How Are Type 4 Tanks Outperforming Type 3 with Advanced Composite Materials in CNG Storage?

Highlights:

• Introduction
• Reduces maintenance and environmental damage
• Safety and efficiency contribute to better fuel economy
• Minimized operational cost balances the initial investment

Composite materials are combined to create a product with superior properties, compared to individual components, with different physical and chemical features. They generally consist of high-strength fibers, such as carbon fiber or fiberglass, embedded in a resin matrix in CNG tanks. In type 3 CGN tanks, the composite materials are used to reinforce the aluminum liner. The composite wrap helps the tank handle the high pressures of CNG. In type 4 tanks, the composite material is wrapped around a plastic liner. The wrap improves the tank's structure, allowing it to withstand even higher pressures while keeping it lightweight.

Light weight and corrosion resistant plastic liners reduce maintenance and environmental damage

The plastic liner is resistant to corrosion, which enhances the tank's durability. This aluminum liner is denser than its plastic counterpart, which adds to the overall weight of the type 3 tank. The plastic liners in type 4 tanks weigh lighter than aluminum, and they are corrosion resistant. This implies that the type 4 tanks are less likely to suffer from degradation due to environmental factors, leading to a longer lifespan and reduced maintenance needs.

The reduced weight makes the vehicles much more efficient, allowing for greater payload capacity and potentially better fuel economy. For example, a type 4 tank with a capacity of 30,000 liters weighs around 500 kg, compared to a similar type 3 tank that weighs about 800 kg. Hexagon Agility and Aerojet Rocketdyne conducted extensive R&D on advanced composite materials for CNG tanks. Their joint study, published in June 2022, highlighted that type 4 tanks are up to 40% lighter than traditional type 3 tanks, enhancing vehicle efficiency and payload capacity significantly. It also highlighted the practical benefits and performance improvements achieved through using composite materials in CNG tank technology. Furthermore, composite materials technology innovations provide superior strength and durability, which is important for the safety and longevity of CNG tanks. This promotes their adoption in both commercial and passenger vehicles, contributing to the growth of the global CNG type 3 and type 4 tank industry.

Safety and efficiency enhancements contribute to better fuel economy

Safety is the key factor in CNG tank design. Type 4 tanks feature a polymer liner fully encased in a composite shell. This design eliminates the metal liner, reducing the risk of corrosion and fatigue failure. The composite shell provides enhanced resistance to impact and higher-pressure tolerance. In addition, the advanced composite materials used in type 4 tanks create better thermal insulation and resistance to extreme temperatures, further securing the vehicle by maintaining structural integrity under adverse conditions. Quantum Fuel Systems and Trelleborg had a research work published in February 2023 that focused on the impact resistance and pressure durability of composite-wrapped CNG tanks. The study confirmed that type 4 tanks, with their advanced composite wraps, offer superior safety and structural integrity compared to type 3 tanks.

Increased weight reduces the payload capacity of a vehicle and results in higher fuel consumption. The all-composite construction of type 4 tanks eliminates the heavy metal liner found in type 3 tanks. This weight reduction contributes to improved vehicle fuel efficiency by decreasing the vehicle's overall mass and thereby reducing fuel consumption. Additionally, the lighter type 4 tanks allow for more efficient use of space, enabling larger tank capacities without adding substantial weight. The vehicles can carry more compressed natural gas and achieve greater driving range. Increased pressure tolerance and better thermal performance of type 4 tanks also account for more efficient fuel storage and utilization, optimizing fuel economy and extending the vehicle’s operational range between refueling stops.

Minimized operational cost balances the initial investment

Using composite materials in type 4 tanks results in higher initial costs compared to type 3 tanks due to the advanced manufacturing processes and materials involved. However, these costs are frequently balanced by savings eventually. Type 4 tanks are lighter and more durable, which leads to better fuel economy and lower maintenance expenses. Their resistance to corrosion and extreme conditions also extends the tank's lifespan, reducing replacement frequency and overall operational costs. Thus, the long-term benefits in terms of fuel savings and lower maintenance make type 4 tanks a cost-effective choice, even though the initial investment is higher.

In June 2021, Luxfer Holdings PLC signed an agreement with Momentum Fuel Technologies to supply neck-mounted GStor Go Type 4 cylinders. This collaboration aimed to advance the use of high-pressure composite cylinders in CNG applications, using Luxfer's expertise in composite materials and Momentum's market reach. The agreement highlighted a major step toward enhancing the safety, efficiency, and cost-effectiveness of type 4 CNG tanks, contributing to the broader adoption of advanced composite technology in the industry.

To conclude, the type 4 tanks offer various advantages in terms of weight reduction, strength, durability, and safety by utilizing a combination of a lightweight plastic liner and a high-strength composite wrap. These benefits convert into improved vehicle efficiency, longer range, and potentially lower long-term costs, despite the higher initial investment. Acknowledging the importance of composite materials in these tanks thus helps fleet operators make informed decisions that align with their operational and financial objectives.

 We offer detailed business updates and insights on upcoming industry prospects for CNG Type 3 and Type 4 tanks. For further details, contact our analysts without delay!

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