Periodic Reporting for period 2 - ROAD TRHYP (ROAD trailer design - use of Type V theRmoplastic tube with light composite structure for HYdrogen transPort)
Berichtszeitraum: 2024-07-01 bis 2025-12-31
Today, existing hydrogen transportation solutions, such as trailers, 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, considering the upcoming ramp-up of gaseous Hydrogen delivery.
The main objectives of the ROAD TRHYP project are to:
- Develop and validate a trailer integrating Type V thermoplastic composite tubes to maximise the quantity of gaseous hydrogen transported
- Optimize Type V tubes
- Decontaminate Type V tubes at a low cost to meet hydrogen specifications for fuel cells
- Present new features of our trailer concept to norm committees
- Propose mitigation measures to operate the trailer in safe conditions
- Demonstrate the low environmental impact of the solution
- Lower TCO
By the end of the project, the consortium will design a trailer capable of handling a payload of 1.5 tonnes of Hydrogen with 700 bar tubes and a capital expenditure (capex) lower than 400 €/kg. This will enable a decrease in the number of transport rotations between the production site and the delivery site, consequently reducing the environmental footprint of transporting compressed hydrogen, and also downsizing 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 trailer applications, the knowledge developed on composite materials could benefit main actors in the mobility sectors amongst others. As a consequence, the project will help achieve the European Green Deal, making hydrogen a widespread energy carrier by 2030.
The main objectives of the ROAD TRHYP project are to:
- Develop and validate a trailer integrating Type V thermoplastic composite tubes to maximise the quantity of gaseous hydrogen transported
- Optimize Type V tubes
- Decontaminate Type V tubes at a low cost to meet hydrogen specifications for fuel cells
- Present new features of our trailer concept to norm committees
- Propose mitigation measures to operate the trailer in safe conditions
- Demonstrate the low environmental impact of the solution
- Lower TCO
By the end of the project, the consortium will design a trailer capable of handling a payload of 1.5 tonnes of Hydrogen with 700 bar tubes and a capital expenditure (capex) lower than 400 €/kg. This will enable a decrease in the number of transport rotations between the production site and the delivery site, consequently reducing the environmental footprint of transporting compressed hydrogen, and also downsizing 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 trailer applications, the knowledge developed on composite materials could benefit main actors in the mobility sectors amongst others. 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 cylinders has yielded promising results. The technology has demonstrated its reliability, and the performance achieved to date is encouraging. We have successfully created a Tube monolithic structure using thermoplastic composite tapes, achieving a gravimetric index exceeding 7%. Two versions of the cylinder have been developed: one with a liner and one without.
Key improvements demonstrated thus so far include :
- Gravimetric Index: Enhanced gravimetric index.
- Monolithic Structure: A monolithic structure where the liner is an integral part of the composite.
- Boss Design: An improved boss design, allowing for easy replacement i the case the thread is damaged (for instance).
- Key parameters for the decontamination have been identified: It has been possible to achieves 5 µmol/mol water content with standard equipment in a Type V cylinder, making it compatible with fuel cell applications.
The design of the Multi Element Gas Container and its demonstrator is now finalised. It is projected to transport 1.5 tons of gaseous Hydrogen, with the precise amount to be determined once we have a more accurate estimate of the Type V composite cylinder's weight at 700 bar working pressure.
Furthermore, the analysis of Regulations, Codes, and Standards for trailers and Hydrogen Refueling Stations (HRS) has been completed, revealing no major issues. This work provides recommendations (regarding regulations and norms) to use such trailer design at hydrogen refueling stations. From a safety perspective, we identified three primary accidental scenarios leading to hydrogen release: hose rupture, leakage on filling hose, or piping failures. Mitigation measures have been proposed.
A Life Cycle Analysis has been conducted on Type I (metal), Type IV and Type V trailers. The analysis demonstrates that Type V trailer generally delivers the best environmental performance, particularly at medium and long transport distances, due to its higher transport capacity.
Key improvements demonstrated thus so far include :
- Gravimetric Index: Enhanced gravimetric index.
- Monolithic Structure: A monolithic structure where the liner is an integral part of the composite.
- Boss Design: An improved boss design, allowing for easy replacement i the case the thread is damaged (for instance).
- Key parameters for the decontamination have been identified: It has been possible to achieves 5 µmol/mol water content with standard equipment in a Type V cylinder, making it compatible with fuel cell applications.
The design of the Multi Element Gas Container and its demonstrator is now finalised. It is projected to transport 1.5 tons of gaseous Hydrogen, with the precise amount to be determined once we have a more accurate estimate of the Type V composite cylinder's weight at 700 bar working pressure.
Furthermore, the analysis of Regulations, Codes, and Standards for trailers and Hydrogen Refueling Stations (HRS) has been completed, revealing no major issues. This work provides recommendations (regarding regulations and norms) to use such trailer design at hydrogen refueling stations. From a safety perspective, we identified three primary accidental scenarios leading to hydrogen release: hose rupture, leakage on filling hose, or piping failures. Mitigation measures have been proposed.
A Life Cycle Analysis has been conducted on Type I (metal), Type IV and Type V trailers. The analysis demonstrates that Type V trailer generally delivers the best environmental performance, particularly at medium and long transport distances, due to its higher transport capacity.
The gravimetric index achieved so far is above its objective of 7% (for a 300 bar WP cylinder). Prototypes of Type V cylinders feature a monolithic composite structure, with a single wall extending from the cylinder's interior to its outer composite layer. This offers a distinct advantage over current Type IV cylinders by enabling an efficient drying process using existing equipment in filling centers. It is no sensitive to collapse and therefore allows to defuel the cylinder at high speed.
Furthermore, as the liner is thinner compared to Type IV cylinders, for the same outer diameter, the inner volume is higher compared to Type IV.
Additionally, the design of Type V cylinders requires fewer assembly arrangements compared to traditional Type IV tubes.
Type V trailer delivers better environmental performance compared to existing Type IV trailer.
Furthermore, as the liner is thinner compared to Type IV cylinders, for the same outer diameter, the inner volume is higher compared to Type IV.
Additionally, the design of Type V cylinders requires fewer assembly arrangements compared to traditional Type IV tubes.
Type V trailer delivers better environmental performance compared to existing Type IV trailer.