NCC to accelerate UK’s cryogenic storage capabilities

NCC said its UK-based composite cryogenic storage tank testing programme will validate and accelerate design, manufacture, and test capabilities, starting with a linerless carbon fibre tank for storing liquid hydrogen (LH2).

Cryogenic storage tanks will be required in hydrogen-powered aircraft due to come into service in the mid-2030s. Most designs for storing LH2 have centred around relatively heavy metallic tanks, while composite tanks developed in the space industry tend to be suited to low cycle applications. In comparison, commercial hydrogen aircraft will need fuel tanks to be as light as possible, undergo high cycles, and last for several decades.

To support the UK’s transition to a low-carbon economy, the NCC said it is developing underpinning knowledge for composite cryogenic storage tanks and testing by developing product demonstrators with increasing complexity. Its engineers have also created and built a range of comprehensive cryogenic concepting and design tools to help UK organisations overcome known engineering challenges.

With no clear existing industry standards for aerospace cryogenic tanks, the ability to analyse a range of designs is essential. This led to the development of a range of concepting tools covering tank design, space exploration, permeability, microcracking, plus thermal and mechanical stresses. These tools form a baseline toolset that can be used by industry for cryogenic tank projects, enabling detailed design and manufacturing risk identification and analysis.

Testing cryogenic tanks requires access to specialist testing facilities; LH2 requires well-insulated cryogenic storage vessels to maintain it at a temperature of -253°C, and handling requires specialist knowledge and equipment.

Working in partnership with Filton Systems Engineering (FSE), the NCC has developed a tank-testing programme that uses an LH2 vacuum test chamber and cryo-rated testing instrumentation. The NCC has designed and manufactured five linerless carbon fibre demonstrator tanks, using a mix of automated fibre placement (AFP), tape winding, and hand lay-up composite processes. The tanks will be used for the liquid hydrogen testing programme, starting at the end of April 2023, with results expected this summer.

In a statement, Daniel Galpin, advanced research engineer, NCC, said: “The cross-sector capability we’ve developed will enable UK industry to accelerate and advance engineering expertise in composite cryogenic storage, and secure future commercial competitiveness. Our comprehensive programme will enable us to support customers on their journey to design, validate, manufacture, and test high-cycle composite cryogenic tanks.”