Proceedings of the 2002 U.S.

DOE Hydrogen Program Review

NREL/CP-610-32405

Hydrogen Composite Tank Program

Principal Investigator: Dr. Neel Sirosh, Director of Fuel Storage
QUANTUM Technologies WorldWide, Inc.
17872 Cartwright Road, Irvine, CA 92614
Phone: (949) 399-4698; e-mail: [email protected]

Introduction
There is a strong demand in the automotive market for cost-effective and efficient high-pressure
hydrogen storage systems. Worlds premier automotive OEMs developing fuel cell vehicles
have demonstrated significant interest in compressed hydrogen storage systems developed and
validated by QUANTUM Technologies, under DOE contract DE-AC36-00GO10494. The
currently validated QUANTUM TriShield tank technology (see Fig. 1) meets the percent
weight, energy density, and specific energy goals of 6% hydrogen by weight, 1,050 W-h/L, and
2,000 W-h/kg, targets of the DOE and significant cost reductions are possible with further
optimization.

Fig. 1 TriShieldTM Type IV Tank

The 5,000 and 10,000 psi tanks developed by QUANTUM Technologies have been validated to
meet the requirements of DOT FMVSS304, NGV2-2000 (both modified for 10,000 psi hydrogen)
and draft E.I.H.P standard. Typical safety tests completed, in order to ensure safety and
reliability in an automotive service environment included: Burst Tests (2.35 safety margin),
Fatigue, Extreme Temperature, Hydrogen Cycling, Bonfire, Severe Drop Impact Test, Flaw
Tolerance, Acid Environment, Gunfire Penetration, Accelerated Stress, Permeation and Material
Tests.

Proceedings of the 2002 U.S. DOE Hydrogen Program Review

NREL/CP-610-32405

Over the next decade beyond, a significant market is expected to develop for fuel cell powered
products. These products will be designed to provide clean, quiet, vibration-free electric power
on demand for a variety of applications in the transportation and industrial vehicle, stationary
power and portable power markets. In the automotive market, each of DaimlerChrysler, Ford,
General Motors, Honda, Hyundai, Nissan, and Toyota has recently announced its intention to
introduce fuel cell vehicles sometime between 2003 and 2005, with mass production of fuel cell
vehicles anticipated to begin in the latter part of the decade.
Project Goals and Objectives
The objective of the DOE Hydrogen Composite Tank Program was to design, develop, validate,
fabricate, and manufacture hydrogen fuel tanks and in-tank regulators (Fig. 2) along with vehicle
integration brackets and isolators and have them delivered to Virginia Tech University and
Texas Tech University in support of the Future Truck competition.

Fig. 2 In-Tank Pressure Regulator

This project is part of the DOE program to demonstrate the feasibility of the use of compressed
hydrogen as an automotive fuel. However, the lack of convenient and cost-effective hydrogen
storage, particularly for an on-board vehicular system, is a major impediment to its widespread
use. Improvements in the energy densities of hydrogen storage systems, reductions in cost,
and increased compatibility with available and forecasted systems are required before viable
hydrogen energy use will be realized. Possible approaches to hydrogen storage include:
compression, liquefaction, chemical storage, metal hydrides, and adsorption. Although each
storage method has desirable attributes, no approach currently satisfies all the efficiency, size,
weight, cost, and safety requirements for transportation or utility use. Research continues in
these areas, with progress being made in all approaches.
Specific goals of the project were to:
Develop and demonstrate 7.5 wt % and 8.5 wt% Type IV composite hydrogen storage
tanks of specified sizes
Validate 7.5 wt% and 8.5 wt% Type IV composite hydrogen storage tanks
Develop and validate 5,000 psi in-tank-regulators
Build, assemble, test and supply tanks with in-tank-regulators for DOE Future Truck and
Nevada hydrogen bus programs
Demonstrate 10,000 psi hydrogen storage tanks

Proceedings of the 2002 U.S. DOE Hydrogen Program Review

NREL/CP-610-32405

Milestones
Key milestones in the development and commercialization of QUANTUMs high-pressure
storage technologies include:
1999

Breakthrough in new, ultra lightweight, low-cost storage addressing barriers related

to permeability and effects of hydrogen embrittlement.

