Cryogenically Flexible, Low Permeability Thoraeus Rubber H2 Dispenser Hose

One of the Department of Energy’s, Efficiency and Renewable Energy Fuel Cell Technology and Hydrogen Delivery, goals is to realize hydrogen as a safe, reliable, and cost competitive replacement for gasoline. A single hydrogen dispenser hose exists on the market, though it does not meet the service requirement of 25,550 fills/year for a combined working pressure of 875-bar and temperature range of -50C to +90C. The current hose price also does not allow for a cost of $2-4 gallon of gas equivalent. A new class D hydrogen dispensing hose, for use on station side applications, is being systematically and chemically engineered to survive 51,240 fills (70 fills/day, 2 years). This metal-free state-of-the-art hose is based on a unique fiber reinforced, high performance, cryogenically flexible polymer to resist hydrogen embrittlement, survive the Joule-Thompson effect thermal cycles, perform consistently at pressures greater than 875-bar (H70 service, 700- bar and safety overpressure), and endure mechanical wear and fatigue at the pump. During Phase I and II, a superior class of non-electrically conductive, low glass transition temperature polymer hose cores were developed that exhibit ultra-low hydrogen presence after severe 180 bending in a -50C chamber, and offer an innovative path to dissipate static electricity. A novel creamer coupling agent was developed to minimize the coefficient of thermal expansion between the fitting and hose, and resulted in significantly enhanced hose burst strengths. Fiber reinforced H2 hoses were modeled and produced using an automated filament winding manufacturing process (16, 3 meter hoses possible per day for reduced cost) with burst strengths > 31,000 psi, with failure due to fitting slippage. During the Phase IIB program, the down-selected H2 hose shall be commercialized with a new fitting to increase the current Technology Readiness Level of 7 to 9. Fittings and hose assembly partners have been formalized to proceed with the certification and commercialization plan. The new hose and fitting system shall be presented to hydrogen dispensing stations and fittings/breakaway/fueling nozzle manufacturers with a detailed integration design plan and cost analysis. The fully integrated hydrogen dispensing hose system, rated for H70 service, shall be demonstrated as compliant with SAE TIR J2601 and NIST Handbook 44, as a durable and competitive alternative to gasoline. This H2 hose shall serve as a new standard for metal-free, hydrogen embrittlement mitigating, high-pressure hoses with the additional benefits of enhanced flexibility, consumer maneuverability, fire resistance, and low temperature durability.