CNG Cylinders Type I: Material & Production

CNG
Boiler & Pressure Vessel 2009 27 2552

National Metal and Materials Technology Center (MTEC) National Science and Technology Development Agency (NSTDA)

Overview

Gas Filter

Switch

ECU

Electronic Spark Advance Control Pressure Regulator

Injector Rail Pressure Gauge Refilling Valve

Tank & Safety Valve

Material
0.20

Gas capacity-weight ratio (m3/kg)

(BS 5045) (HOS) (BS 1045/1288) Carbon manganese Chromium molybdenum steel steel

0.15

(BS 399/400) Carbon steel 0.10

0.05 1900 1920 1940 1960 1980 2000

Year

Primary alloying element: C, Si, Mn Secondary alloying element: Cr, Mo, Ni Trace element: P, S

Material

High strength steels for CNG cylinders

Steel Grade CM (BS 5045) NCM (BS 5045) 4340 (AISI) 4320(AISI) 4130(AISI) 34CrMo 4 (DIN 17200) From MTEC Tank %C 0.37 max. 0.270.35 0.380.43 0.170.22 0.280.33 0.30.37 0.22 %Si 0.10.35 0.10.35 0.150.35 0.150.35 0.150.35 0.4 max. 0.41 %Mn 0.4-0.9 0.5-0.7 0.6-0.8 0.450.65 0.4-0.6 0.6-0.9 0.66 %Cr 0.81.2 0.50.8 0.70.9 0.40.6 0.81.1 0.91.2 1.15 %Mo 0.150.25 0.4-0.7 0.2-0.3 0.2-0.3 0.150.25 0.150.3 0.42 %Ni 0.5 max. 2.3-2.8 1.652.0 1.652.0 0.25 max. NA 0.17 %P 0.05 max. 0.05 max. 0.035 max. 0.035 max. 0.025 max. 0.035 max. 0.08 %S 0.05 max. 0.05 max. 0.040 max. 0.040 max. 0.025 max. 0.035 max. 0.06

Material

High strength steels for CNG cylinders

Mechanical Properties YS (N/mm2) UTS (N/mm2) Elongation (%) IE (J) at -50C ISO 9809 990 1100 14 60 Faber 890 990 14 35 4340 - I 1004.3 1118.7 17 70 4340 - II 957.6 1046.6 18 81

4340-I: Tempering @ 590C, 4340II: Tempering @ 620C

Material

Microstructure

Material

Seamless pipe
Advantages - Thin wall (Thickness to OD ratio = 0.2%) - Dimension accuracy (prevent eccentricity and thickness deviation) - Improved inner surface (prevent roll-in scale) Standard: JIS G 3429 (Seamless Steel Tubes for High Pressure Gas Cylinder) Grade: STH 22 (Chrome-molybdenum steel tube) Chemical composition: C = 0.33-0.38%, Si = 0.15-0.35%, Mn = 0.40-0.90%, P = 0.030% max. S = 0.030%(max), Ni = 0.25%(max), Cr = 0.80-1.20%, Mo = 0.15-0.30%

Production

CNG Type
Type-1: Type-2: Type-3: Type-4: Metal Cylinders Metal liner - Hoop wrapped cylinders Metal liner - Fully wrapped cylinders All Composite cylinders

Weight
100% 55-65% 25-45% 30%

Cost
40% 80-95% 90-100% 90%

Type 1

Type 2

Type 3

Type 4

Production

NGV Cylinder Weight vs. Cost

0.30
3 1 2

7 5 14 10 9 11

0.20

0.10
13

15 12

1. Steel : billet 2. Steel : plate 3. Steel : tube 4. HS steel : plate 5. HS aluminum : billet 6. Aluminum : tube/E-glass hoop 7. Steel : plate/E-glass hoop 8. Steel : billet/E-glass hoop 9. Aluminum : tube/E-glass full 10.Aluminum : plate/E-glass full 11.Aluminum : plate/S-glass full 12.Aluminum : thin/carbon full 13.Plastic/carbon full 14.Plastic/E-glass full 15.Plastic/hybrid full

Specific Weight (lb/scf)

0.00 $0.00

$0.50

$1.00

$1.50

Total Cost ($/scf)

Ref. Compressed Natural Gas Storage Optimization for Natural Gas Vehicles Final Report, Dec., 1996, Prepared by IGT and Powertech Labs for GRI

Production

CNG cylinder type-I :most commonly used in Thailand

CNG Type : 1 steel cylinder Material : BS5045 Steel / AISI4340 Cylinder Volume : 70 Litters Weight : 70-80 kg Working pressure : 200 bars Mileage : about 200 km/refill Periodic Test : every 5 years Service Life : 20 years

Production CNG Cylinder Type - I

Detailed manu. process (steel billet)

Heating Cupping Hot Extrusion Wall thickness reduction

External Internal shot blasting

Shell Inspection

Hot spinning

Neck Machining

Quenching & Temping

shot blasting

(www. faber-italy. com)

Production CNG Cylinder Type - I

Detailed manu. process (steel billet)

Hardness Test Shell Inspection Neck Threading

Ultrasonic Inspection

Marking

Volumetric Expansion Hydro test

Surface Coating

Final Operation

Shell Inspection

(www. faber-italy. com)

Production CNG Cylinder Type - I

Main manu. process (steel plate)

Cold Deep Drawing

Annealing

Cold Deep Drawing

Flow Forming

Hot Neck Spinning

Main machines required

- Drawing hydraulic press: tonnage 1500 ton up - Flow forming machine - Hot spinning machine

Production CNG Cylinder Type - I

Main manu. process (steel tube)

Base Spinning

Base Shaping Internal Dressing

Flowing Forming

Hot Neck Spinning

Main Machines Required

- Flow Forming Machine - Hot Spinning Machine

Production CNG Cylinder Type - I

Prototype testing (ISO 11439)

1. Material tests 2. Hydrostatic Pressure Burst test 3. Pressure Cycling Test 4. Leak Before Break Test 5. Bonfire Test 6. Gunfire Test
Bonfire test

Gunfire test Leak before break test

Gunfire test

Thank You for Your Attention!!!