Abstract
In order to enable an emission-free society by 2050, the distribution of green hydrogen is a key element for a successful transformation of the energy supply. This paper presents the design and manufacturing of composite pipelines made of fiber-reinforced plastic (FRP) and its potential for the transport of high-pressurized gases such as hydrogen. Furthermore, the extent to which FRP-pipelines can be a potential complement to existing steel pipelines is being discussed.
The wet winding process is an established manufacturing process for FRP-pipes which, however, provide only a fraction of all necessary requirements. Oftentimes, a trade between the different factors cost, weight, performance and feasibility is made. By means of benchmarking the alternative manufacturing approaches such as multi-supply filament winding (MFW) and radial braiding, the potential for cost-effective high-pressure composite pipelines are investigated within this paper. For the aspired operational pressure of 350 bars, suitable lay-ups are derived and validated via simulation according to ISO 14692. As pre-impregnated fibers, so-called towpregs, enable elevated winding speeds and reduced resin content variance, the study focusses on this material. Additionally, MFW allows the processing of up to 48 towpregs simultaneously and therefore, increased productivity compared to single-filament winding. Using the generated data and based on the material combinations investigated, the productivity of the MFW process is examined. The most promising design is selected for the manufacturing of a demonstrator via MFW. Finally, recommendations for the industrial upscale of composite pipeline manufacturing are presented and the manufacturing approach via radial braiding as an alternative is discussed.
