Development of High Pressure

Hydrogen Storage Tank for Storage

and Gaseous Truck Delivery

Don Baldwin, Principal Investigator/Presenter

Hexagon Lincoln Project ID#
June 10, 2015 PD021
This presentation does not contain any proprietary, confidential, or otherwise restricted information
 OVERVIEW

Timeline Barriers
• Barriers addressed
• Project start date: July 2008
E. Gaseous Hydrogen Storage
• Project end date: June 2015 and Tube Trailer Delivery Costs
I. Other Fueling Site/Terminal
Operations
Budget
Partners
• Total Project Budget: $4.594M • Discussions with ABS on pressure
• Total Recipient Share: $1.824M vessel qualification
• Discussions with US DOT
• Total Federal Share: $2.770M regarding Special Permits for
• Total DOE Funds Spent*: $2.178M modules and trailers in USA
• Discussion with and input to ANL
* As of 3/31/15 for Hydrogen Refueling Station
Cost Reduction
• Extensive testing at Powertech
Labs and Stress Engineering
Services 2
RELEVANCE

• Relevance: to reduce the cost of a near-term means of

transporting gaseous H2 from the production or city gate
site to the station.
– Design and develop the most effective bulk hauling and storage
solution for hydrogen in terms of cost, safety, weight, and volumetric
efficiency. This will be done by developing and manufacturing a tank
and corresponding ISO frame that can be used for the storage of
hydrogen in a stationary or hauling application. Complete 4Q 2009.
– Based on current knowledge of tube trailer design, carry out
preliminary design and qualify a 3600 psi tank and ISO frame that will
hold 510000 in3 (~8500L) water volume. Complete 4Q 2009.
– Complete trade studies needed to increase vessel capacity by
increasing pressure to 5000 psi (ultimately exceeds the DOE’s FY10
capacity target by >15%). Complete 1Q 2011.
– Complete the enhancement of the 250 bar system with respect to
capacity (> 700 kg/liter) and safety (fire protection). Complete 4Q
2012.
– First deployment of TITAN Magnum trailer in CNG service. 2Q 2013.
– First deployment of TITAN XL40 trailer in CNG Service. 1Q 2015.
– Filling/decanting demonstration with compressed H2. 2Q 2015.

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 OBJECTIVES-TECHNICAL TARGETS 2010/2015*

Hydrogen delivery targets ISO container with four 3600 psi tanks
(FY 2009 Work Scope)
$500/kg of hydrogen stored by The TITAN Module, with four tanks installed, met the $500
FY2010, $300/kg by FY2015 per kg hydrogen objective in 2010. However, since 2010
increases in market prices for materials of construction
(specifically carbon fiber and specialty forgings) have forced
us to increase our current pricing to about $800/kg (1Q 2013).
[We have strong domestic and international sales of our high-
capacity modules and trailers at this price level for CNG.]
Volumetric capacity 0.03 kg/liter by The baseline tank has a capacity of 150 kg hydrogen in a
FY2010, >0.035 kg/liter by FY 2015 volume of ~8500 liters, achieving a performance of ~0.018
kg/liter.

Tube trailer delivery capacity 700 kg The current ISO assembly, with four tanks installed, will
by FY2010 and 1,140 kg by FY2017 contain approximately 616 kg of hydrogen. At 90% hauling
efficiency, delivery of 555 kg of hydrogen

* Based on the Fuel Cell Technologies Office 2007 MYRD&D

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 OBJECTIVES-TECHNICAL TARGETS 2015/2020
Hydrogen delivery targets ISO container with four 3600 psi tanks
(FY 2009 Work Scope)
$730/kg of hydrogen delivered by The TITAN Module, with four tanks installed, met the $500 per kg
FY2015, $575/kg by FY2015 hydrogen objective in 2010. However, since 2010 increases in market
prices for materials of construction (specifically carbon fiber and
specialty forgings) have forced us to increase our current pricing to
about $800/kg (1Q 2013). [We have strong domestic and international
sales of our high-capacity modules and trailers at this price level for
CNG.]
Delivery Pressure 400 bar by FY2015, The current delivery pressure is 250 bar. Design and trade studies have
520 bar by FY2020 been performed which indicate that a delivery pressure of 350 bar is
optimal for TITAN modules/trailers. Higher pressures are achievable but
would require extensive redesign and retooling of the manufacturing
infrastructure.

