HyPStore: Advancing low-carbon hydrogen production and safe storage for mobility

HyPStore aims to revolutionise hydrogen storage and production with innovative, safe, and efficient solutions, advancing the mobility sector's shift towards low-carbon technologies.

HyPStore is an innovative and disruptive solution that revolutionises the production and storage of liquid hydrogen. Our project focuses on developing mechanically robust, impermeable tanks with enhanced safety features, including a Leak-Before-Break (LBB) fail-safe design. These advancements will enable a new generation of hydrogen storage solutions, contributing significantly to the mobility sector.

Addressing the need for efficient hydrogen storage and distribution

The global commitment to reducing climate change impacts and achieving net-zero carbon dioxide emissions by 2050 is driving a shift from fossil fuels toward renewable and reduced-emission fuels like hydrogen. One of the main challenges in the hydrogen industry is the efficient storage and distribution of hydrogen, whether as compressed gas or cryogenic liquid. Due to their lightweight, high mechanical properties, and corrosion resistance, composite tanks are in high demand, particularly in transportation sectors like aerospace.

HyPStore stands out in the field of hydrogen storage with several unique innovations. The project focuses on developing impermeable all-composite tanks designed for liquid hydrogen storage. These tanks will be manufactured using graphene nanoplatelets tailored for optimal performance. The in-house manufacturing process combines dry filament winding with graphene, ensuring high-quality and efficient production.

One of the key features of these tanks is the incorporation of self-healing systems that address matrix microcracks caused by cryogenic conditions. This self-healing capability ensures the longevity and reliability of the tanks under extreme conditions.

The introduction of Leak-Before-Break (LBB) features is a significant safety enhancement. These features prevent catastrophic bursts due to overpressurisation by allowing for progressive and controlled failure of the tank.

The tanks will also be coated with high fire retardance, durability against ageing and chemical erosion, toughness against external impacts, and low gas permeability. This combination of features ensures that the tanks are safe, durable, and efficient for long-term use.

Benefits and impact

The HyPStore project offers numerous benefits and has the potential to make a significant impact on the hydrogen industry and beyond.

Environmental benefits:

• Elimination of CO2 emissions in flights by using green hydrogen, produced carbon-free
• Hydrogen combustion could reduce the climate impact of flights by up to 75%, making it an essential step towards sustainable aviation

Weight reduction and efficiency:

• Significant weight reduction of 20%-25% compared to Type-IV tanks and up to 85%-90% compared to Type-I tanks
• Replacement of metal components with composite materials, resulting in a gravimetric efficiency of approximately 70%
• Alignment with the International Air Transport Association's Aircraft Net-Zero Roadmap

Enhanced safety features:

• Incorporation of LBB (Leak-Before-Break) features for progressive and controlled tank failure, preventing catastrophic bursts and enhancing overall safety

Economic advantages:

• HyPStore tanks contain 50% more hydrogen than Type-IV tanks, reducing the size and/or number of tanks needed.
• Potential to double the payload capacity and range of aircraft for the same size/number of tanks, offering significant economic advantages

Increased hydrogen storage capacity:

• Cryogenic liquid hydrogen offers the highest density, allowing LH2 tanks to contain 50% more hydrogen than Type-IV tanks
• Crucial for efficient hydrogen utilisation in various applications

Socio-economic impact:

• Reinforcement of the competitiveness of the UK's and Australia's hydrogen industries
• Contribution to the growth and development of these industries, creating new opportunities and driving innovation

The Brunel Composites Centre (BCC) plays a crucial role in the HyPStore project by focusing on integrating LBB safety design features into the tanks. This involves introducing prearranged design features in the composite structure to create cracks and leak paths for pressure relief in the event of overpressurisation. By doing so, BCC aims to increase the safety of the tanks and prevent catastrophic failures, ensuring the reliability and safety of hydrogen storage solutions.

Project partners

The HyPStore consortium is a collaborative effort involving several key partners:

• Graphene Innovations Manchester LTD (Lead)
• Marshall Slingsby Advanced Composites Limited
• Stratospheric Platforms Ltd
• First Graphene Limited (ASX: FGR) (UK)
• Queen Mary University of London
• Brunel Composites Centre, Brunel University of London
• Australia Sunlight Group
• University of Southern Queensland
• University of Melbourne

This diverse consortium brings expertise from various fields to advance hydrogen storage technology and contribute to a sustainable, low-carbon future.