CNG Cylinders Type I: Material & ProductionCNG Cylinders Type I: Material & Production
National Metal and Materials Technology Center (MTEC)National Metal and Materials Technology Center (MTEC)National Science and Technology Development Agency (NSTDA)National Science and Technology Development Agency (NSTDA)
““การผลิตการผลิต การใชการใช และการกํากับดูแลถังและการกํากับดูแลถัง CNG CNG ใหปลอดภัยใหปลอดภัย””Boiler & Pressure Vessel 2009Boiler & Pressure Vessel 2009
2727 กุมภาพันธกุมภาพันธ 25522552ศูนยการประชุมศูนยการประชุมอิมแพคอิมแพคเมืองทองธานีเมืองทองธานี
Tank & Safety Valve
Pressure Regulator
Pressure Gauge Refilling
Valve
SwitchECU
Electronic SparkAdvance Control
Gas Filter
Injector Rail
OverviewOverview
MaterialMaterial
• Primary alloying element: C, Si, Mn• Secondary alloying element: Cr, Mo, Ni• Trace element: P, S
0.05
0.10
0.15
Gas
cap
acit
y-w
eigh
t ra
tio
(m3
/kg)
0.20
1900 1920 1940 1960 1980 2000
(BS 399/400)(BS 399/400)Carbon steelCarbon steel
(BS 1045/1288)(BS 1045/1288)Carbon Carbon
manganese manganese steelsteel
Chromium molybdenum Chromium molybdenum steelsteel
(BS 5045)(BS 5045)
(HOS)(HOS)
YearYear
High strength steels for CNG cylindersHigh strength steels for CNG cylinders
0.060.080.170.421.150.660.410.22From MTEC Tank
0.035 max.
0.035 max.NA
0.15-0.3
0.9-1.20.6-0.9
0.4 max.
0.3-0.37
34CrMo 4 (DIN 17200)
0.025 max.
0.025 max.
0.25 max.
0.15-0.25
0.8-1.10.4-0.6
0.15-0.35
0.28-0.334130(AISI)
0.040 max.
0.035 max.
1.65-2.00.2-0.3
0.4-0.6
0.45-0.65
0.15-0.35
0.17-0.224320(AISI)
0.040 max.
0.035 max.
1.65-2.00.2-0.3
0.7-0.90.6-0.8
0.15-0.35
0.38-0.434340 (AISI)
0.05 max.
0.05 max.2.3-2.80.4-0.7
0.5-0.80.5-0.7
0.1-0.35
0.27-0.35NCM (BS 5045)
0.05 max.
0.05 max.
0.5 max.
0.15-0.25
0.8-1.20.4-0.9
0.1-0.35
0.37 max.CM (BS 5045)
% S%P%Ni%Mo%Cr%Mn%Si%CSteel Grade
MaterialMaterial
81703560IE (J) at -50˚C
18171414Elongation (%)
1046.61118.79901100UTS (N/mm2)
957.61004.3890990YS (N/mm2)
4340 - II4340 - IFaberISO 9809Mechanical Properties
43404340--I: Tempering @ 590I: Tempering @ 590˚̊C, 4340C, 4340––II: Tempering @ 620II: Tempering @ 620˚̊CC
High strength steels for CNG cylindersHigh strength steels for CNG cylindersMaterialMaterial
MicrostructureMicrostructureMaterialMaterial
Seamless pipeSeamless pipeMaterialMaterial
•• AdvantagesAdvantages-- Thin wall (Thickness to OD ratioThin wall (Thickness to OD ratio
= 0.2%)= 0.2%)-- Dimension accuracy Dimension accuracy
(prevent eccentricity and thickness(prevent eccentricity and thicknessdeviation)deviation)
-- Improved inner surfaceImproved inner surface(prevent roll(prevent roll--in scale)in scale)
•• Standard: Standard: JIS G 3429JIS G 3429 (Seamless Steel Tubes for High Pressure Gas Cylinder)(Seamless Steel Tubes for High Pressure Gas Cylinder)
•• Grade:Grade:STH 22 (ChromeSTH 22 (Chrome--molybdenum steel tube)molybdenum steel tube)
•• Chemical composition:Chemical composition:C = 0.33C = 0.33--0.38%, Si = 0.150.38%, Si = 0.15--0.35%, 0.35%, MnMn = 0.40= 0.40--0.90%, P = 0.030% max.0.90%, P = 0.030% max.S = 0.030%(max), Ni = 0.25%(max), Cr = 0.80S = 0.030%(max), Ni = 0.25%(max), Cr = 0.80--1.20%, Mo = 0.151.20%, Mo = 0.15--0.30%0.30%
Type 2Type 2 Type 3Type 3 Type 4Type 4
Type 1Type 1
CNG Type Weight Cost
Type-1: Metal Cylinders 100% 40%
Type-2: Metal liner - Hoop wrapped cylinders 55-65% 80-95%
Type-3: Metal liner - Fully wrapped cylinders 25-45% 90-100%