Tube trailer delivery capacity 700 kg by The Titan module system, (four large tanks) contains
FY2015 and 940 kg by FY2020 approximately 616 kg of hydrogen. At 90% hauling efficiency,
delivery of 555 kg of hydrogen
The Titan V Magnum, (5 large tanks and 9 small tanks) contains
approximately 800 kg of hydrogen. At 90% hauling efficiency,
delivery of approximately 720 kg of hydrogen.
The Titan V XL40 ( 5 large tanks and 7 medium tanks) is being
developed and will contain approximately 890 kg of hydrogen. At
90% hauling efficiency, delivery of approximately 800 kg of
hydrogen. 5
APPROACH/MILESTONES

Task 1.0 Develop and Task 2.0 Develop and Task 3.0 5000 psi
Qualify a 3600 psi Qualify an ISO Frame Trade Study
Tank

•Design and qualify 8500 liter •ISO container to hold four tanks with a •A higher pressure
tank combined capacity of 600 kg of tank will be required
•Focus on large tank hydrogen to meet DOE goals
manufacturing •Completed 3Q 2009 •Initial review suggest
•Completed 4Q 2009 •DOT SP obtained in 1Q2012 a 5000 psi tank will
•Characterize interaction of CHG •Pursuing DOT SP approval for be the most cost
with tank under deep cycling larger volume trailer systems effective
prior to use in CHG service •Completed 1Q 2011
•Expected Completion 2Q 2015 •Expected Completion 4Q 2015

Task 5.0 Cost

Task 4.0 Develop and Reduction Studies Task 6.0 Investigate
Qualify a 5000 psi Tank Increased Capacity

•This task is no longer being •Reduce cost •Design and prototype a

pursued. •Increase safety Titan5 trailer that will
•Lack of market definition in •Continued development of increase storage capacity
regards to working pressure emergency venting system per truck load.
5000 or 7250 psi and •Laboratory equipment to •Completed 1Q 2012
forecasting of market size. characterize the effects of •Optimize trailer systems to
•High testing costs ~$5 hydrogen on polymer maximize capacity in target
million to fully qualify. liners markets (including USA)
•Completed 4Q 2012 •Completed 4Q 2012

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TECHNICAL ACCOMPLISHMENTS/PROGRESS/RESULTS
Completed the design, manufacture and assembly of ISO format container (standard
dimensions) capable of storing ~616 kg H2 @ 3600 psi.
• Successful completion of all qualification tests for a 3600 psi pressure
vessel per ABS Document No. ABSHOU557163
• Completed Testing of Container per CSC 49 CFR Part 451
• DOT Special Permit 14951 issued 22 February 2012
2014 saw continued evolution of module functionality and safety systems with
accumulation of field experience in CNG service
• Different jurisdictions
• Different environments

Gaining real world experience in fuel gas distribution 7

TECHNICAL ACCOMPLISHMENTS/PROGRESS/RESULTS
HEXAGON LINCOLN TITAN™ Module System

Compressed Hydrogen Gas

Capacity
250 bar – 616 kg (554 kg delivered)
350 bar – 809 kg (728 kg delivered)
540 bar – 1155 kg (1040 kg delivered)
Gross Vehicle Weight (GVW)(with prime
mover)
250 bar – 28 450 kg
350 bar – 30 820 kg
540 bar – 39 440 kg

Compressed Natural Gas

Capacity (250 bar at 15° C) – 7412 kg
GVW (With prime mover) – 35 250 kg

Highly modular system with increased volume and light weight 8

TECHNICAL ACCOMPLISHMENTS/PROGRESS/RESULTS
• Completed the design, manufacture and assembly of integrated TITAN V Magnum
trailer system capable of storing ~800 kg H2 @ 3600 psi.
– Maximum width and height allowed on Interstate Highway System
– Gross Vehicle Weight within limits for Interstate up to 350 bar
• 2013 saw first deployment of TITAN V Magnum systems in CNG service
– Very good handling characteristics (low center of gravity) and functionality
• 2015 introduction of TITAN V XL40 will increase storage to ~890 kg H2 @ 3600 psi

Our first trailer systems are performing well in CNG service 9

TECHNICAL ACCOMPLISHMENTS/PROGRESS/RESULTS
HEXAGON LINCOLN TITAN™ V Magnum Trailer System
Compressed Hydrogen Gas
Capacity
250 bar – 800 kg (720 kg delivered)
350 bar – 1050 kg (907 kg delivered)
540 bar – 1500 kg (1350 kg delivered)
GVW (with prime mover)
250 bar – 31 000 kg
350 bar – 34 200 kg
540 bar – 45 700 kg

Compressed Natural Gas

Capacity (250 bar at 15 C) – 9649 kg
GVW (With prime mover) – 39 830 kg

Integrated trailer system allows increased lading with excellent roadability 10

MAGNUM VS XL40

11
XL40 First Unit

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TECHNICAL ACCOMPLISHMENTS/PROGRESS/RESULTS
• Trade Studies Performed to Maximize Cost
Effectiveness of Modules/Trailers
• More Hydrogen Capacity and Lower GVW Reduce
Operating Expenses
• 350 bar TITAN™, TITAN V MagnumTM and TITAN V
XL40 Systems Would be a Logical Next Step
– 2.4 SR Design Fits ISO Frame and Trailer Widths
– From .018 to .024 kg H2 per Liter
– Increased Payload
• 616 to 816 kg H2 Capacity for TITANTM
• 801 to 1051 kg H2 Capacity for TITAN V MagnumTM
• 889 to 1205 kg H2 Capacity for TITAN V XL40
– 5% reduction in $ per kg H2 [capital expenditure for
rolling stock only]

