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

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 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 pelletized composites for injection molding or 3-D printing of nozzle structures. In Phase I, new montmorillonite intercalated composites shall be compounded with current low hydrogen permeable polymers and pelletized through an extruder for use in traditional and new manufacturing techniques. Representative nozzles shall be formed via injection molding and 3-D printing for test conditions that mimic repeated filling of light duty vehicles at hydrogen stations. Digital image correlation, X-ray analysis and pressurized leak testing shall be carried out at Pacific Northwest National Laboratory to achieve Technology Readiness Level 5. A plan to reach Technology Readiness Level 7 shall be established through field testing at hydrogen stations with our partners.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.