Nano-Layered Electrospun In-Line Filters for Heavy Duty Hydrogen Fueling Stations, Topic 15c

The Department of Energy’s Hydrogen and Fuel Cell Technologies Office and members of the medium and heavy-duty hydrogen transportation industry have identified a need for high pressure in-line particulate filtration systems. The goal for this program is to demonstrate filters that can remove particulate contaminants from hydrogen fuel dispensed at fast flow rates of 10 kg/min while remaining durable at 1,000 bar at -40 °C. The objective of this program is to develop and demonstrate both new materials and a new fabrication method for the production of high performance, high-pressure, larger diameter in-line hydrogen fuel filters. The proposed innovation for this program involves the production of high-performance polymer nanocomposites via nano-layered extrusion of engineering polymers followed by electrospinning into a novel particulate filter will allow for fast flow rates and can remove more than 99% of particulates larger than 3 micrometers, limiting particulates to less than 1 mg/kg hydrogen. In Phase I, new nanolayered dual extruded polymer composites shall be immediately electrospun for form filter materials. Novel filters based on high pressure engineering polymers shall be produced that won’t evolve gases(to interfere with filtration or corrupt the fuel. The chemistry of these filters shall be synthetically engineered to attract and remove impurities. The electrospinning process shall create a novel network with physical filtration attributes to remove small 3 micrometer particulates to reach a Technology Readiness Level 4. The new filters shall be tested alongside commercial filters for a benchmark study to reach TRL 5. A plan to reach Technology Readiness Level 7 in Phase II has be established to validate that filter meets SAE J2719 particulate requirements, does not generate a pressure drop or reduce fast flow rates through resistance, and is easily replaceable at the service stations through field testing. New high-pressure, non-offgassing, in-line particulate filters shall benefit hydrogen fueling stations and specifically medium- and heavy-duty hydrogen fuel cell vehicles as current filters do not support fast fill needs and may poison hydrogen fuel. Importantly, new cost competitive filters will enable enhanced impurity adsorption and innovative electrospinning will result in a tortuous micron sized physical network to trap particulates.