Search Results (57)

During fast-fill, large type IV polymer composite hydrogen storage tanks experience significant temperature gradients associated with both the compression of the gas and a Joule–Thomson effect that can compromise vessel integrity, significantly affecting overall safety. In order to remedy this concern, the current work proposes a novel active mixing approach in which the tank rotates, which leads to enhanced internal convective heat transfer and consequently minimizes temperature gradients. Transient CF simulations were performed using the Redlich–Kwong real-gas equation of state, capturing the high-pressure thermodynamic behavior of hydrogen precisely. The study, based on the 1000 s fast-refueling of a tank of 20.56 m³ internal volume, was carried out to assess the tangential speeds of rotation at 10, 30, and 50 rad/s, respectively. Results also show that thermal performance has a strongly nonlinear dependence on rotational speed. At 10 rad/s, a reasonably even temperature profile develops with a much lower energy cost. The most significant suppression of peak temperatures, and therefore the most efficient cooling, is seen at 30 rad/s. Nevertheless, when the rotation speed further elevates to 50 rad/s, abundant viscous dissipation heating results in an unwanted secondary temperature increase while partially counteracting the benefits brought about by improved mixing. On the whole, the results indicate that an ideal operating window more closely correlated with 30 rads/s is seen to provide the most beneficial compromise between temperature uniformity, maximum temperature limitation, and energy consumption for rapid refueling of large composite hydrogen storage systems. Full article

This paper addresses the current development status of a innovative direct high-pressure electrolyser (DHPEL, operating up to 700 bar) and its integration into a microgrid system in which solar energy constitutes the primary energy source and a hybrid energy storage system, comprising a battery and hydrogen, is employed. The DHPEL under development enables the direct production and storage of hydrogen at high pressures, thereby obviating the need for intermediate mechanical compression. In combination with standardized pressure vessels (300–350 bar) or the increasingly widespread use of CFRP-based high-pressure storage tanks (up to 700 bar), the DHPEL concept represents a technically and economically attractive option for microgrids with hybrid energy storage. The hybrid storage concept is based on functional differentiation between the storage media: the battery is intended to act predominantly as a buffer or short-term storage unit, and the hydrogen is designated for long-term energy storage. In principle, this configuration facilitates an autonomous energy supply relying exclusively on renewable energy sources; this is achieved by enabling the surplus solar energy generated in summer to be converted into hydrogen and subsequently utilized in winter. A rule-based energy-management algorithm is presented, prioritizing hydrogen production from surplus energy during the summer period and aiming to minimize interaction with the public electricity grid. This is particularly relevant for high-latitude regions, such as Germany, where solar irradiation is significantly lower in winter than in summer. A quasi-optimal sizing of all components in the microgrid, along with a realistic techno-economic assessment of the overall system, is performed using an energy-management model implemented in Simulink and utilised with realistic boundary conditions. A case study utilizing realistic solar generation and empirically derived electrical load profiles demonstrates the technical and economic viability of seasonal energy shifting from summer to winter (resulting in an autarky degree exceeding 1) within an economically acceptable cost range. Full article

Composite hydrogen storage vessels exhibit pronounced anisotropy, multilayered winding architectures, and strong ultrasonic attenuation, which severely degrade the focusing accuracy and defect visibility of the conventional isotropic total focusing method (TFM). To address these challenges, this study proposes an enhanced TFM framework for defect inspection in composite hydrogen storage vessels by integrating anisotropic delay correction, Gray-code coded excitation, and coherence-weighted reconstruction. First, an anisotropic propagation delay model is established using forward ray tracing to compensate for beam deviation and focusing mismatch induced by the anisotropic winding structure. Then, Gray-code excitation and pulse compression are introduced to improve signal energy and echo detectability under high-attenuation conditions. Finally, coherence-weighted imaging is applied to suppress incoherent background noise and structural artifacts, thereby enhancing defect contrast and image readability. The proposed method is validated on hydrogen storage vessel specimens containing artificial defects, with CT results used as references. Experimental results show that, compared with conventional isotropic TFM, the proposed collaborative approach significantly improves defect imaging quality for defects of different sizes and depths. The signal-to-noise ratio is increased from 7.2, 12.8, 14.8, and 7.4 dB for isotropic TFM to 32.5, 29.9, 52.6, and 42.7 dB, respectively, for the combined anisotropic, coded-excitation, and coherence-weighted TFM. In addition, the defect depth estimation remains stable and agrees well with the CT references, yielding approximately 9.0–9.6 mm for shallow defects and 18.7–19.3 mm for deeper defects. These results demonstrate that the proposed method can effectively improve defect detectability, image contrast, and depth characterization for embedded delamination-like artificial defects in composite hydrogen storage vessels, providing a promising ultrasonic imaging strategy for thick-walled anisotropic composite pressure structures. Full article

