Burst pressure performance comparison of type V hydrogen tanks: Evaluating various shapes and materials

Hydrogen, as a clean energy carrier, presents a significant step toward sustainable energy solutions but faces challenges in storage due to its low energy density and high volatility. This study addresses the optimization of Type V hydrogen storage tanks by investigating the burst pressure performance of spherical, cylindrical, and toroidal shapes. Using finite element analysis (FEA) and first-order shear deformation theory, we examined how these geometries impact burst pressure outcomes across a range of composite materials and layup configurations. The materials tested included carbon T700/epoxy, Kevlar/epoxy, E-glass fiber/epoxy, and basalt/epoxy. Results demonstrate that the toroidal shape significantly outperforms spherical and cylindrical designs in stress distribution and burst pressure, with basalt/epoxy composites exhibiting superior burst pressure performance (12.7 MPa) compared to Kevlar/epoxy (10.8 MPa), E-glass fiber/epoxy (11.4 MPa), and carbon T700/epoxy (8.9 MPa). Kevlar/epoxy toroidal tanks outperform other materials in weight performance, having a structural performance index of 0.0305 Mpa.m3/kg and hydrogen density per unit mass of 0.0251 kg H2/kg. The stacking sequence [-45/45]s optimized stress distribution for the toroidal shape across all materials. The findings highlight that toroidal designs offer significant advantages for high-pressure hydrogen storage, providing efficient stress management and improved safety. This paper underlines the potential of toroidal vessels for enhancing hydrogen storage efficiency and emphasizes the importance of material selection and stacking sequences in achieving optimal burst pressure performance for international organization for standardization (ISO) certification.