New-generation hydrogen tanks for heavy-duty mobility

The New-generation hydrogen tanks for heavy-duty mobility project focuses on developing an advanced type 4+ hydrogen tank. Westport Fuel Systems (WFS), ENVALIOR (formerly DSM), and Alformet are working together to develop this technology and build prototypes. These will be tested against technical requirements, including the R134 standard. The tanks are intended for use in trucks but are also suitable for off-road and maritime applications and other mobile systems.

Key benefits of these tanks include:

• Reduced weight

• Improved thermal performance and increased storage capacity

• Use of recyclable materials (thermoplastic material reinforced with carbon fibre)

Together, these improvements make hydrogen an even more attractive sustainable alternative.

New-generation hydrogen tanks for heavy-duty mobility: objectives and actions

Westport Fuel Systems (WFS), ENVALIOR (formerly DSM), and Alformet are jointly developing new hydrogen tank technology. At least twenty prototypes are needed to conduct all burst and pressure tests up to 1,000 bar (in line with R134 standards), as the prototypes cannot be reused after testing. To thoroughly evaluate performance during transport, the partners will also build a hydrogen truck demonstrator equipped with eight prototype tanks. The consortium partners will carry out the following activities:

• ENVALIOR is developing carbon tape with a tensile strength exceeding 2.2 GPa. The tape consists of carbon fibre and a polyamide matrix, and is intended for the tank liner.

• WFS is designing hydrogen tanks that meet R134 requirements. The process starts with a smaller tank (115 litres) to test high-pressure performance, followed by a larger tank (500–600 litres) suitable for transport applications. WFS is also designing and developing the tank safety valves, rated for 700 bar, in line with R134 legislation.

• Alformet is developing the tape-winding equipment – based on laser technology – for the new tank design using the new thermoplastic tape.

• ENVALIOR, Alformet and WFS will jointly build the tank prototypes.

• The three partners will test the design concepts using the prototypes and assess compliance with R134 standards.

• They will also conduct a pilot using a hydrogen truck demonstrator fitted with eight prototype tanks to demonstrate real-world application of the newly developed tank technology.

Project consortium

The project is a collaboration between ENVALIOR (formerly DSM), Alformet and Westport Fuel Systems (WFS).