The reliable joining of ultra-thick aluminum alloy plates remains a critical technical challenge in modern industrial manufacturing, often hindered by defects such as porosity and excessive distortion associated with conventional fusion welding. The novelty of this work lies in the characterization of the intermediate layer overlapping zone in 110 mm ultra-thick plates, which has rarely been reported. The motivation is to overcome the limitations of single-pass FSW for thick plates, such as insufficient material flow and high tool forces, by adopting a sequential double-sided strategy. Furthermore, this technique may help moderate the through-thickness heat input variation, although no direct thermal measurements were made. The weld nugget zone consists of uniformly fine, recrystallized α-Al grains. In contrast, the heat-affected zone displays distinctly laminar grain structures. The overlapping regions within the intermediate layer, which undergo two thermal cycles, exhibit refined grain sizes. A well-defined interface is evident between the advancing-side weld nugget zone and the thermo-mechanically affected zone. The overall tensile strength of the FSW joint is approximately 81% of the base material, and the tensile specimen fractured at the interface between the thermo-mechanically affected zone and the heat-affected zone. Along the thickness of the weld joint, a “W”-shaped microhardness distribution is observed at the surface and subsurface, whereas the intermediate layer exhibits a distinct “V”-shaped profile. The lowest microhardness value is located in the intermediate layer overlapping area due to the insufficient heat input and limited grain growth in this region. In summary, under the specific welding parameters tested (130 rpm, 15 mm/min, 110 mm thick), double-sided friction stir welding produces defect-free joints in AA 5052-H32, suggesting its potential for thick-plate applications, offering a practical and effective solution for manufacturing high-performance aluminum alloy structures. Potential industrial applications include pressure vessels for chemical storage, ship hull structures, and heavy-duty transportation components where ultra-thick aluminum plates are required. Full article

A 70 MPa Type IV hydrogen composite pressure vessel (CPV) was instrumented with embedded Fiber Bragg Grating (FBG) sensors to realize in situ strain monitoring during hydraulic fatigue cycles. FBG arrays were co-wound with carbon fibers during the filament winding process, forming an integrated multi-point sensing network within the composite layers. Hydraulic fatigue tests were conducted under pressure cycling between 2 MPa and 87.5 MPa, reaching 48,000 cycles. The embedded FBG sensors were able to stably record cyclic strain evolution with peak amplitudes of approximately 6000 με in the hoop layer and 3500 με in the helical layer under hydraulic cycling. The hoop layers exhibited gradually decreasing strain amplitudes from the inner to outer regions, while the helical layer maintained stable signal performance. Analysis of fiber survival times indicated that the FBGs embedded in helical layers remained functional throughout the entire test, confirming the long-term monitoring capability under high-pressure oil environments. This study demonstrates a practical embedded-sensing approach compatible with the filament-winding process, providing experimental support for fatigue-life evaluation and in-service safety monitoring of high-pressure hydrogen storage vessels. Full article

The widespread adoption of hydrogen fuel cell electric vehicles (FCEVs) is currently hindered by the significant cost and lack of geometric flexibility of conventional Type IV pressure vessels made from carbon fiber reinforced plastic (CFRP). These tanks are difficult to integrate into future vehicle platforms optimized for modular batteries. This study, therefore, presents a novel compressed hydrogen storage system (CHSS) based on a modular assembly of seamless steel cylinders. The objective of this approach is to create a design-flexible and cost-effective alternative that adapts to the limited installation space of modern electric vehicle architectures while offering a sustainability advantage through the high recyclability of steel. The system was specifically designed to meet the stringent requirements of the UNECE R134 regulation and subsequently subjected to rigorous experimental validation. The evaluation included all four test sequences required for component certification: Baseline Tests, Performance Durability Test, On-Road Performance Test and Fire Test. The successful validation demonstrates that the developed modular steel-based CHSS meets all relevant safety and performance requirements. It, therefore, represents a technically and economically promising technology that can make a decisive contribution to accelerating hydrogen mobility through its superior design flexibility and sustainability. Full article

