Presentation for RTD trainees - StorHy Hydrogen Storage

STORHY 

“Hydrogen Storage Systems for Automotive Application” 

Integrated Project n° 502667 

Hydrogen and Fuel Cell Review Days 2007, Brussels 10th-11th October 

Volker Strubel 

Josef Zieger 

Sitra Colom 

Guido Bartlok 

Jiri Muller 

Georg Mair 

Florent Montignac 

Angelika Bertalanic


1. Project Objectives 

StorHy – General Project Information 

“Hydrogen Storage Systems for Automotive Application” 

Integrated Project n° 502667 within the EU FP6 

Co-ordinator: MAGNA STEYR Fahrzeugtechnik AG & Co KG 

Time frame: 2004 – 2008 (4,5 years) 

Official project start: March 1 st , 2004 

Budget: € 18.7 m 

EU contribution: € 10.7 m 

Website: www.storhy.net 

34 partners from 13 European countries 

(5 OEMs, 14 research institutes and 15 supplier companies)

Source: Daimler Chrysler 

Gas: 

700 bar Technologies 

Source: Dynetek 



StorHy – Overall Structure 

Users: 

Vehicle Requirements 

Source: BMW 

Source: PSA Source: Daimler Chrysler 

Liquid: 

Lightweight 

Free-form Tank 

Source: SP Cryo 

Safety Aspects and Requirements 

Multi-Criteria Evaluation 

Solid: 

Advanced Alanates 

Source: IFE



Hydrogen Storage: Consumer Expectations 

Public Acceptance of Hydrogen Applications – 

Study by DC 

Main conditions for consumer acceptance of FC vehicles* 

� Driving range 

� Refuelling process 

� High safety level 

� Vehicle costs 

� Communication / education 

*Excerpt only!

Consumer 

Expectations 

Driving range 

> 400 km – 600 km 

Driving performance 

Usable space 

Refuelling 

convenient and safe 

Safety 



StorHy:Hydrogen Storage Requirements 

Technical 

Requirements 

Unit StorHy 

Targets 2010 

Hydrogen storage mass kg 6 - 10 

System grav. energy density kWh/kg 

wt.% 

System vol. energy density kWh/l 

kg H 2 /100l 

Filling cycles 3*5,000 

Loss of usable H2 (boil-off) g/h *stored 

kg H2 1 

Vehicle costs Costs of storage system €/ kg H2 Not defined 

2.0 

6 

1.5 

4.5 

Refuelling rate kg H 2 /min 1.2 

Burst pressure 700 bar bar 1,645 

Permeation rate H 2 Ncm 3 /h *l EHIP II 

1

International technology watch 

� Increase of service pressure from 350 bar – 700 bar 

� 700 bar Type III fully wrapped aluminum liner 

� 700 bar Type IV fully wrapped non-load carrying plastic liner 

� 700 bar system prototypes or small series announced in 

USA, Japan and Europe 


2. Alignment to SRA/DS 

Compressed Hydrogen Storage: 

State-of-the-Art 

Source: Dynetek

700 bar Type III vessel with 

metallic liner made by deep drawing 

� Material & microstructure 

– Modified CrMo steels 

� Liner material characterization 

– 5 steels assessed concerning H 2 

embrittlement 

� 700 bar design & calculation 

– Analytical + FE calculations for 

composite thickness + optimized 

modulus (fibre type) + winding path 

� Vessel testing 

– Ambient T cycling < 15,000 cycles 

– Burst factor: > 2.35 

– Other EIHP-II tests were performed 

successfully 



StorHy: 700 bar C-H 2 Vessels 

Source: AL 

Source: Faber 

Source: Faber 

Technical data: 

• Mass of vessel: 40 kg 

• Internal volume: 39 l 

• H 2 storage capacity: 3.85 wt.% 

• Operating pressure: 700 bar 

• H 2 mass stored: 1.6 kg

700 bar Type IV vessel with 

rotomoulded plastic liner 

� Polymeric material & microstructure 

– Development of specific PA6 formation 

(permeation / mechanical elasticity / 

processability) 

