Maturing the production standards of ultraporous structures for high density hydrogen storage bank operating on swinging tem-peratures and low compression

Project Information

MAST3RBoost

Grant agreement ID: 101058574

DOI

10.3030/101058574

EC signature date 22 May 2022

Start date 1 June 2022

End date 31 August 2026

Funded under

• Digital, Industry and Space

Total cost

€ 4 638 418,50

EU contribution

€ 4 638 414,00

Coordinated by

ENVIROHEMP SL
Spain

Periodic Reporting for period 2 - MAST3RBoost (Maturing the production standards of ultraporous structures for high density hydrogen storage bank operating on swinging tem-peratures and low compression)

Reporting period: 2023-12-01 to 2025-05-31

Summary of the context and overall objectives of the project

Because the transport segment makes up about one-third of all CO2 emissions in the EU (> 1,000 MILL ton), its decarbonization represents a key element in achieving the energy transition. Fuel Cells and Hydrogen (FCH), outperforming batteries in all relevant indicators, is the most promising solution for decarbonizing trucks, buses, ships, trains, large cars, with commercial vehicles being considered the early adopters. By 2030 this new industry has the potential to generate a € 130 bn market only in the EU. The market-entry goal is to fit 5 kg H2 in a gasoline equivalent tank (80 kg/90 l). However, state-of-the-art technology for H2 storage on-board, based on compression at 700 bar, is still disappointing in terms of volumetric density (25 gH2/lsys), preventing a widespread penetration of FCEVs. At least 40 gH2/Lsys is considered a significant milestone (settled by the DOE) to provide the market with an actual FECV replacement to current internal combustion engine vehicles, ICEV. MAST3RBoost will enable a disruptive path to meet these goals based on a new generation of ultraporous materials (ACs and high-density MOF) with H2 delivery capacities 33% higher than current record holders (NU-1103, SNU-70, MOF-5). KPIs already demonstrated are > 9 wt% and 44 gH2/lPS at 100 bar and below. Best candidate materials will be improved with Supervised Machine Learning and industrially produced as pellets or monoliths at a scale beyond 10 kg for the first-time. A brand-new pressure vessel technology of 20+ litres will be fully designed via Digital Twins within the consortium to operate at the optimum thermodynamic (TPS) regime for the materials. This will be the first adsorption-based demonstrator worldwide with a capacity of 1 kg H2, aiming at a system KPI as high as 33 gH2/lsys, and become a record-holder among all H2 storage technologies, with a projected system cost of 1,780 € (5.6 kg H2). MAST3RBoost’s ground-breaking additive manufacturing technology (WAAM) will create lightweight type I vessels with dedicated shapes to better fit on-board specific transportation spaces. In round numbers, the project will produce materials with a projected SAM by 2028 of € 345 MILL. A business case based on a 1,250 ton plant (CAPEX: € 14 MILL) of the new ultraporous material has the potential to support 20,000 unit passenger FCEV (or 2,000 heavy-duty FCEV), with an estimated FOB price <15 €/kg.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

During the second reporting period (RP2), significant progress was achieved in the MAST3RBoost project across multiple technical and dissemination work streams.

The project successfully advanced the scale-up of both activated carbon (AC) and metal-organic framework (MOF) adsorbents. Several ultraporous AC materials were produced at multi-kilogram scale in both powder and pellet form, with BET surface areas exceeding 3000 m²/g. Pelletisation processes were optimised to enhance thermal conductivity and mechanical properties, while maintaining high hydrogen storage capacity. Scaled-up MOFs and their composites also demonstrated effective densification with stable structural and sorption characteristics. Selected MOF powders achieved hydrogen uptakes of up to 4.2 wt.% at 100 bar and 77 K.

Major progress was made in the development of the hydrogen storage prototype tank. Structural components were manufactured using wire arc additive manufacturing (WAAM), and coating strategies were tested and validated. A polyurethane-based e-coating demonstrated excellent adherence, durability, and applicability for internal surfaces with limited access, even under thermal stress. Full coating application was successfully completed on final-scale tank units.

Machine Learning continued to guide the discovery and optimisation of material recipes, supporting the selection of promising synthesis conditions and identifying the most informative experimental configurations. The digital infrastructure was expanded and harmonised datasets now support advanced modelling and active learning approaches across different material classes.

A detailed life cycle and economic assessment was completed for the first time at kilogram scale for both AC and MOF materials. Datasets included energy, time and process inputs from scaled-up routes. Alternative scenarios reflecting future industrial conditions were also considered, providing a basis for long-term sustainability analysis.

Dissemination and communication activities continued with technical workshops, international conference participation and dedicated training sessions. Outreach focused on sharing the project’s innovative approach to materials development, data integration, and digital modelling. Publications and intellectual property activities are underway to consolidate the generated knowledge.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The most significant results produced by the MAST3RBoost project beyond the state of the art include:

• Ultraporous carbons achieved hydrogen uptake of 13.9 wt% gravimetric and 56 g/L volumetric at 100 bar, 77 K — exceeding typical benchmarks.
• Efficient Material Densification: MOF and carbon composites were densified without performance loss; some pelletised MOFs exceeded 1.7 wt% uptake at 1 bar.
• Durability of Adsorbents: Long-term cycling and accelerated aging tests confirmed stable porosity and hydrogen uptake over extended lifespans.
• Advanced Hydrogen Storage Prototype: A full-scale aluminium tank was designed and partially assembled using WAAM.
• Tank Coating Innovation: A novel internal e-coating method was validated, enabling application in geometrically constrained vessels while ensuring high thermal and mechanical resilience.
• Digital Infrastructure for Materials Discovery: Harmonised, structured datasets enabled cross-material comparison and data-driven decision-making through shared platforms.