2000

As part of a DOE-sponsored development program with Lawrence Livermore

National Laboratory and Thiokol, achieved a World Record hydrogen storage mass
efficiency of 11.3 weight percentage on a prototype 350 bar (5,000 psi) tank
This achievement received an innovation award from the DOE Hydrogen
Technical Advisory Panel (HTAP)
Awarded patent for in-tank regulator for fuel cell and natural gas vehicles.
Commenced shipping high efficiency TriShieldTM hydrogen storage tanks (5,000
psi and 3,600 psi) for a number of vehicles and stationary applications (Fig. 3).

Fig. 3: 5,000 psi (350 bar) TriShield Tanks

2001

QUANTUMs 350 bar tank in a Hyundai Santa Fe FCEV is the first to fill to 350
bar with hydrogen.
Demonstrated proof-of-concept 10,000 psi (700 bar) tank and began validation
testing.
In November 2001, achieved European Integrated Hydrogen Project (EIHP)
specifications for 5,000 psi hydrogen storage tank, the first all-composite tank to
achieve this.
Achieved CSA certification for industrys first 5,000 psi (350 bar) in-tank
regulation system under NGV 3.1 standards.
Designed and developed industrys first hydrogen 10,000 psi (700 bar) in-tank
regulation system.
Developed industrys first solenoid valve designed exclusively for hydrogen use
Shipped tanks for DOE Future Truck and Nevada bus programs

Received industrys first regulatory certification of 10,000 psi hydrogen storage tanks
(EIHP-based tests)
Shipped 10,000 psi tanks systems for OEM applications
Obtained Japanese (KHK) certification for 5,000 psi hydrogen storage tanks

Proceedings of the 2002 U.S. DOE Hydrogen Program Review

NREL/CP-610-32405

Developed, validated and shipped tanks for Future Truck 2002 (Ford)

Status of Progress
Developed at QUANTUMs Advanced Technology Center in Irvine, California, the QUANTUM
TriShieldTM all-composite hydrogen storage cylinder removes the barriers to more rapid
commercialization of hydrogen-powered fuel cell vehicles. QUANTUM has introduced this
rugged, low cost, ultra-lightweight, storage efficient hydrogen storage tank to improve the range
and safety of hydrogen powered fuel cell vehicles.
The QUANTUM advanced composite tank technology incorporates a TriShieldTM design
philosophy (see Fig. 4). The QUANTUM Type IV TriShieldTM cylinder, as illustrated below, is
comprised of a seamless, one piece, permeation resistant, cross-linked ultra-high molecular
weight polymer liner that is overwrapped with multiple layers of carbon fiber/epoxy laminate and
a proprietary external protective layer for impact resistance. TriShieldTM hydrogen tanks feature
a single-boss opening to minimize leak paths.
TriShieldTM hydrogen tank is designed to accommodate QUANTUMs patented in-tank regulator,
(see Fig. 2) which confines high gas pressures within the tank and, thus, eliminates highpressure fuel lines downstream of the fuel storage subsystem. By combining a check valve to
assist tank filling, fuel filtering, fuel tank pressure and temperature monitoring, pressure relief
device and tank lock-off in the regulation module the system cost can be significantly reduced.