� Liner material characterization: 

Permeation of PA polymer liner assessed 

at 700 bar f (T, p): 

– Material level: Pe ∼1*10-16mol/(Pa.s.m) – Vessel level: ongoing 

� 700 bar vessel design & calculation 

– Analytical + FE calculations 

for composite thickness 

� Vessel testing 

– Ambient T cycling > 15,000 cycles 

– Burst factor: 2.2 



StorHy: 700 bar C-H2 Vessels 

Source: CEA/Ullit 

Source: CEA 


• Mass of vessel: 29 kg 



• Operating pressure: 700 bar 

• H 2 mass stored: 1.6kg



StorHy: Test Results of C-H 2 Vessels 

Type III 

(steel liner) 

Type IV 

(PA liner) 

Thermoplastic 

modular system 

Burst test Passed Close to target Feasibility GF/PP 

Cycling test Not passed Passed Not tested yet 

Status 

Cycling behaviour 

to be improved 

Burst behaviour to 

be improved 

Feasibility at 

300 bar 

Typical failure mechanisms for C-H 2 vessels identified 

Measured proposed for further improvements steps: 

� R&D activities required for a fundamental understanding of 

aging & failure behaviour composite and liner materials, 

advanced modelling and simulation concepts

Steel liner 

Production 

Polymer liner 

Production: 

Rotomolding 


StorHy contribution (excerpt) 

Liner fabrication Composite manufacturing Post processing 

Alu liner 

Production 

Polymer liner 

Production: 

Blowforming 


C-H 2 Storage: Production Steps 

CF raw materials Impregnation bath 

Filament winding Curing 

Autofrettage 

Process 

Vessel testing 

Recycling 

Dismantling 

Shreddering 

CF Recycling

Ring winding head with modular siphon impregnation 

units and suitable advancement of the path generation 

� Increase of the lay-down rate (> factor 3) 

� Better exploitation of the fibre performance, which entails weight 

reduction potentials for pressure vessels 

� Clean work station due to an almost closed system 

� Reduction of resin consumption 

� Almost no hazardous waste 

Winner of two Innovation Awards! 



StorHy: C-H 2 Vessel Production – 

Improved Winding and Impregnation 

Source: IVW

� Development of pre-treatment technology 

– Hybrid shredder (Kema) selected 



StorHy: C-H 2 Composite Vessel 

Recycling Concepts 

� Development of recycling processes 

– Fluidised bed process selected 

– Good quality fibre (similar stiffness 

Clean flue 

and 50% strength) has been recycled gas 

To energy 

recovery 

� R&D to increase material recycling rate: Afterburner 

– Microwave pyrolysis process in a 

fluidised bed 

– 86% total material recovery achieved 

(increase from 63% for fluidised bed) Air Inlet 

� Recycling of a thermoplastic composite 

vessel by granulation and injection moulding 

demonstrated (GF/PP COMAT system) 

Recovered 

Source: UNOTT 

CF fibre 

Twin screw shredder 

Fluidised Bed Recycling 

Cyclone 

300 mm 

Scrap CFRP 

Fan 

Recovered Fluidised 

Fibre 

Bed 

Electric Pre-heaters 

Air distributor 

plate

High pressure H 2 

V 1 

Booster Cooler 



Refuelling C-H 2 : State-of-the-Art 

V 2 

700 bar filling nozzle 

Source: Weh 

� For fast filling, gaseous 

hydrogen needs to be cooled 

down to prevent excessive 

pressure and temperature 

levels 

� Hydrogen cooler required in 

the refuelling station! 

