<figure><img src="image_1.png" /></figure>

HAL
open science

# H2 CPV recent developments

Stéphane Villalonga

► To cite this version:

Stéphane Villalonga. H2 CPV recent developments. Horizon Hydrogène, Content and Business Paris, Nov 2023, Paris, France. hal-05470052

HAL Id: hal-05470052

https://hal.science/hal-05470052v1

Submitted on 21 Jan 2026

HAL is a multi-disciplinary open access
archive for the deposit and dissemination of sci-
entific research documents, whether they are pub-
lished or not. The documents may come from
teaching and research institutions in France or
abroad, or from public or private research centers.

L'archive ouverte pluridisciplinaire HAL, est
destinée au dépôt et à la diffusion de documents
scientifiques de niveau recherche, publiés ou non,
émanant des établissements d'enseignement et de
recherche français ou étrangers, des laboratoires
publics ou privés.

<figure><img src="image_2.png" /></figure>

Distributed under a Creative Commons CC BY 4.0 - Attribution - International License
<figure><img src="image_3.png" /></figure>

<figure><img src="image_4.png" /></figure>

Stéphane VILLALONGA

CEA, Le Ripault, France

Horizon Hydrogène 2023

Paris, le 28 novembre 2023

H2 CPV RECENT DEVELOPMENTS
# Acknowledgement

* Audience

* HH 2023 team

* Abbas & Albert from ENSAM

* ANR & Clean Hydrogen Joint Undertaking

* Academic & Industrial partners

* CEA H2 CPV Team
# Agenda

* CEA & H₂ CPV

* H₂ CPV manufacturing

* H₂ CPV certification

* H₂ CPV cost

* H₂ CPV recent developments

<figure><img src="image_5.png" /></figure>
# Commissariat à l'énergie atomique et aux énergies alternatives

<figure><img src="image_6.png" /></figure>

<figure><img src="image_7.png" /></figure>

<figure><img src="image_8.png" /></figure>

<figure><img src="image_9.png" /></figure>

<figure><img src="image_10.png" /></figure>

<figure><img src="image_11.png" /></figure>

<figure><img src="image_12.png" /></figure>

## The CEA is active in four main areas:

* low-carbon energies

* defense and security

* information technologies

* health technologies

10 research centres

19 925 technicians, engineers, researchers and staff

1 351 PhD & Post Doc

750 priority patents filed / year

200 start-ups since 1972 in the innovative technologies sector

<figure><img src="image_13.png" /></figure>

CEA is “The World's most innovative research institution”
(Reuters, 8th of March, 2016)

<figure><img src="image_14.png" /></figure>
# H₂ CPV R&D at CEA Le Ripault

CPV : Composite Pressure Vessel

<figure><img src="image_15.png" /><figcaption>Dedicated R&D H₂ CPV plateform at CEA</figcaption></figure>

<figure><img src="image_16.png" /></figure>

* **Materials**

* Polymer & Composite : characterisation, ageing

* Material studies: PEPR ANR Hyperstock

* New Fastcuring Epoxy Matrix: ANR Fastcure 2 project

* Rotomolding monitoring: ANR Ulhys project

<figure><img src="image_17.png" /></figure>

FASTCURE 2

ULHYS

* **Design & FE Calculation**

* **Industrial Processes and Manufacturing** (industrial transfer)

* **CPV Testing & SHM**

Standard, EC79,&R134 Regulation, additional severe condition tests

* **Standard & Regulation contribution**

(AFNOR, ISO-TC197, EC-SFEM, UNECE-GTR13)

## CPV prototyping and testing

<figure><img src="image_18.png" /></figure>
Pressure Vessel type

<figure><img src="image_19.png" /><figcaption>Type I</figcaption></figure>

<figure><img src="image_20.png" /></figure>

Metallic vessel

20 MPa

<figure><img src="image_21.png" /><figcaption>Type II</figcaption></figure>

<figure><img src="image_22.png" /></figure>

Circumferential
Composite
Metallic vessel

25-30 MPa

Metallic « liner »

<figure><img src="image_23.png" /><figcaption>Type III</figcaption></figure>

≈ 0,60 g /L/bar*

<figure><img src="image_24.png" /></figure>

Full Composite
Metallic liner

30-70 MPa

<figure><img src="image_25.png" /><figcaption>Type IV</figcaption></figure>

≈ 0,42 g /L/bar*

<figure><img src="image_26.png" /></figure>

Full Composite
Plastic liner

70 MPa

Plastic liner

<caption>Type V</caption>

≈ 0,35 g /L/bar*

<figure><img src="image_27.png" /></figure>

Full Composite
Linerless

x MPa?