Maritime transport is under increasing pressure to cut greenhouse gas and pollutant emissions to meet global decarbonization goals and tighter environmental standards. Ship electric propulsion systems offer a promising solution for short-range maritime operations, particularly for small vessels and coastal activities. Full-electric vessels can significantly reduce operational emissions; however, a key challenge is the extensive charging time for onboard energy storage, which can affect operational continuity and logistical efficiency. This study examines mission planning and energy management for a hybrid multi-source electric mail boat operating in the Aeolian archipelago. It evaluates the viability and performance of a daily inter-island route powered by a high-temperature methanol fuel cell, batteries, and photovoltaic panels. A routing and simulation framework was developed to model the boat’s itinerary among seven islands, accounting for realistic navigation speeds, scheduled stops, solar energy availability, and battery state-of-charge constraints. The study analyzes distance, travel time, energy consumption, solar power generation, and fuel–electric usage with high temporal resolution, enabling detailed analysis of power flows during sailing and docking. Several operational strategies were assessed, including periods of increased speed supported by battery assistance and fuel–electric cell output, combined with coordinated energy management to keep battery levels above a lower acceptable threshold while completing the route in a single day. The methodology provides a practical tool for planning low-emission island networks and supports the integration of innovative energy systems into small electric workboats operating in specific maritime regions. Full article

This study investigates the Container Consolidation Problem (CCP), a critical operational challenge in container terminals where containers with specific attributes must be relocated during yard crane idle periods. The primary objective is to maximize yard space availability for incoming vessels by strategically grouping containers, thereby alleviating storage pressure and enhancing throughput. A mixed-integer programming model is formulated to minimize the total handling time, incorporating complex constraints related to crane availability, relocation sequencing, and slot assignment. Due to the combinatorial complexity inherent in large-scale yard operations, a comprehensive optimization framework is proposed. This framework balances computational efficiency with solution quality, offering a robust approach to solve large-scale instances within practical time limits. Computational experiments demonstrate that the proposed methodology consistently yields high-quality solutions, effectively resolving the trade-off between solution speed and optimality. The research provides not only a novel methodological perspective for solving this NP-hard problem but also offers significant practical value. By optimizing crane scheduling, the model directly contributes to reducing operational costs, improving the turnover rate of yard space, and strengthening the overall efficiency of the maritime supply chain. Full article

The integration of Artificial Intelligence (AI) into the design, manufacturing, and lifecycle management of Composite Overwrapped Pressure Vessels (COPVs) is transforming the pathway toward autonomous and adaptive composite systems. This paper presents a comprehensive review and roadmap for AI-enabled COPVs development, bridging materials design, process optimisation, and predictive maintenance. The study synthesises over a decade of research on data-driven composite manufacturing, combining technology intelligence, PESTEL-SWOT environmental assessment, and cross-sectoral analysis of industrial and academic advances. A unified workflow is proposed to illustrate AI integration across the COPVs lifecycle, highlighting data feedback loops for continuous optimisation through digital twins and intelligent process control. Structural Health Monitoring (SHM) plays a central role in this ecosystem by providing real-time high-fidelity data on damage evolution and environmental interactions in COPVs. Through embedded sensing technologies such as fibre optic sensors and acoustic emission systems, SHM enhances digital twin fidelity, supports AI-based anomaly detection, and strengthens model validation in safety-critical hydrogen storage applications. Critical challenges are identified, including limited hydrogen-exposure datasets, lack of real-time adaptability, explainability in safety-critical design, and sustainability of AI-intensive workflows. These challenges highlight the need for tighter SHM-AI integration to enable reliable condition assessment and prognostics under multi-physics loading conditions. Based on these findings, the paper outlines actionable research directions to enable reliable, transparent, and sustainable AI adoption in composite manufacturing under the Industry 4.0 and hydrogen-economy paradigms. Full article

