Performance assessment of 700-bar compressed hydrogen storage for light duty fuel cell vehicles

Type 4 700-bar compressed hydrogen storage tanks were modeled using ABAQUS. The finite element model was first calibrated against data for 35-L subscale test tanks to obtain the composite translation efficiency, and then applied to full sized tanks. Two variations of the baseline T700/epoxy composite were considered in which the epoxy was replaced with a low cost vinyl ester resin and low cost resin with an alternate sizing. The results showed that the reduction in composite weight was attributed primarily to the lower density of the resin and higher fiber volume fraction in the composite due to increased squeeze-out with the lower viscosity vinyl ester resin. The system gravimetric and volumetric capacities for the onboard storage system that holds 5.6 kg H2 are 4.2 wt% (1.40 kWh/kg) and 24.4 g-H2/L (0.81 kWh/L), respectively. The system capacities increase and carbon fiber requirement decreases if the in-tank amount of unrecoverable hydrogen is reduced by lowering the tank “empty” pressure. Models of an alternate tank design showed potential 4-7% saving in composite usage for tanks with a length-to-diameter (L/D) ratio of 2.8-3.0 but no saving for L/D of 1.7. A boss with smaller opening and longer flange does not appear to reduce the amount of helical windings.