The project

Because the transport segment makes up about one-third of all CO2 emissions in the European Union (> 1,000 MILL ton), its decarbonization represents a key element in achieving the energy transition. Fuel Cells and Hydrogen (FCH), outperforming batteries in all relevant indicators, is the most promising solution for decarbonizing trucks, buses, ships, trains, large cars, with commercial vehicles being considered the early adopters. By 2030 this new industry has the potential to generate a €130 bn market only in the European Union. The market-entry goal is to fit 5kg H2 in a gasoline equivalent tank (80 kg/90 l). However, state-of-the-art technology for H2 storage on-board, based on compression at 700bar, is still disappointing in terms of volumetric density (25 gH2/lsys), preventing a widespread penetration of FCEVs.

Based on a new generation of Machine Learning-improved ultraporous materials – such as Activated Carbons (ACs) and high-density MOFs (Metal-organic Frameworks) –, MAST3RBoost project will enable a disruptive path to meet the industry goals by developing the first worldwide adsorption-based demonstrator at the kg-scale. Lightweight vessels –embedding the ultraporous materials– will be created taking advantage of the innovative Wire-Arc Additive Manufacturing, with dedicated shapes to better fit on-board specific transportation spaces.

Recycled raw materials for the manufacturing of the ultraporous materials will be actively pursued, both from waste agroforestry biomass and from solid urban waste. The research and development process will be performed applying Life Cycle thinking strategies to minimise overall environmental impacts and improve economic performance of the hydrogen storage system from the design phase.

The concept is built on the following pillars

  • Machine Learning: unsupervised algorithms
  • Scale-up and densification of materials
  • Numerical calculations & Digital Twin of system
  • System integration and qualification
  • Eco-design of storage system

OBJECTIVES

01.

Development of standards for the repeatable and scalable production of ultraporous structures with controlled textural and chemical profiles

02.

Prototypes of at least 4 densified ultraporous materials from the carbon and MOF families

03.

Creation of harmonized data management standards to enable the application of high throughout Machine Learning to further develop porous materials for hydrogen storage via Open Research strategies

04.

Development of an ad-hoc and cost-efficient Wire Arc Additive Manufacturing (WAAM)-process using materials suitable for cryogenic temperatures and coatings to cope with chemical compatibility

05.

Design and manufacturing of a pressure vessel for the storage of 1 kg of H2 at 100 bar and main components

06.

Qualification of demonstrator for high density storage system including TPS asset for H2 release at ΔT=80 K and 5 bar

07.

Protection of new foreground with an effective knowledge transfer

08.

Providing common space for discussion and training with the complete value-chain, including end-users

09.

Promoting new policy making and standards with a solid EU-based benchmark for further innovation