High-Pressure, Low Temperature Composite Nozzles for Long-Term H2 Dispensing, Topic 10b

The Department of Energy’s Office of Energy Efficiency and Renewable Energy has identified a need for high-performance materials and innovative manufacturing solutions to produce rugged hydrogen dispensing nozzles. Specifically, high-pressure and low temperature durable materials and nozzle designs that minimize ice-over, leaks and maintenance are needed. The goals for this program are to: develop materials suitable for hydrogen nozzles and produce prototype dispensing nozzles for field testing. The objective of this program is to develop and demonstrate innovative materials and methods to produce leak-free hydrogen dispensing nozzles. The approach involves the compounding and extrusion of new montmorillonite stranded and pelletized composites for 3-D printing of nozzle structures and modifying current nozzles with anti-icing nanocomposites. In Phase I and Phase II thus far, new montmorillonite intercalated composites were compouned with current low hydrogen permeable polymers and pelletized through an extruder for use in 3D printing techniques. Representative materials and coatings were subjected to conditions that mimic repeated filling of light duty vehicles at hydrogen stations. Hydrogen exposure was conducted at a national laboratory to evaluate the effects on ice adhesion, abrasion resistance, and mechanical ruggedness to achieve Technology Readiness Level 5. New commercial nozzles were modified with NanoSonic’s zero-freeze coating and tested in the field at a hydrogen station for a six month period with no reports of issues or failures. This test was conducted after a nozzle manufacturer noted immediate removal and zero freezing of the new nozzle from receptacles. Additional research is planned for the Phase IIA program to develop the entire nozzle and housing which will include integrated sensors through an advanced 3D printing approach. A plan to reach Technology Readiness Level 7 shall be continued through prototyping and field testing at hydrogen stations with our partners. Digital image correlation, X-ray analysis and pressurized leak testing shall be carried out at a national laboratory to achieve Technology Readiness Level 5. A down-selected set of polymers shall be produced via reactive extrusion for 3D nozzle prototyping. New composite nozzles and modified commercial nozzles shall be tested at hydrogen dispensing stations and per the current SAE J2600 specification. Lower cost and more reliable hydrogen dispensing nozzles shall significantly reduce unscheduled maintenance and reduce the overall capital costs associated with hydrogen fueling. These locally produced nozzles shall benefit our nation by enhancing the lifetime, safety and reliability of hydrogen nozzles and thereby ensure domestic leadership in the hydrogen infrastructure.