Periodic Reporting for period 1 - ROAD TRHYP (ROAD trailer design - use of Type V theRmoplastic tube with light composite structure for HYdrogen transPort)
Reporting period: 2023-01-01 to 2024-06-30
Nowadays, existing hydrogen transportation solutions use tubes with a working pressure between 200 and 300 bar. This is not efficient in terms of quantities or cost to address large refueling stations knowing the upcoming ramp-up of fuel cell-based vehicles.
The overall objective of the ROAD TRHYP project is to develop and validate a trailer integrating new thermoplastic composite tubes (Type V) to maximise the quantity of H2 transported while satisfying end-user requirements (safety, ability to be decontaminated) and enforced regulations with a low cost. By the end of the project, the consortium will design a trailer capable of handling a payload of 1.5 tonne of H2 with 700 bar tubes and a capex lower than 400 €/kg. This enables the decrease of the number of transport rotations between the site of production and the delivery site, consequently the reduction of the environmental footprint of transporting compressed hydrogen, but also a downsizing of the compressor at the hydrogen refueling station. In the meantime, the project will heavily investigate new fire testing methodologies and safety barriers for Type V adoption.
ROAD TRHYP’s overall ambition is to develop Europe’s value chain of Type V technologies. More specifically, the project intends to address all manufacturers across Europe who could benefit from the project’s innovative process and materials. Beyond the targeted commercial Type V trailers applications, the knowledge developed on composite materials could benefit main actors in the mobility sectors or the hydrogen storage for inter-seasonal energy storage. As a consequence, the project will help achieve the European Green Deal making hydrogen a widespread energy carrier, by 2030.
The overall objective of the ROAD TRHYP project is to develop and validate a trailer integrating new thermoplastic composite tubes (Type V) to maximise the quantity of H2 transported while satisfying end-user requirements (safety, ability to be decontaminated) and enforced regulations with a low cost. By the end of the project, the consortium will design a trailer capable of handling a payload of 1.5 tonne of H2 with 700 bar tubes and a capex lower than 400 €/kg. This enables the decrease of the number of transport rotations between the site of production and the delivery site, consequently the reduction of the environmental footprint of transporting compressed hydrogen, but also a downsizing of the compressor at the hydrogen refueling station. In the meantime, the project will heavily investigate new fire testing methodologies and safety barriers for Type V adoption.
ROAD TRHYP’s overall ambition is to develop Europe’s value chain of Type V technologies. More specifically, the project intends to address all manufacturers across Europe who could benefit from the project’s innovative process and materials. Beyond the targeted commercial Type V trailers applications, the knowledge developed on composite materials could benefit main actors in the mobility sectors or the hydrogen storage for inter-seasonal energy storage. As a consequence, the project will help achieve the European Green Deal making hydrogen a widespread energy carrier, by 2030.
So far, the development of Type V cylinder has been facing some problems. To overcome the problems, we have been using a liner to wind thermoplastic Tapes and ended with a monolithic structure as expected. The performances of the cylinder is promising but still need to be improved.
The carbon fiber content on the raw material (Tape) has reached 57% which is achievement compared to the starting point of 50%. It is the same range as carbon fiber content in carbon/Epoxy Type IV cylinder.
The design of the Multi Element Gas Container and the demonstrator are finalised. It is possible to reach 1,5 T on gH2 transported but the exact amount will be given when we have a better estimate of the weight of the Type V composite cylinder.
The demonstrator of 3 cylinders can be equipped with either 300 bar or 700 bar WP tubes.
The analysis of the Regulations Codes and Standards for trailers and Hydrogen Refueling Stations (HRS) are finalised. No major issued have been identified. That work will allow to define recommendation (regulation and norms) to use the trailer at the Hydrogen refuelling station.
On the safety side, we identified 3 main accidental scenarios leading to release of Hydrogen (hose rupture, leakage on filling hose or pipings). Simulation has shown that in case of a jet fire, flames about 70 m will occur. In the next steps, mitigation measures will be defined.
A Life Cycle Analysis has been carried out on Type I (metal) and Type IV (composite) trailer. It show that in terms of, for instance, CO2 emission, resource use (fossil or mineral) and particle emission there is a reduced impact using Type IV trailer compared to Type I. The next step is to do the calculation for Type V trailers with the innovative design.
The carbon fiber content on the raw material (Tape) has reached 57% which is achievement compared to the starting point of 50%. It is the same range as carbon fiber content in carbon/Epoxy Type IV cylinder.
The design of the Multi Element Gas Container and the demonstrator are finalised. It is possible to reach 1,5 T on gH2 transported but the exact amount will be given when we have a better estimate of the weight of the Type V composite cylinder.
The demonstrator of 3 cylinders can be equipped with either 300 bar or 700 bar WP tubes.
The analysis of the Regulations Codes and Standards for trailers and Hydrogen Refueling Stations (HRS) are finalised. No major issued have been identified. That work will allow to define recommendation (regulation and norms) to use the trailer at the Hydrogen refuelling station.
On the safety side, we identified 3 main accidental scenarios leading to release of Hydrogen (hose rupture, leakage on filling hose or pipings). Simulation has shown that in case of a jet fire, flames about 70 m will occur. In the next steps, mitigation measures will be defined.
A Life Cycle Analysis has been carried out on Type I (metal) and Type IV (composite) trailer. It show that in terms of, for instance, CO2 emission, resource use (fossil or mineral) and particle emission there is a reduced impact using Type IV trailer compared to Type I. The next step is to do the calculation for Type V trailers with the innovative design.
Prototype of Type V cylinders already made show a composite monolithic structure (one wall from the inside of the cylinder up to the outer composite layer). This is a unique advantage compared to existing Type IV cylinders as it can lead to an efficient cylinder drying process using existing equipment in filling centers.