Source: Linde / Aral

Fast filling demonstrated on vessel 

level 

� Filling temperature down to -100°C 

demonstrated 

� 100% filling rate easy to reach 

� Gentle cylinder treatment compared to 

warm filling – but thermal stress for 

storage components, esp. sealing 

� Cooling down to -40 °C seems to be 

good compromise 

� Deeper cooling still needs to be 

evaluated with regard to costs and 

material exposure 

700 bar cold (–40°C) filling test in 

F-Cell vehicle 

� Safe and optimized filling demonstrated Source: ET, AL, Dynetek, DC, Weh 



StorHy: C-H 2 Cold Filling 


• Filling T: -85°C 

• Filling time:

Advanced C-H 2 700 bar filling devices 

developed and tested: 

� Filling nozzle with infrared 

communication interface 

� Linear shut-off valve 

� Break-away device 

Sources: WEH 



StorHy: C-H 2 700 bar Filling Devices 

Source: Weh 

Break-away device with 

infrared communications 

interface 

Linear shut-off valve 

Filling nozzle with/without infrared 

communication interface 

Start of commercialization

Source: MAGNA STEYR 



Cryogenic Liquid Storage System 


� Small series, automotive, approved L-H 2 storage systems with 

double-walled stainless cylinders 

� First cylindrical prototypes with lightweight aluminum tank 

shells 

� First flat-shaped prototypes with lightweight steel tank shells 

Source: Linde 

Source: Air Liquide

Structure and coating concepts for liner 

Moisture, air, oil, etc 

Hydrogen 

Outgassing 

Outgassing 



StorHy: L-H2 Lightweight Design 

Lightweight cylindrical tank 

Carbon fibre composite structure of inner tank and outer jacket 

Liner 

Outer Jacket Composite 

High Vacuum: 10 -5 – 10 -6 Liner 

mBar 

Liner 

Inner Tank Composite 


Aluminium sheet (outer jacket) 

Galvanic copper coating 

(inner tank) 

Source: SP Cryo

Free-form tank system with auxiliary system box 

Free-form design 



StorHy: L-H 2 Free-form Design 

Risk analysis 

(FMEA and FTA) 

Free-form tank 

demonstrator 


Concept calculation 

(e.g. showing deformation 

at 10.8 bar) 

Vehicle integration 

concepts

Weight [kg] 

Mass comparison of gasoline and L-H 2 tank systems 

Energy content equivalent to 10 kg hydrogen 

200 

175 

150 

125 

100 

75 

50 

25 

0 

10 kg 



StorHy: L-H 2 Weight Reduction Potential 

3 

30 

65 

100 kg 

Gasoline 38 dm³ LH2 Steel 

E 68 

cylindrical shape 

25 

40 kg 

10 10 10 

LH2 Lightweight 

StorHy 

cylindrical shape 

Auxiliary System 

Tank 

Fuel 

20 

25 kg 

LH2 Lightweight 

2010 

complex shape 

Source: SP Cryo

Pre-processing 

Component 

production 

Valves, Sensor 

Prepreg 

(e.g. knitting) 

Piping 

Insulation 

Alu liner 

StorHy contribution (excerpt SP Cryo) 



Manufacturing process CFRP tank 

CFRP inner tank manufacturing 

Tension 

sheet 

Dome & 

pipes 

Inner tank - coating of liner 

CFRP outer jacket manufacturing 

Impregnation 

Curing 


Post-processing 

Assembly 

Welding 

Evacuation of 

insulation gap 

Testing


� Intensive international R&D efforts focus on different types of materials 

and storage systems 

But: 

� None of these materials fulfills automotive targets (storage density, 

operation temperature etc.) yet! 



Solid Storage 

• Metal and complex 

hydrides 

• Chemical hydrides 

• Nanoporous 

structures 

Source: DoE 2007

Storage Material 

Magnesium Alanate 

• Mg(AlH4 ) 2 : Solvent-free and fast synthesis 

• Deuterised Mg(AlD4 ) 2 for neutron diffraction 

• Structure of Mg(AlH 4 ) 2 : Neutron and 

synchrotron X-ray diffraction 

• Details of thermal and isothermal 

decomposition of Mg(AlH4 ) 2 

Sodium Alanate 

• Purification of NaAlH4 and synthesis of 

NaAlD4 Catalyst 

• Improved synthesis of catalyst: Ti13 *6THF 



StorHy: Characterisation of Alanates 

First step: Magnesium and Sodium Alanates 

Automotive Challenges 

Scale-up strategies 

promising, but 

reversibility not sufficient! 