Fig. 4: TriShieldTM Tank Construction

Gaseous fuels, especially hydrogen, inherently have a much lower energy density than liquid
fuels, such as gasoline. Compression to high pressure is required to increase the mass of
hydrogen stored, and resulting vehicle range, within a given space on-board a vehicle.
Compressed natural gas, for example, is typically stored at 3,000 psi (200 bar) or 3,600 psi (250
bar). Hydrogen needs to be compressed to even higher pressures because of its even lower
energy density. To date, hydrogen tanks designed for fuel cell vehicles have been developed to
store hydrogen at pressures of up to 10,000 psi (700 bar) to maximize vehicle range. Hydrogen

Proceedings of the 2002 U.S. DOE Hydrogen Program Review

NREL/CP-610-32405

cylinders are actually designed to handle pressures considerably higher than the rated service
pressure to meet a minimum safety factor of 2.35 burst strength and to accommodate an
increase in gas temperature during fast filling.
Standards developed by ANSI/AGA, NGV2-1998 and NGV2-2000 have become the key for
industry acceptance of high-pressure storage cylinders, although FMVSS 304 is the minimum
standard required by the U.S. Department of Transportation (DOT). Since no international
standards or specifications have yet been approved for hydrogen cylinders, they are currently
following compressed natural gas (CNG) tank classifications, which fall into these categories:

Type I - all metal cylinder

Type II load-bearing metal liner hoop wrapped with continuous filament
Type III non-load-bearing metal liner axial and hoop wrapped with continuous filament
Type IV - non-load-bearing non-metal liner wrapped with continuous filament

The International Standards Organization (ISO) is developing fuel cell vehicle and hydrogen
storage standards within technical committees TC22/SC21 and TC197. The European
Integrated Hydrogen Project (EIHP) has also formulated state-of-the-art hydrogen system
standards. The standards, both those based on CNG and those being developed for hydrogen,
specify a number of tests to ensure safety, reliability, and durability of the compressed hydrogen
fuel storage system. The various types of validation tests are listed in Figure 5.
Hydrostatic Burst
Ambient Cycle
Gunfire Penetration (see picture)
Flaw Tolerance
Drop Test
Hydrogen Cycle
Tensile Properties
Boss End Material
Extreme Temperature Cycle
Acid Environment
Bonfire (see picture)
Accelerated Stress
Permeation
Softening Temperature
Resin Shear
Boss Torque Resistance
Fig. 5 Validation Tests
Future Work
The storage, transport, and delivery of hydrogen are critical elements for a practical hydrogen
energy system. The goal to develop efficient and cost-effective hydrogen storage systems is
driven primarily by the mobile applications for hydrogen, where size and weight of a storage

Proceedings of the 2002 U.S. DOE Hydrogen Program Review

NREL/CP-610-32405

device are major constraints. Other applications will also benefit from the technological
advances made for on-board hydrogen storage systems. Since the energy density of hydrogen
gas is significantly less than that of conventional fuels, larger tanks are required for equivalent
range. Furthermore, the geometry of traditional high-pressure cylinders generally does not
conform to the available space on the vehicle, thereby raising tank packaging issues. Tank cost
and weight also significantly influence the amount of fuel that can be carried.
QUANTUM is working with ATK Thiokol Propulsion, its strategic alliance partner, in addressing
these issues through the development of high-pressure conformable tanks for on-board
hydrogen storage. The lightest-weight approach uses high-strength, filament-wound carbon
fiber composite for structural efficiency, with polymer liners as permeation barriers. The quasiconformable storage concept uses multiple cells, with the number and shape of the cells tailored
to maximize internal volume within a rectangular envelope while maintaining membrane loading
for structural efficiency. Each cell is filament-wound with a combination of hoop and helical
layers, followed by a hoop overwrap over the assemblage of cells. Depending on the shape of
the envelope, up to 50 percent more storage may be possible with a conformable tank than with
cylinders.
Hydrogen poses challenges, both real and perceived, as a transportation fuel. The most
challenging application is the light-duty vehicle or, more specifically, the automobile.
Automobiles impose the greatest constraints with respect to available space on-board the
vehicle and consumer expectations for vehicle range. In the near-term, fuel cell vehicles will
likely first be introduced for fleet applications in 2003-05. Fleet applications will likely have
centralized refueling available, so a vehicle range of 100 150 miles (160 - 241 km) would be
acceptable. In terms of mass of hydrogen, this range could be achieved with about 3 kg of
hydrogen supplying a fuel cell vehicle. Mature compressed and liquid hydrogen storage
technologies of reasonable size and weight could achieve this short-term goal, as shown in the
following table. Metal hydrides, although providing more compact storage, would impose a
significant weight penalty.
Technology
5,000 psi Compressed H2 Tanks
10,000 psi Compressed
Tanks
Metal Hydrides
Liquid H2