Linerless

<figure><img src="image_28.png" /></figure>

<footnote>* Approximative vessel mass for 1 bar of burst pressure and 1 liter internal volume with vessel diameter around 300-500 mm</footnote>
# Type IV CPV for on-board H₂ storage

* Metallic boss (AL)

* Plastic liner (PE, PA)

* Composite shell (CF+epoxy)

<figure><img src="image_29.png" /></figure>

1 tow of 24k filaments

7µm filament diameter

Carbon fibre mass = 70% Composite mass

<figure><img src="image_30.png" /></figure>

<figure><img src="image_31.png" /></figure>

thermoplastic powder

<figure><img src="image_32.png" /></figure>

Epoxy resin

<figure><img src="image_33.png" /></figure>
# H₂ CPV Process and Manufacturing at CEA

<figure><img src="image_34.png" /><figcaption>## Rotomolding</figcaption></figure>

<figure><img src="image_35.png" /></figure>

<figure><img src="image_36.png" /></figure>

https://www.youtube.com/watch?v=zCE3VibUGJU

<figure><img src="image_37.png" /><figcaption>## Robotic Filament Winding</figcaption></figure>

<figure><img src="image_38.png" /></figure>

<figure><img src="image_39.png" /><figcaption>CEA H₂ 62L CPV</figcaption></figure>

<figure><img src="image_40.png" /><figcaption>Full thermoplastic CEA H₂ 37L CPV</figcaption></figure>

<figure><img src="image_41.png" /><figcaption>CEA H₂ 36L CPV</figcaption></figure>

<figure><img src="image_42.png" /></figure>
# Rotomolding & Filament Winding

<figure><img src="image_43.png" /></figure>

<figure><img src="image_44.png" /></figure>

<figure><img src="image_45.png" /></figure>
# CPV testing facilities at CEA Le Ripault

<figure><img src="image_46.png" /></figure>

<figure><img src="image_47.png" /></figure>

<figure><img src="image_48.png" /></figure>

<figure><img src="image_49.png" /></figure>

<figure><img src="image_50.png" /></figure>

<figure><img src="image_51.png" /></figure>

<figure><img src="image_52.png" /></figure>

<figure><img src="image_53.png" /></figure>

<figure><img src="image_54.png" /></figure>

<figure><img src="image_55.png" /></figure>

<figure><img src="image_56.png" /></figure>

<figure><img src="image_57.png" /></figure>

<figure><img src="image_58.png" /></figure>

(c) Hypactor Project [JTI GA 621194]
CEA Impact with pneumatic canon (5kJ)

<figure><img src="image_59.png" /></figure>
<figure><img src="image_60.png" /></figure>

# Tunnel R&D project

<figure><img src="image_61.png" /></figure>

<figure><img src="image_62.png" /></figure>

FUEL CELLS AND HYDROGEN
JOINT UNDERTAKING

<figure><img src="image_63.png" /></figure>

CEA Grenoble
CEA Saclay

<figure><img src="image_64.png" /></figure>

<figure><img src="image_65.png" /></figure>
<table><tr><td>Target</td><td colspan="2">HYperStock: Hyperbaric hydrogen storage: materials and methodologies repository</td></tr><tr><td>Coordination</td><td>Université de Franche-Comté (David Chapelle)</td><td>5-year duration</td></tr></table>

## Issues

* National strategic advantages

* Enhancing the security and confidence of hyperbaric solutions

* Providing solutions for the advent of H2 heavy-duty mobility

* Reducing the carbon footprint of reservoirs, including lifecycle analysis

* Increasing the social acceptability of hyperbaric solutions

<figure><img src="image_66.png" /></figure>

## Technical program- Objectives

<figure><img src="image_67.png" /></figure>

## Planned resources

<figure><img src="image_68.png" /></figure>

28 m.y

8 Ph-D, 66 months post-doctoral

8 laboratories + CEA + IFPEN

PEPR H2: Decarbonated Hydrogen Priority Research Program and Equipment
# Fastcure 2 R&D project

Goal 2020 - 2023: increase CPV manufacturing rate

SOA: thick carbon- epoxy curing at low temperature: 15 h

thick composite (3 cm) at low curing temperature (PE ou PA liner)

* towpreg formulation (2021) : curing time 6 h (1 patent)