Source: IFE 

Source: FZK 

Scale-up strategies 

promising, but material 

storage density of 3 wt. % 

not sufficient 

Source: IFE, FZK

Storage Material 

Screening experiments for synthesis and 

characterization for new mixed alanates: 

• Mg-Al-Li-H, Mg-Al-Ca-H, Ca-Al-Li-H, Ca-Al-Na-H 

• Mg-Al-Li-H, Mg-Al-Ca-H, Mg-Al-Na-H, Mg-Al-K-H 

• Mg-Al-Li-H, Mg-Al-Ca-H, Ca-Al-K-H 

Synthesis and stabilisation of aluminium hydride 

AlH3 (Alane) – basic research purpose 

vial 



StorHy: Screening for new Alanates 

Second step: Adaptation of work programme 

stainless 

steel 

impactor 

liquid nitrogen 

Spex 6750 freezer mill for cryomilling 

Source: IFE, FZK, GKSS 

INTENSITY (arb. units) 

8000 

6000 

4000 

2000 

800 

0 

α'-AlD 3 and α-AlD 3 

PND, Kjeller 

-800 

10 20 30 40 50 60 70 80 90 100 110 120 130 

2θ(º) 

Automotive Challenges 

No new reversible 

hydrogen storage 

compound found 

No break-through up to 

now 

High material storage 

density 10.1%, but not 

reversible! 

Simplified method to 

synthesize AlH 3 by milling at 

liquid nitrogen temperature, 

compared to wet chemistry 

Work in progress to change 

the stability of AlH 3

H 2 -concentration [wt.%] 

5 

4 

3 

2 

1 

2nd absorption 

Concept for upscaling of material production processes 

preparation 

from NaAlH4 simple preparation with Ti-nano 

from NaH/Al clusters, 

with TiCl , 125°C 100°C, 100 bar 

4 

100 bar (STORHY) 

(Fichtner et al.) 

preparation from 

NaAlH with TiCl , 125°C, 79-88 bar 

4 3 

(Sandrock et al.) 

0 

0 10 20 30 40 50 60 

Time [min.] 

Design and development of operational prototype solid storage tanks 

Laboratory tank for 0.5 kg of alanate 

Length: 40 cm / Diameter: 6 cm 

Capacity: 20 g H 2 



StorHy: Upscaling of Solid Storage Tank 

� Evaluation of low cost 

production routes for complex 

hydrides using catalysed NaAlH 4 

as model material 

� Up-scaling to kg amounts 

demonstrated at GKSS mechanical 

processing facility 

Source: GKSS/TUHH 

8 kg alanate Pilot tank 

(currently manufactured) 

Length: 120 cm, Diameter: 22 cm 

Capacity: 0.4 kg H 2,

Calculated performance of tanks based on lab-scale data (NaAlH 4 ) 

Hydrogen absorbed in g 

400 

350 

300 

250 

200 

150 

100 

50 

Concept for filling 

� Hydride tank is cooled by external heat 

consumer working at approx. 100°C 

� Coupling of hydrogen and heat transfer 

medium prior to filling 

Concept for driving 

� Fuel cell is cooled to 80°C by hydride 

tank and internal heat exchanger 

0 

Alpha version 

100°C 

130°C 

290 s 458 s 540 s 


273 

Oil 

625 

10 

1 

2 3 

9 

8 

7 6 

5 4 3 

2 

0 200 400 600 800 1000 

tins 

Ø 6 

Ø 10 

1236 

310 g 

4 

8 

5 

Simulation based on kinetic 

data obtained from optimized 

StorHy material produced in 

kg scale 


StorHy: Solid Filling 

External 

Heat 

Consumer 

Quick coupling 

Internal heat 

exchanger 

Fuel cell 

Vehicle 

Source: NCSRD/GKSS/TUHH 

Heat 

transfer 

medium 

Hydride 

Tank 


Less than 10 min. charging 

time expected even in costeffective 

design (pilot tank)