This paper aims to investigate the effects of the co-pyrolytic product produced from the co-pyrolysis of waste cooking oil (WCO) and polypropylene (PP) on pure bitumen by using some physical and rheological tests. To reach this goal, the product was obtained by producing from the co-pyrolysis of WCO and PP at distinct conditions. Different pyrolytic products with different structural properties can be obtained from the co-pyrolysis of various materials at different pyrolysis conditions. It was not found any study in which bitumen was modified with the co-pyrolytic product produced from the co-pyrolysis of WCO and PP materials at specified blending ratios and conditions, as described in this paper. For this reason, this paper investigates the effects of this co-pyrolytic product as an additive on bitumen in order to improve some of the rheological and physical properties of bitumen and to overcome some problems for the first time. The mixture ratio was determined as 1:2 (WCO:PP). PG 64-22 neat bitumen was modified with this co-pyrolytic product, and some features of the bituminous binders were detected by using differential scanning calorimetry (DSC), Fourier transform infrared spectroscopy (FTIR), penetration, softening point, dynamic shear rheometer (DSR), rotational viscometer (RV), a rolling thin film oven test (RTFOT), a pressurized aging vessel (PAV), a bending beam rheometer (BBR), storage stability, and scanning electron microscopy (SEM) tests. From the FTIR results of the modified binders, it was found that the intensity of the peak around 2357.69 cm⁻¹ increased with the addition of this pyrolytic product. This pyrolytic additive hardened the pure bitumen’s consistency, increased its viscosity, improved its resistance against rutting deformations, and enhanced its high-temperature performance. It can be said that PG 64-22 pure bitumen can easily be modified with this pyrolytic product at the conditions described in this study. Additionally, this co-pyrolytic product improved the high-temperature performance grade (PG) of pure bitumen from PG 64 to PG 76 when it was used at 5% of the weight of neat bitumen. The findings demonstrated that the modified bituminous binders containing 3% and 5% co-pyrolytic product had suitable storage stabilities. Full article

Hydrogen permeation parameters of PA12 were obtained through high-pressure hydrogen permeation experiments conducted under various temperature and pressure conditions. The temperature-dependent mechanism governing the hydrogen permeation behavior of PA12 was further examined using dynamic mechanical analysis (DMA). A multi-field coupled numerical model was established and validated against the experimental results. Based on the validated numerical approach, the hydrogen permeation behavior of a type IV hydrogen storage vessel with local reinforcement was investigated. The results show that both temperature and pressure have a significant influence on the hydrogen permeation performance of PA12. When the temperature is below the glass transition temperature ($\mathit{Tg}$) of PA12 (48.34 °C), the diffusion coefficient remains low, whereas temperatures above the $\mathit{Tg}$ led to a marked increase in the diffusion coefficient. In addition, the local reinforcement patch effectively prolongs the time required to reach steady-state permeation, reduces the hydrogen permeation flux before and after steady state, and enhances the overall resistance to hydrogen permeation of the type IV vessel. As the diffusion coefficient of the liner material increases, the hydrogen diffusion rate increases substantially, leading to greater hydrogen accumulation in the dome region and higher permeation levels both before and after steady state. These findings provide theoretical guidance and design references for optimizing the hydrogen-resistant performance of type IV hydrogen storage vessels. Full article

The growing demand for efficient hydrogen storage solutions highlights the need for reliable and safe composite overwrapped pressure vessels (COPVs). This study investigates the application of an inline monitoring system combining laser-based measurements and photogrammetric line photography to assess COPV quality during fabrication, including quantitative evaluation of liner concentricity and high-resolution line scanning of the composite surface to detect and measure fiber orientations. Fiber detection and angle measurement using the Hough Transform provide detailed assessment of local winding orientation, while global Fourier Transform analysis supports comparative evaluation across vessels or segments, allowing identification of dominant fiber directions and detection of micro-scale deviations. The integrated approach enables early detection of geometric inconsistencies and localized winding irregularities, providing robust performance-based criteria for accept-reject decisions, while filtering out minor noise and ensuring reliable quantitative evaluation. This framework enhances inline quality control, optimizes material usage, and supports the safe deployment of COPVs in hydrogen storage systems, contributing to efficient and reliable energy storage solutions. Full article