* wet winding formulation (2022) : curing time 6h45 (1 patent)

Result : Curing time reduction : 50%

Project partners

<figure><img src="image_69.png" /></figure>

INSA

INSTITUT NATIONAL
DES SCIENCES
APPLIQUÉES
LYON

VITECH
COMPOSITES

<figure><img src="image_70.png" /></figure>

FASTCURE 2

anr

S2e2
SMART ELECTRICITY CLUSTER

<figure><img src="image_71.png" /><figcaption>CEA H₂ 62L 700 bar CPV</figcaption></figure>

<figure><img src="image_72.png" /></figure>
# ULHYS R&D project

ULHYS

<figure><img src="image_73.png" /></figure>

Simulation of rotomolded polymer viscosity for Hydrogen by ultraSonic testing method

ANR-21-CE05-0019-01

## Rotomolding process optimization used for hydrogen storage tank type IV manufacturing

** to understand and knowing the four steps of rotomolding process, the process used for producing polyethylene liners.

** Two complementary approaches:

* an ultrasonic testing method to monitor in situ and in real-time the polymer viscosity evolution during a rotomolding cycle,

* the simulation of the rotomolding during polymer processing.

<figure><img src="image_74.png" /><figcaption>CEA Mold with US sensors</figcaption></figure>

## Project partners

<figure><img src="image_75.png" /></figure>

INSTITUT NATIONAL
DES SCIENCES
APPLIQUÉES
CENTRE VAL DE LOIRE

université
de TOURS

<figure><img src="image_76.png" /></figure>

GREMAN

matériaux microélectronique
acoustique nanotechnologies

UMR 7347 - Université de Tours / CNRS

<figure><img src="image_77.png" /></figure>

<figure><img src="image_78.png" /></figure>

Procédés et Ingénierie en
Mécanique et Matériaux

cea

LE RIPAULT

<figure><img src="image_79.png" /></figure>

RheaWave
the echo that matters

<figure><img src="image_80.png" /></figure>
# H2 CPV Manufacturing

<figure><img src="image_81.png" /></figure>

## 62 L, 700 bar H2 CPV

Rotomolding: **40 min**

Filament Winding: **1h30min**

Epoxy Curing at low temperature: **12h00-18h00**

Total = **14h00-20h00**

Time order for CPV manufacturing:

**hour**

<figure><img src="image_82.png" /></figure>

Time order for automotive industry :

**minute**

<figure><img src="image_83.png" /></figure>
# CPV certification & Design

<figure><img src="image_84.png" /></figure>

<table><thead><tr><th></th><th>406/2010</th><th>nb minimum reservoirs</th></tr></thead><tbody><tr><td>4.2.1. Épreuve d'éclatement</td><td>3</td><td></td></tr><tr><td>4.2.2. Épreuve de cycles de pression à température ambiante</td><td>2</td><td></td></tr><tr><td>4.2.3. Épreuve de comportement à fuite avant rupture</td><td>3</td><td></td></tr><tr><td>4.2.4. Épreuve d'exposition au feu</td><td>1</td><td></td></tr><tr><td>4.2.5. Épreuve de pénétration</td><td>1</td><td></td></tr><tr><td>4.2.6. Épreuve d'exposition aux agents chimiques</td><td>1</td><td></td></tr><tr><td>4.2.7. Épreuve de tolérance aux défauts du composite</td><td>1</td><td></td></tr><tr><td>4.2.8. Épreuve de rupture accélérée sous contrainte</td><td>1</td><td></td></tr><tr><td>4.2.9. Épreuve de cycles de pression à température extrême</td><td>1</td><td></td></tr><tr><td>4.2.10. Épreuve de choc</td><td>1</td><td></td></tr><tr><td>4.2.11. Épreuve d'étanchéité</td><td>1</td><td></td></tr><tr><td>4.2.12. Épreuve de perméation</td><td>1</td><td></td></tr><tr><td>4.2.13. Épreuve de couple sur le bossage</td><td>1</td><td></td></tr><tr><td>4.2.14. Épreuve de cycles de pression avec l'hydrogène gazeux</td><td>1</td><td></td></tr><tr><td>4.2.15. Épreuve hydraulique (tous les réservoirs de la fab.)</td><td>1</td><td></td></tr><tr><td>total</td><td>19</td><td></td></tr></tbody></table>