Type-4: All Composite cylinders 30% 90%
ProductionProduction
1. Steel : billet2. Steel : plate3. Steel : tube4. HS steel : plate5. HS aluminum : billet6. Aluminum : tube/E-glass hoop7. Steel : plate/E-glass hoop8. Steel : billet/E-glass hoop9. Aluminum : tube/E-glass full10.Aluminum : plate/E-glass full11.Aluminum : plate/S-glass full12.Aluminum : thin/carbon full13.Plastic/carbon full14.Plastic/E-glass full15.Plastic/hybrid full
11
8
2
15
4
0.00
0.10
0.20
0.30
$0.00 $0.50 $1.00 $1.50
Total Cost ($/scf)
Spe
cific
Wei
ght (
lb/s
cf)
1
7
13
6
3
10
12
914
5
NGV Cylinder Weight vs. Cost
Ref. “Compressed Natural Gas Storage Optimization for Natural Gas Vehicles” Final Report, Dec., 1996, Prepared by IGT and Powertech Labs for GRI
ProductionProduction
CNG Type : 1 CNG Type : 1 –– steel cylindersteel cylinder
Material : BS5045 Steel / AISI4340Material : BS5045 Steel / AISI4340
Cylinder Volume : 70 LittersCylinder Volume : 70 Litters
Weight : 70Weight : 70--80 kg80 kg
Working pressure : 200 barsWorking pressure : 200 bars
Mileage : about 200 km/refillMileage : about 200 km/refill
Periodic Test : every 5 yearsPeriodic Test : every 5 years
Service Life : 20 yearsService Life : 20 years
:most commonly used in Thailand
ProductionProduction
CNG cylinder typeCNG cylinder type--II
Heating
External – Internal shot blasting
Cupping –Hot Extrusion
Wall thickness reduction
Shell Inspection
Quenching & Temping
Hot spinning
shot blastingNeck Machining
(www. faber-italy. com)
Production Production –– CNG Cylinder Type CNG Cylinder Type -- II
Detailed Detailed manumanu. process (steel billet) . process (steel billet)
Hardness Test Shell Inspection Neck Threading
Ultrasonic Inspection MarkingVolumetric Expansion
Hydro test
Surface Coating Final Operation Shell Inspection
(www. faber-italy. com)
Production Production –– CNG Cylinder Type CNG Cylinder Type -- II
Detailed Detailed manumanu. process (steel billet) . process (steel billet)
Cold Deep Drawing
Cold Deep Drawing
Annealing Flow Forming Hot Neck Spinning
•• Main machines required Main machines required -- Drawing hydraulic press: tonnage 1500 ton upDrawing hydraulic press: tonnage 1500 ton up-- Flow forming machineFlow forming machine-- Hot spinning machine Hot spinning machine
Production Production –– CNG Cylinder Type CNG Cylinder Type -- II
Main Main manumanu. process (steel plate) . process (steel plate)
Base Spinning Base Shaping – Internal Dressing
Flowing Forming Hot Neck Spinning
(www faber italy com
•• Main Machines Required Main Machines Required -- Flow Forming MachineFlow Forming Machine-- Hot Spinning MachineHot Spinning Machine
Production Production –– CNG Cylinder Type CNG Cylinder Type -- II
Main Main manumanu. process (steel tube) . process (steel tube)
1.1. Material tests Material tests
2.2. Hydrostatic Pressure Burst testHydrostatic Pressure Burst test
3.3. Pressure Cycling Test Pressure Cycling Test
4.4. Leak Before Break Test Leak Before Break Test
5.5. Bonfire TestBonfire Test
6.6. Gunfire TestGunfire Test
Bonfire testBonfire test
Gunfire test
Production Production –– CNG Cylinder Type CNG Cylinder Type -- II
Prototype testing (ISO 11439) Prototype testing (ISO 11439)
Gunfire testGunfire test
Leak before break testLeak before break test
Thank You for Thank You for Your Attention!!!Your Attention!!!