Storage System Volume

145 L

H2 100 L

Storage System Weight

45 kg
50 kg

55 L

215 kg

90 L

40 kg

Short-term Goal: 3 kg H2 (215 km)

In the long-term, average consumers will expect fuel cell vehicles to be transparent compared to
the gasoline-powered vehicles they drive today with respect to cost, convenience and operation.
In fact, it is likely that fuel cell vehicles will have to offer a significant value proposition to
encourage consumers to adopt a new technology rather than continue with something that is
tried and true. Vehicle range will be an important factor to consumers, especially as a hydrogen
refueling infrastructure begins to develop. Fuel cell vehicle range of over 400 miles (644 km)
will be needed, or roughly 7 kg of hydrogen stored on-board. Advanced storage materials,

Proceedings of the 2002 U.S. DOE Hydrogen Program Review

NREL/CP-610-32405

including alanate hydrides and carbon nano-structures, will have to emerge from the current
conceptual stage to reduce hydrogen storage system size and weight, as shown in the following
table. However, both of these solid-state storage media are years from commercialization.
QUANTUMs 10,000 psi TriShieldTM could potentially meet this long-term goal without
significantly impacting either the passenger or storage compartments.
Technology
5,000 psi Compressed H2Tanks
10,000
Tanks

psi

Compressed

Storage System Volume

320 L

Storage System Weight

90 kg

H2 220 L

100 kg

Alanate Hydrides

200 L

222 kg

Carbon Nanotubes

~ 130 L

~ 120 kg

Long-term Goal: 7 kg H2 (700 km)

Commercialization
The markets for QUANTUMs advanced TriShieldTM high-pressure storage technology appear to
be growing. Quoting one major OEM, the hydrogen storage efficiency achievements by
QUANTUMs TriShieldTM tanks has made us re-think our fuel cell fuel strategy. Major
automotive OEMs and bus OEMs are expected to be the major markets for this technology. In
addition, QUANTUM sees growing interest in stationary and, especially, hydrogen refueling
infrastructure applications for its advanced TriShieldTM storage tanks.
Since 1995, QUANTUM has invested significantly in research and development of technology
and products that support the use of fuel cell systems. The commercialization of our technology
products has established QUANTUM as a leader in fuel storage, fuel metering, and electronic
controls for hydrogen systems. QUANTUM continues to pursue further advances in storage
technology, materials, regulators, metering, sensors, controllers, and refueling infrastructure that
will enable fuel cell vehicles to become as transparent to the consumer and end user as todays
gasoline engine-powered automobiles.
Acknowledgements
The work reported in this paper was co-sponsored in part by the U.S. Department of Energy
though contract DE-AC36-GO10494. QUANTUM appreciates the support from the DOE,
especially from Sigmund Gronich, Neil Rossmeissl, and Christopher Bordeaux of the Office of
Power Delivery Systems, Office of Power Technologies, Energy Efficiency and Renewable
Energy, DOE. We appreciate the directions from Fred Mitlitsky, Blake Myers, and Andrew H.
Weisberg of the Lawrence Livermore National Laboratory and Mary Hartford and Doug Hooker
of the DOE Golden Office in managing the subject DOE contract. We also acknowledge the
directions and input from George J. Thomas of Sandia National Laboratories and Andrew
Haaland of Thiokol Propulsion.