Carbon fibre mass

Burst tests

<figure><img src="image_85.png" /></figure>

Composite Design

<figure><img src="image_86.png" /></figure>

CPV cost

<figure><img src="image_87.png" /></figure>
# CPV certification & Design

<figure><img src="image_88.png" /></figure>

<figure><img src="image_89.png" /></figure>
# Regulation evolution: 11% burst ratio reduction for 70 Mpa CPV => 6% CPV cost reduction

<figure><img src="image_90.png" /></figure>

Example of 70 Mpa CPV
Burst Pressure values
distribution at initial life
with ±10% scatter

<figure><img src="image_91.png" /></figure>

<figure><img src="image_92.png" /></figure>

NEW

June 2023

<figure><img src="image_93.png" /></figure>

* => Composite thickness reduction

* => Mechanical resistance reduction

* => Intrinsic resistance to fire reduction

* =>...

<figure><img src="image_94.png" /></figure>
# H2 CPV cost: main driver: carbon fibre

2016 : CEA Storage system Cost Study (CAPEX, OPEX)
=> 600 € / H₂ kg for 9 000 « 700 bar 62L » units / year

<figure><img src="image_95.png" /></figure>

<figure><img src="image_96.png" /></figure>

COPERNIC: Cost & Performances Improvement for CGH2 composite tanks

Technical developments

DURATION: 2013-2016

FCH Funding: ~3.6M€

COPERNIC (JTI, GA 325330, 2013-2016)

- Reducing costs thru increased productivity and enhanced tank architecture

CEA : project leader

<figure><img src="image_97.png" /><figcaption>Share of material cost, for 61l tank, 9,000 tanks/year</figcaption></figure>

<figure><img src="image_98.png" /></figure>
# H2 CPV cost: main driver: carbon fibre

<table><thead><tr><th>Type</th><th>Qty<br>[kg]</th><th>Rate<br>[€/kg]</th><th>Costs<br>[€]</th></tr></thead><tbody><tr><td>PA Liner</td><td></td><td></td><td>40</td></tr><tr><td>Glass fiber</td><td>1.00</td><td>2.00</td><td>2</td></tr><tr><td>Carbon fiber</td><td>25.00</td><td>16.00</td><td>400</td></tr><tr><td>Resin</td><td>13.00</td><td>6.00</td><td>78</td></tr><tr><td>Boss parts</td><td></td><td></td><td>80</td></tr><tr><td>Impact protection</td><td></td><td></td><td>20</td></tr><tr><td><strong>Total:</strong></td><td></td><td></td><td><strong>620</strong></td></tr></tbody></table>

<figure><img src="image_99.png" /></figure>

544 € / kg H2 stocké

<table><tbody><tr><td></td><td>cost €</td></tr><tr><td>material €</td><td>1860000</td></tr><tr><td>labour €</td><td>300000</td></tr><tr><td>overhead €</td><td>300000</td></tr><tr><td>OPEX €</td><td>2460000</td></tr><tr><td>CAPEX €</td><td>10850000</td></tr><tr><td>nb CPV / year</td><td>3000</td></tr><tr><td>nb year</td><td>7</td></tr><tr><td>300 000 CPV / year</td><td>cost €</td><td>%</td></tr><tr><td>material €</td><td>1860000</td><td>46%</td></tr><tr><td>labour & overhead €</td><td>600000</td><td>15%</td></tr><tr><td>Capex/year €</td><td>1550000</td><td>39%</td></tr><tr><td>total €</td><td>4010000</td><td>100%</td></tr><tr><td>1 CPV €</td><td>1337</td></tr><tr><td>kg H2</td><td>2,48</td></tr><tr><td>prix au kg H2 stocké €</td><td>539</td></tr></tbody></table>

<figure><img src="image_100.png" /></figure>

* Cout matériaux < 50% total

* Part importante du CAPEX => productivité faible

* Part faible du personnel et frais généraux

* la technologie n'est pas mature

* Objectif de l'industrie auto pas encore atteint

<figure><img src="image_101.png" /></figure>
# H2 CPV recent developments

## Material:

- Low cost carbon fibre

- Tow-preg use for better composite quality (lower variability, lower porosity)

## Design:

- Conformable vessel

## Manufacturing

- Robotic filament winding machine

- Fastcuring epoxy system (ex epoxy with ionic liquids: ANR Fascture 2 project)

- Injection rather Impregnation

## Recyclability

- Composite with Thermoplastic matrix

## Regulation & Standard:

- Burst ration safety factor reduction from 2.25 to 2 (=> - 175 bar)

<figure><img src="image_102.png" /></figure>
Merci pour votre attention

Thank you for your attention