Public Funding for Celanese Sales UK Limited

The objective of this project is to develop a novel, low cost, high pressure (350-700bar) gaseous hydrogen storage vessel for the automotive and industrial markets. This tank aims to offer significantly improved fatigue performance than current solutions with the added benefit of being fully recyclable at the end of life. This step change in performance will be achieved by the development of monolithic thermoplastic composite pressure tanks. The project will research and develop new formulations of low cost engineering thermoplastic polymers and co-polymers that have excellent hydrogen barrier properties, are low density (resulting in a lighter weight structure) and are inherently recyclable so the product can be broken down and re-used at the end of its service. Working prototypes will be built and tested to: a) determine the enhanced durability capabilities of the monolithic vessel; b) test the prototype to current hydrogen storage standards; c) conduct a comprehensive life cycle and techno-economic analysis.

One of the key barriers to the more widespread adoption of high performance carbon fibre-reinforced polymer composites in the automotive sector is the difficulty in achieving the required short cycle time, high volume production to satisfy the requirements of mainstream applications. With thermosetting-based composite systems this is particularly challenging because of their reliance on a definite cure schedule. Thermoplastic-based systems on the other hand, which can be reversibly heated, formed and cooled, offer more flexibility in this respect. Therefore, the objective of the proposed project is to develop a short cycle time, high volume manufacturing process for carbon fibre-reinforced thermoplastic components. The vision is to develop production technologies for the rapid “stamp-forming” of CFRP parts in a fashion that is somewhat analogous to the stamping of sheet metals. In addition to providing the automotive sector with a viable processing route for high performance composite components, the technology should also be transferable to medium volume aerospace parts.

Awaiting Public Summary