vessel. Highly optimized Type III (metal lined) and Type IV (polymer lined) COPVs that are manufactured using filament winding process have been designed and qualified for the above mentioned application. However, the main structural component of the COPVs is carbon fiber and the high cost of carbon fiber composite in a pressure vessel is a primary challenge in reducing the cost of gaseous hydrogen storage. Continuous and remote monitoring of structural health of the COPVs as well as optimization of the strength translation of carbon fibers have the potential to allow for reduced factor of safety, thereby reduced amount of carbon and associated cost of the vessel. In the current program, the project team including Steelhead Composites (SHC), University of Tennessee, Knoxville (UTK), Teijin Carbon America, Oak Ridge National Laboratory (ORNL) and LUNA designed, fabricated, and tested smart composite pressure vessels with integrated sensors. Iterative loops of design and testing using coupons, subscale STEB vessels and full size vessels proved that a new generation of high performance carbon fiber can be used for efficient design of Type 3 vessels for H2 storage. Novel analysis techniques were developed to predict the initiation and propagation of interlaminar damage inside the composite shell due to impact damage, a real threat in practical operation. Such an analysis scheme is typically not used in tank design but is an essential tool for health monitoring of composite vessels. Remote sensing of the key signatures of the tank’s operating parameters such as pressure, acceleration and humidity was demonstrated using a unique device that can wirelessly transmit and stream the data to a remote server. Fiber optic sensors were successfully integrated during fabrication of the tanks. These sensors provide a wealth of information regarding the structural health of the vessel when it is subsequently pressurized or subjected to impact damage. Excellent correlation was demonstrated between the fiber optic sensor and mechanical strain gage data, and between the measurements and analytical predictions.

08 HYDROGEN↗
DOE OSTI2023

Turboexpander for Direct Cooling in Hydrogen Vehicle Fueling Infrastructure

Hydrogen fuel cell electric vehicles (FCEVs) have been identified as one of a few options for zero carbon emissions transportation. A major advantage of FCEVs is that they can fuel quickly and follow a familiar fueling behavior to hydrocarbon-fueled vehicles. Whether light duty or heavy duty, the goal for a hydrogen dispenser is to fuel a vehicle in the same amount of time as the fossil fuel equivalent. When hydrogen is dispensed into the vehicle storage system, however, the temperature rises due to the Joule-Thomson effect and the heat of compression. Typically, vehicles store the compressed hydrogen in composite overwrapped pressure vessels that have a polymer liner with an operational temperature limit of 85°C. This temperature limit can be exceeded during fast fueling if hydrogen is not precooled. Precooling allows for a dispenser to fuel a vehicle at a faster flow rate by preventing the storage tank on the vehicle from overheating. Fueling protocols and requirements are presented in SAE J2601 Fueling Protocols for Light Duty Gaseous Hydrogen Surface Vehicles [1]. A heavy-duty equivalent is under development with similar requirements for precooling. Currently, conventional precooling for light-duty vehicle refueling uses a heat exchanger and chiller to cool the hydrogen gas to -40°C before entering the vehicle. The precooling system represents a significant part of the station capital and operating costs, so if the cost of the precooling system can be reduced by improving its efficiency, the overall station capital and operating cost can be reduced. In this project, National Renewable Energy Laboratory (NREL) and Sandia National Laboratories (SNL) researchers teamed up to investigate the turboexpander precooling application. A turboexpander is a device that places a turbine in a flow path where a pressure differential can be attained. This expansion device will extract work and lower the temperature of the fluid as the pressure reduces. While initial calculations based on established principles showed potential for a turboexpander to generate cooled gas, much work needs to be done to prove the concept. Turboexpanders typically work best under steady state conditions, while the dispenser is a very dynamic flow system. Dynamic turboexpander systems have been proven, such as a turbocharger on a gasoline vehicle. The inlet pressure at a dispenser is also much higher than any other known turboexpander system but should behave similarly to higher density fluids at lower pressures. Having both performed initial calculations, NREL and SNL researchers teamed up to investigate the turboexpander precooling application further. A project was soon built around the idea with SNL performing system modeling using previously proven capabilities and NREL performing hardware characterization with established station capabilities. Creare LLC was contracted as the turbomachinery expert to design and build the concept device. Part way through the project, however, contracting issues with the funding partner caused the project to terminate early before building and characterizing the concept device. While the project could not continue, many key findings were already learned. This paper is a summary of those findings.