350 bar operation would be optimal for module and trailer efficiency 13
TECHNICAL ACCOMPLISHMENTS/PROGRESS/RESULTS

• Practical Limit in Industry is 350 bar

– Higher pressures exacerbates thick-wall effects in
pressure vessel and reduces strength translation
– Limited availability of high-flow gas management
components at higher pressures
– Availability/reliability of high-volume H2
Compressors
• Need Solid Definition of Market Size and Operating
Parameters [i.e.; 350 bar vs 540 bar] before a Business
Case Can be Made for Investment in Qualification at a
Higher Pressure
• ARNL has conducted trade studies to determine
optimized configurations for tube trailers; E.G., using
a consolidation approach with a mix of 250 bar and
high-pressure tankage
Operational and business issues are being studied. Answers soon? 14
TECHNICAL ACCOMPLISHMENTS/PROGRESS/RESULTS

TITAN systems are raising the bar for fuel gas transport 15
TECHNICAL ACCOMPLISHMENTS/PROGRESS/RESULTS

• H2 Deep Cycle Test Plan

– First fill of TITAN™ tanks with CHG
– Two TITAN™ tanks are test specimens
– Four TITAN™ tanks are accumulators
– Transfer H2 between test units 3 to 4 times
• Monitor temperature and pressure
• Monitor for H2 emission
• Monitor for liner stability
– Inspect condition of tanks
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Test Setup at Powertech Labs

Electrolyzer and
Compressor
(behind Storage
Module) Storage
Tower

Low Pressure
Storage (from
Electrolyzer)
Storage Module
(4 Tanks)

Camera
End Test
Tanks Valve Nitrogen
End purge gas 17
Electrolyzer Room at Powertech Labs

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Compressor Room at Powertech Labs

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TITAN™ Storage Module (H2 Accumulators)

Pressure
Transducers to
be located at
each tank

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 TITAN™ Test Specimens

Additional concrete
block wall to be built
on this end
Cameras to be
installed in this end

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H2 Deep Cycle Test Timeline

• Setup complete mid April 2015

• First fill complete mid to late April
• First transfer early May
• Finish remaining cycles in May
• DOE personnel to visit mid May

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COLLABORATIONS

• American Bureau of Shipping on qualification of existing and

potential changes to composition of current pressure vessels.
• Lincoln Composites has received Special Permit from the U.S. DOT
authorizing the manufacture, making, sale and use of the Titan bulk
hauling 4 cylinder module in February 2012.
• Discussion with and input to ARNL for Hydrogen Refueling Station
Cost Reduction studies
• Lincoln Composites has initiated Special Permit discussions with
U.S. DOT towards authorizing the manufacture, making, sale and
use of the Titan 5 bulk hauling trailer systems
• Extensive testing activities
– Powertech Labs
– Stress Engineering Services

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REMAINING CHALLENGES AND BARRIERS

• Experience with deep cycling of TITAN pressure vessels

with CHG is needed to define operating protocols for use
of TITAN systems in CHG service at 250 bar

• U.S. DOT Special Permit approval is needed prior to the

manufacture, making, sale and use of Titan V trailer
systems in the United States

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FUTURE WORK

• A program of deep cycle testing of TITAN pressure

vessels with CHG will be performed in 1Q and 2Q 2015
– Characterize CHG-specific operating protocols for use of TITAN
systems in CHG service at 250 bar

• Hexagon Lincoln will prepare and submit an application

for Special Permit approval with U.S. DOT for the
manufacture, making, sale and use of Titan V trailer
systems in the United States
– Initial discussions with DOT indicate structural testing is required

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SUMMARY
• Hydrogen delivery and storage are key to the roll out of PEMFC technology
• Low cost, near-term delivery pathways such as tube trailer transport will
enable early adoption of these technologies
• Developing a bulk storage unit that can be transported on an ISO frame or
integrated into a trailer is a critical part of this strategy

Technical Targets
DOE Goals Estimated Results
$500/kg of hydrogen stored by FY2010, $300/kg by FY2015 3600 psi - $800 per kg of H2

Volumetric capacity 0.03 kg/liter by FY2010, >0.035 kg/liter by Current 3600 psi tank – 0.018 kg/liter
FY 2015

Tube trailer delivery capacity 700 kg by FY2010 and 1,100 kg 3600 psi (4-tube ISO container) - contains 616 kg of hydrogen,
by FY2017 555 kg deliverable at 90% efficiency.
Tube trailer delivery capacity 700 kg by FY2015 and 940 kg by 3600 psi (4-tube ISO container) - contains 616 kg of hydrogen,
FY2020 (DRAFT) 555 kg deliverable at 90% efficiency.
3600 psi (5-tube trailer with additional 9 tanks) – contains 800
kg of hydrogen, 720 kg deliverable at 90% efficiency.
3600 psi (5-tube trailer with 7 intermediate tanks) – to contain
890 kg of hydrogen, 800 kg deliverable at 90% efficiency.
Tube trailer operating pressure goal is <10,000 psi by FY2012 Current module configuration is 3600 psi

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