� Assessment of test procedures for C-H 2 vessels 


Bonfire 

� Interlaboratory tests at various European test facilities 

� Validation of hydrogen sensors 

3. Cross-cutting Issues: 

StorHy: Safety Assessment

-90° 

Development of test procedures for C-H 2 vessels: 

Impact test 

Estimation of 

statistical crash energies 

-60° 

-120° 

Polarplot Crashenergy [KJ] 

-30° 

-150° 

300 

250 

200 

150 

100 

50 

0 


0° 

180° 

10% 

50% 

90% 

99% 

Source: BAM, Cidaut 


StorHy: Safety Assessment of C-H 2 Storage 

30° 

150 ° 

60° 

120° 

90° 

Estimation of energy 

impacting on storage 

system in crash models 

Assessment of the 

residual burst strength 

Vessel impact tests

of Solid Storage Materials 

Alanate powder release experiments 


Ignition by water droplets 

Flame 240 ms 240 ms 

560 ms 


StorHy: Chemical Safety Experiments 

1. Disk bursts at p = 10 bar 

2. Material is released into various environments 

30 ms 60 ms 

3. High speed images 

4. Assessment of sound levels 

Source: FZK 

opening of burst disc 

560 ms 

Pure hydrogen 

reproduction 

2005 

Water mist 

Spark ignition

Multi-criteria evaluation 

� Five different evaluation domains addressed 


Technical performance 

Costs Safety 

Environmental impact 


StorHy: Evaluation 

� Focus on technical and environmental parameters 

Social acceptance 

Source: CEA

Volumetric energy density [kg H 2 /100 l] 

Comparison of system storage densities 

5.00 

4.00 

3.00 

2.00 

1.00 

0.00 

Solid Storage 

System Reference 

Solid Storage StorHy 

System NaAlH 4 

(Not yet optimised) 

0.00 2.00 4.00 6.00 8.00 10.00 12.00 14.00 16.00 18.00 20.00 

Gravimetric energy density [wt.%] 


? 

C-H 2 StorHy 700 bar 

Swap Rack 

C-H 2 Referenc 350 bar 

Swap Rack 

StorHy target 

6 wt.% 

StorHy Target 

4.5 kg H 2 /100 l 

C-H 2 StorHy System Type IV 700 

bar (extrap.) 

C-H 2 Reference System 

Typ III H 2 350 bar 

4. Future Perspectives 

StorHy: Evaluation 

L-H 2 StorHy System 

Lightweight Free-form 

(extrap.) 

L-H 2 StorHy System 

Lightweight Cylindrical 

L-H 2 Reference System 

Stainless Steel

Medium-class Car: Fuel cell vehicle with C-H 2 storage 

Today: 

� Driving range lower 

than 400 km 

e.g. F-Cell 2002 

Source: DC 

Power el.: 72 kW 

Hydrogen mass: 1.9 kg 

C-H2 storage: 350 bar 

Max. speed: 150 km/h 

Range: 150 km 



Hydrogen Storage in different 

Vehicle Concepts 

Tomorrow: 

� Driving range of 400 km to 500 km by 

700 bar C-H2 storage systems 

e.g. F600 Hygenius Concept Car 

Source: DC 

Cooling 

System 

System 

module 

Power: 60/85 kW 

Hydrogen mass: 4 kg 

C-H2 storage: 700 bar 


Range: >400 km 

Source: DC 

Battery

Delivery van: FC City Car with range extender 

Today: Tomorrow: 

