Design, analysis and optimization of H2 tank
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Date
2025-03-04
Authors
Μπόγδου, Αναστασία Δέσποινα
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Abstract
This thesis presents a comprehensive study on the design, analysis, and optimization of composite hydrogen pressure vessels (CPVs) for advanced hydrogen storage applications. With the rising demand for sustainable energy and the increasing role of hydrogen as a clean fuel, this research addresses the critical challenges in developing safe, efficient, and lightweight storage solutions, particularly for automotive and fuel cell systems. The work begins with a thorough introduction to hydrogen—its properties, advantages as an alternative fuel, and its application in internal combustion engines and fuel cell technologies. A detailed review of various hydrogen storage methods is provided, ranging from mechanical storage, solid-state storage, liquid hydrogen, and cryo-compressed hydrogen, to chemical storage. This broad overview establishes the context for selecting composite materials as a superior alternative for pressure vessel construction.
A significant portion of the study is dedicated to composite materials, highlighting the characteristics of both fiber and matrix constituents. Emphasis is placed on the manufacturing techniques critical to achieving high-performance CPVs, such as the filament winding method, prepreg tape application, and advanced composite lay-up processes. The selection of these techniques is justified by their ability to optimize the strength-to-weight ratio and enhance the overall structural integrity of the vessels. Focusing on Type V CPVs—fully composite pressure vessels—the thesis develops a robust analytical framework to evaluate their mechanical behavior under high-pressure conditions. The study employs classical laminate theory, netting analysis, and grid theory to predict stress and strain distributions within the vessel walls. Additionally, advanced failure criteria, including the Tsai-Wu, Tsai-Hill, Von Mises, and Hashin models, are utilized to assess potential failure modes and ensure the vessel's reliability under operational loads.
To validate the analytical models, finite element analysis (FEA) is conducted. The FEA process involves creating detailed geometric models, defining appropriate mesh configurations, and applying realistic boundary conditions and load cases. The simulation results, which capture the complex interactions between material properties and structural responses, are compared with theoretical calculations of burst pressure to verify the accuracy of the design. Optimization strategies are then applied to refine the CPV design, focusing on adjusting filament winding patterns and composite lay-up configurations to achieve an optimal balance between material efficiency and mechanical performance. The resulting design not only meets stringent safety and regulatory standards but also demonstrates significant improvements in performance and durability compared to conventional metallic vessels.
In conclusion, the research provides compelling evidence that advanced composite materials, when coupled with optimized design and analysis techniques, can effectively address the challenges of high-pressure hydrogen storage. The insights gained from this study contribute to the development of next-generation hydrogen storage systems, paving the way for their broader application in the automotive and energy sectors.
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Keywords
Compressed hydrogen storage, Hashin damage criterion, Progressive damage, Composite pressure vessels