As the hydrogen economy rapidly expands, carbon-fiber-reinforced polymer composites (Towpreg) have become key materials for next-generation hydrogen pressure vessels, offering superior processability, reproducibility, and storage stability compared to conventional wet-winding composites. Since hydrogen storage vessels are evaluated at three representative service temperatures (−40, 25, and 85 °C), Towpreg materials must maintain consistent mechanical performance across this range to meet certification standards. This study establishes an integrated methodology combining Towpreg panel fabrication, temperature-controlled tensile and fatigue testing, and quantitative assessment of thermo-mechanical stability using DM epoxy resin as the matrix. To address artifacts such as tab slippage at high temperatures and inefficiency at low temperatures, a “Localized Thermal Control” approach was developed. The HY-Mini Heater System enables localized heating at 85 °C, while the HY-Cooler System applies a Joule–Thomson-based Stirling cooler for efficient localized cooling at −40 °C. Quantitative evaluation showed tensile strengths of 2973.3 MPa (RT), 2767.3 MPa (HT, ~7% decrease), and 2907.7 MPa (LT, ~2% decrease). Under R = 0.1 fatigue testing, the Basquin slope (m) was 11.97 (RT), 9.98 (HT), and 10.6 (LT), while the intercept (log b ≈ 3.7) remained nearly constant. These results confirm the excellent thermo-mechanical stability of the carbon-fiber-reinforced polymer composites (Towpreg) for hydrogen tank applications. Full article

Type IV composite overwrapped pressure vessels—characterized by a polymer liner fully wrapped in fiber-reinforced polymer—are emerging as lightweight, corrosion-proof alternatives to traditional metal cylinders in fire safety applications. This paper presents a comprehensive review of Type IV high-pressure vessels used in portable fire extinguishers and self-contained breathing apparatus (SCBA) systems. We outline recent material innovations for both the non-metallic liners and composite shells, including multilayer liner designs (e.g., high-barrier polymers and nanocomposites) and advanced fiber/resin systems. Key manufacturing developments such as automated filament winding, resin infusion, and in-line non-destructive testing are discussed. Technical performance in fire applications is critically examined: current standards and certification requirements (EU and international), typical design pressures (e.g., 300 bar in SCBA) and safety factors, common failure modes (liner collapse, fiber rupture, etc.), inspection protocols, and a comparison with Type IV hydrogen storage cylinders. Market trends are also reviewed, highlighting the major manufacturers and the growing adoption of composite extinguishers (e.g., 20-year service-life composite units) versus conventional steel. The review draws on 7–10 peer-reviewed studies to analyze the state of the art, finding that Type IV vessels offer significant weight reduction (>30%) and corrosion resistance at the cost of more complex design and certification. In firefighting use, these cylinders demonstrably improve firefighter mobility and reduce maintenance, while meeting rigorous safety standards. Remaining challenges include further improving liner permeability barriers to prevent gas leakage or collapse, understanding long-term composite aging under cyclic loads, and optimizing fire resistance. Overall, Type IV composite pressure vessels represent a major innovation in fire suppression technology, enabling safer and more efficient extinguishing equipment. Future research and standardization efforts are recommended to fully realize their benefits in fire protection. Full article

This research evaluates Battery Energy Storage Systems (BESS) and Compressed Air Vessels (CAV) as complementary solutions for enhancing micro-grid resilience, flexibility, and sustainability. BESS units ranging from 5 to 400 kWh were modeled using a Nonlinear Autoregressive Neural Network with Exogenous Inputs (NARX) neural network, achieving high SOC prediction accuracy with R² > 0.98 and MSE as low as 0.13 kWh². Larger batteries (400–800 kWh) effectively reduced grid purchases and redistributed surplus energy, improving system efficiency. CAVs were tested in pumped-storage mode, achieving 33.9–57.1% efficiency under 0.5–2 bar and high head conditions, offering long-duration, low-degradation storage. Waterhammer-induced CAV storage demonstrated reliable pressure capture when Reynolds number ≤ 75,000 and Volume Fraction Ratio, VFR > 11%, with a prototype reaching 6142 kW and 170 kWh at 50% air volume. CAVs proved modular, scalable, and environmentally robust, suitable for both energy and water management. Hybrid systems combining BESS and CAVs offer strategic advantages in balancing renewable intermittency. Machine learning and hydraulic modeling support intelligent control and adaptive dispatch. Together, these technologies enable future-ready micro-grids aligned with sustainability and grid stability goals. Full article