Source: PSA 

Power el. 28 kW 


FC power 5 kW 

Battery: 15 kWh 

Hydrogen C-H2 @350bar: 1,6 kg 

Range H2 : 70 km 

Range Battery: 80 km 





Source: PSA 

Power 28 kW 


FC power: 10 kW 

Battery: 15 kWh 

Hydrogen C-H2 @700bar: 2,7 kg 

Range H2 : 170 km 

Range Battery: 80 km

Today: Tomorrow: 

Bi-Fuel (L-H 2 + Gasoline) 


Power: 191 kW (260 bhp) 

Hydrogen mass: > 8 kg 

L-H2 storage: Stainless steel 

Cylindrical 

Range H2 : > 200 km 

+ Range Gasoline: > 500 km 


Source: BMW 




Hydrogen ICE with L-H 2 Storage 

Monofuel (L-H 2) 

- Highly efficient hydrogen ICE 

- Lightweight cryogenic storage 

Power: > 100 kW (136 bhp) 

Hydrogen mass: > 7 kg 

L-H2 storage: Lightweight 

Free-form shape 

Range H2 : > 500 km 

+

C-H 2 storage 

� Storage densities of ~4.5 wt.% and ~2.4 kg H 2/100 l are achievable 

on system level 

� StorHy results regarding C-H 2 vessels close up to worldwide R&D 

� Further optimisation requires fundamental understanding of 

ageing and failure behaviour of composite and liner materials, 

modelling and simulation concepts 

� StorHy results on filling components and production concepts 

show promising advanced solutions 

� Further cost reduction requires new industrialisation concepts for 

mass production and new CF fibres 

� Higher storage densities and further cost reduction require change 

of Regulations, Codes & Standards as well as new vehicle 

platforms (e.g. compatible with single cylinder storage concepts) 

� New advanced safety approach necessary in the future, e.g. based 

on Probabilistic Safety Assessment 



StorHy: Preliminary Conclusions

L-H 2 storage 

� Storage densities up to 14 wt.% and 4 kg H 2/100 l are achievable on 

system level for metal design, even up to 18 wt.% using advanced 

composite materials 

� StorHy results demonstrate a free form tank design with improved 

conformability to better enable vehicle integration 

� StorHy results show promising advanced solutions beyond 

worldwide R&D, but still further R&D efforts are required for 

industrialisation and system validation 

� Substantial cost reduction is indispensable 

� Lightweight L-H 2 storage systems show considerable potential in 

combination with new H 2 ICE 

� Further L-H 2 specific challenges, such as boil-off and permeation, 

have to be addressed 




Solid Storage (1) 

� Up to now, storage densities of ~2 wt.% are achieveable on system 

level with complex hydrides on alanate basis 

� At present, no solid storage material fulfils the major targets for 

automotive applications 

� StorHy tank development demonstrates feasibility of a fast heat 

removal using lightweight complex hydrides 

� StorHy safety study shows minimised explosion in case of 

hydrogen release 

� StorHy up-scaling results show high potential for mass production 

of complex light weight hydrides at low costs 




Solid Storage (2) 

� Further research for novel storage materials with improved storage 

densities, kinetics and thermodynamic behaviour as well as for 

advanced system components, e.g. heat exchanger, is still required 

� Automotive solutions are not realistic in the medium term 

� Stationary or marine applications have more potentials for a market 

entry in the near future 




General conclusions 

Beyond StorHy, further R&D activities are proposed for: 

� In-depth system/vehicle validation in demonstration projects 

� Industrialisation and cost reduction concepts 

� Safety assessment and new advanced safety approaches 

� Optimisation of Regulations, Codes & Standards (e.g design 

requirements for pressure vessels) 

� New storage concepts, such as pressure tanks with new high 

performance tensile fibres, hybrid tanks (pressure / cryogenic / 

solid storage), etc. 

� User-oriented fundamental research on solid storage materials, 

their safety and technical development of solid storage tanks 





More information? 