08 HYDROGEN↗
DOE OSTI2024

Electrolyte Assisted Hydrogen Storage Reactions (Final Technical Report)

The goal of this project is to address critical deficiencies of hydrogen storage systems design based on hydride materials, as originally identified by the DOE Hydrogen Storage Engineering Center of Excellence (HSECoE). Baseline hydrogen storage technology presently relies on compressed gas operating at ~700 bar pressure, which imposes huge demands on fuel delivery, fuel storage and system cost. For onboard storage applications, Type IV composite overwrapped pressure vessels and associated balance-of-plant components are necessary to ensure safe and effective fuel delivery. However, such compressed gas technology falls well-short of volumetric targets even at 700 bar, given the density of gaseous molecular hydrogen is only 40 g·H2/l at ambient temperatures. One alternative is to utilize hydride materials which accommodate hydrogen in atomic form. Certain hydrides can attain volumetric densities that exceed the density of liquid H2 (71 g·H2/l) while also offering advantageous thermodynamic properties. However, such material systems presently rely on solid-state diffusion for hydrogen release, which has a very high activation barrier for atom mobility and, thus, requires impractically-high temperatures for operation. The initial focus of our research effort is to employ and demonstrate an electrolyte system to mediate the diffusion of species at lower temperatures relevant to transportation applications, with the goal of establishing the critical factors necessary to obviate the need for high-temperature release of hydrogen. A parallel goal of this exploratory effort is to determine the effectiveness of modest electrochemical potentials in overcoming any endothermic requirements for hydrogen release in a similar electrolyte-promoted scenario.

08 HYDROGEN↗
DOE OSTI2022

Hydrogen Storage System Cost Analysis (2017-2021) (Final Report)

This final technical report summarizes hydrogen storage system cost analysis results from 2017-2021. Results include onboard hydrogen storage system costs for light-duty vehicles, medium-duty vehicles, heavy-duty vehicles, class 8 long haul trucks, and passenger buses. Multiple storage systems are included, primarily focusing on compressed and cryo-compressed hydrogen in Type 3 and Type 4 storage systems. Additional analysis includes large-scale gaseous and liquid hydrogen storage at refueling stations in tube trailers and Dewars; advanced materials-based storage systems such as metal organic frameworks and metal hydrides; and a baseline setting analysis of compressed natural gas storage systems in support of the Institute for Advanced Composites Manufacturing Initiative (IACMI). Analyses were primarily conducted using a Design for Manufacture and Assembly ® methodology, which is a bottom-up process-based approach to estimating factory costs. Multiple annual production rates are reported to project high-volume costs relevant to mature markets.

08 HYDROGEN↗
DOE OSTI2021

A Multiscale Modeling Approach to Cryocompressed Hydrogen Storage Pressure Vessels – Part II: Constitutive Modeling and Finite Element Analysis

Subjected to thermomechanical cycling, composite cryogenic hydrogen (H2) storage pressure vessels experience high stresses in the carbon fiber (CF)/epoxy overwrap which can lead to vessel failure due to a combination of degradation mechanisms such as matrix cracking, fiber/matrix debonding, delamination, and fiber rupture. The present paper is the second part of a set of two articles on this subject that addresses analysis and design of these pressure vessels. Predictive finite element (FE) modeling capabilities have been used to support a material acceptance process that aims at providing guidance to evaluate specialty resins, vessel liner options, and CF composites through thermomechanical testing. We have applied a multiscale modeling approach recently developed (B.N. Nguyen et al., International Journal of Hydrogen Energy, 2019, https://doi.org/10.1016/j.ijhydene.2019.09.200) to perform three-dimensional (3D) FE analysis and design of a cryo-compressed H2 storage pressure vessel for its operation in a large temperature range from room to cryogenic temperatures. The developed approach termed the micro-meso-macro approach determines the laminar stresses in different layers of the vessel in addition to constituent (i.e., fiber and matrix) stresses that are important to the design of the composite overwrap for its layup and material combination to reduce the risk of vessel failure.

Nguyen, Ba Nghiep↗
DOE OSTI2024

Rational design of semi-interpenetrating network based on hyperbranched polyglycerol grafted MXene/polyurethane–epoxy for compressed hydrogen storage

Here, hydrogen (H 2 ) energy has emerged as a promising alternative in the automotive sector to replace fossil fuel; however, its storage with volumetric efficiency remains a challenge. The latest type IV storage vessel featuring a polymeric liner with composite overwrap incurs hydrogen saturation, which eventually causes failure. To prevent the H 2 dissolution in the liner, we have developed a barrier coating comprised of polyurethane/epoxy semi-interpenetrating network (S-IPN) combined with hyperbranched polyglycerol grafted MXene (h-MXene). The hyperbranched structure facilitated the dispersion of MXene in the coating solution by enhancing the exfoliation and improved the polymer filler interaction by forming covalent and H-bonding through end-terminal hydroxyl groups. Leveraging the dense network of S-IPN combined with the dispersed layer structured h-MXene significantly increased the tortuosity of the spray-coated barrier film applied to the nylon 6 liner. The coating exhibited a 90 % reduction in the H 2 gas permeability at only 2 wt% h-MXene concentration, which further improved to above 98 % at 10 wt% loading. Additionally, the h-MXene considerably improved the adhesion with the liner even in a highly stretched condition, signifying the durability of the coating under cyclic pressurization and depressurization of the storage vessel.

08 HYDROGEN↗