Join the 


StorHy Dissemination 

StorHy Dissemination Event: 

“Hydrogen Storage Perspectives of the Future” 

Date: June 2008 

Further information shortly on www.storhy.net! 

Or contact: volker.strubel@magnasteyr.com


Backup only!



Back up 

L-H 2 Storage System 

Outer jacket 

- Outer vessel 

- Thermal insulation 

- Refueling interface 

- Outer support 

Inner tank 

- Inner vessel 

- Level measurement 

-Pipework 

- Cryogenic shut-off valves 

- Inner tank support 

Auxiliary System Box 

- Shut-off valves 

- Control valve 

- Safety relief valves 

- Sensors (p, T, H 2 ) 

- Heat exchanger

Solenoid 

valve 

Venting 

pipe 

Fixing 

Electrical 

connections 


Valves, 

Fittings 

Pressure 

regulator 


Sensors 

Low 

pressure 

connection 

Back up 

C-H 2 Storage System 

High 

pressure 

vessel 

High 

pressure 

connection 

Type 3 

Type 4 

Fully wrapped 

cylinder & 

metallic liner 

Fully wrapped 

cylinder & 

non-load carrying 

(plastic) liner



Back up 

C-H 2 Storage Reference System 

Source: SP Users

Source: Magna Steyr 


Back up 

L-H 2 Storage Reference System 

Source: SP Users

Source: DC 


Back up 

Solid Storage Reference System 

Source: SP Users

� Material & microstructure 

– Extruded multi-layer based PA 

� Liner material characterization 

– 8 multilayer polymers assessed: f (p,T) 

– Permeation: 2*10-18mol/(Pa.s.m) -> OK 

� 700 bar vessel design & calculation 

– Optimized end cap design 

– CF/PA 700 bar system 

– GF/PP 200 bar system 

� CF for this thermoplastic composite not 

available yet! 

� Vessel testing (GF/PP) 

– Burst pressure = 460 bar 


Back up 

StorHy: 700 bar C-H 2 Vessels 

700 bar modular system with extruded plastic liner 

and thermoplastic composite 

Source: COMAT 

Technical data (CF/PA design): 

• Mass of vessel: 10.9 kg 



• Design pressure: 700 bar 

• H 2 mass stored: 0.4 kg

Type Measure Effort Contribution 

IV 

IV 

IV 

III 

III/IV 

III/IV 

III/IV 

III/IV 

III/IV 

Improve burst behavior 

(design, process) 


Low 100% burst 

Temperature cycling + burst Low Reliability of Type IV 

Evaluate tightness after thermal & 

mechanical ageing (=> depending on 

permeation results) 

Low Improved permeation 

reliability of Type IV 

Improve cycling behaviour Medium Cycling feasibility 

Low / high temperature exposure risk Medium Safety 

Long term behavior (creep…) Medium Safety 

Improve design requirements (safety 

factors) 

Back up 

StorHy: Recommendations for C-H 2 

High Weight, costs 

Innovative manufacturing concepts High Weight, costs 

New innovative fibers High Weight, costs 

Reliable and low cost components Medium Weight, costs, reliability

Source: BAM 

AE 

criterion 

10 


1 

2 

3 

4 

5 

6 

7 

8 

9 

Back up 

StorHy: C-H 2 Vessel Production - 

Quality Survey during Autofrettage 

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Normalized internal pressure 

Defect 

type I 

1 

0,8 

0,6 

0,4 

0,2 

(cylinder 1) 

test pressure 

autofrettage pressure (yileding of metal liner) 

nominal working pressure (15°C) 

residual strain of wrapping after autofrettage 

burst pressure 

0 

0 0,2 0,4 0,6 0,8 1 

Defect 

type I 

(cylinder 2) 

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Defect 

type II 

(cylinder 3) 

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Normalized strain 

Acoustic Emission (AE) 

Example: 

Typ III (CNG) cylinder = metal liner 

with full CF/Epoxy wrapping 

Defect 

type II 

(cylinder 4) 

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“Defect” 

type III 

(cylinder 5) 

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fibre break 

Normalised values 

1,0 

0,8 

0,6 

0,4 

0,2 

strain intensity 

0,0 

0,0 0,2 0,4 0,6 0,8 1,0 

Normalised autofrettage pressure 

AE accumulation 

AE Quality Survey 

Concepts: 

� Successful in 

detecting every 

manufacturing 

defect by at least 2 

of 10 developed AEcriteria! 

see: �

Development of test procedures for C-H2 vessels: 

Bonfire test 

Concept of modular testing 

Test of 

Pressure Relief 

Devices (PRD) 


Back up 


Validation of 

combination 

Pressure or burst pressure p in [MPa] 

pBurst 

p0 

tIgnition 

pBurst 

m > m0 

Burst pressure line as a function of the filling 

m0 

insufficient PRD 

well adjusted PRD 

m < m0 

m

AL 

Interlaboratory tests to evaluate 

C-H 2 testing facilities 

BAM 

Faber 


Back up 


WUT 

Tool kit 

Measuring 

Device 

Sensors 

� Tests performed at BAM, 

WUT, Faber and AL 

� Tests show relevance of 

influence of testing facilities 

on life-time of C-H 2 vessels 

Source: BAM 

Adapter 

Test cylinder 

Paris Paris 

Wroclaw Wroclaw 

Udine Udine

Tests of optical fibre sensors for 

detecting defects of C-H 2 vessels 

� Sensor technologies 

– Fibre Bragg gratings 

– Microbending optical fibres 

� Cycling tests 

– Type III: detectable increase in local deformation 

– Type IV: correlation of optical signals and CF fibre 

fatigue level to be demonstrated 

� Burst test (for type IV) 

– Linear deformation of vessel 

– Detection depends on sensor localization 


Back up 

StorHy: On-board Monitoring System 

Source: WUT

Training Course ‘StorHy TRAIN-IN 2006’ 

� One week full time training course 

on hydrogen storage technologies 

� Date: September 25 th -29 th , 2006 

� Location: University of Applied 

Sciences, Ingolstadt, Germany 

� Over 80 participants from 20 countries 

(students, PhD students, scientists, 

researchers and company representatives) 

� 25 theoretical and practical lectures, 

hardware exhibitions and excursions 

� Very good feedback by participants 

� All lecture handouts and results online 

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StorHy Training Course

Cost reduction of C-H 2 storage systems 


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StorHy: Cost Estimation 

Source: DC

Magnesium Alanate: 

Fundamental work on synthesis, structural and thermal properties 

allowed a complete characterization of this promising complex 

hydride. However, the unfavourable thermodynamic properties of 

this material made the Mg-Alanate not suitable for hydrogen 

storage. 

Sodium Alanate: 

Fundamental work carried out with this material in order to 

improve the kinetics allowed gaining insight into the reaction 

upon cycling under hydrogen. Indeed, XAS studies explained why 

the capacity decreases after some dehydrogenation / 

hydrogenation cycles and why the kinetics slow down at the same 

time. This knowledge in turn allowed a cost-effective production 

method of Al-based hydrogen storage material. 


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StorHy: Work on Alanates

Complex mixed Alanates: 

The following systems {[MgH 2 + Al + LiH] and [MgH 2 + LiAlH 4 ]} are 

extremely lightweight compounds, with a potential to achieve high 

gravimetric storage densities for hydrogen. (MgH 2 + LiAlH 4 ) appear 

as the most promising systems in terms of the formation of a new 

phase and the subsequent decomposition kinetics. However, 

further work is necessary to identify and isolate this new phase in 

order to conclude on the suitability of the material for hydrogen 

storage. 


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StorHy: Work on mixed Alanates

Presentation for RTD trainees - StorHy Hydrogen Storage

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