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The use of hydrogen storage tanks at 100% of nominal working pressure (NWP) is expected only after refuelling. Driving between refuellings is characterised by the state of charge SoC &lt, 100%. There is experimental evidence that Type IV tanks tested in a fire at initial pressures below 1/3 NWP, leaked without rupture. This paper aims at understanding this phenomenon. The numerical research has demonstrated that the heat transfer from fire through the composite overwrap at storage pressures below NWP/3 is sufficient to melt the polymer liner. This melting initiates hydrogen microleaks through the composite before it loses the load-bearing ability. The fire-resistance rating (FRR) is defined as the time to rupture in a fire of a tank without or with blocked thermally activated pressure relief device. The dependence of a FRR on the SoC is demonstrated for the tanks with defined material properties and volumes in the range of 36–244 L. A composite wall thickness variation is shown to cause a safety issue by reducing the tank’s FRR and is suggested to be addressed by tank manufacturers and OEMs. The effect of a tank’s burst pressure ratio on the FRR is investigated. Thermal parameters of the composite wall, i.e., decomposition heat and temperatures, are shown in simulations of a tank failure in a fire to play an important role in its FRR.

A systematic study of different ratios of CO, CO2, N2 gas components on the hydrogen storage properties of the Na3AlH6 complex hydride with 4 mol% TiCl3, 8 mol% aluminum and 8 mol% activated carbon is presented in this paper. The different concentrations of CO and CO2 in H2 and CO, CO2, N2 in H2 mixture were investigated. Both CO and CO2 gas react with the complex hydride forming Al oxy-compounds, NaOH and Na2CO3 that consequently cause serious decline in hydrogen storage capacity. These reactions lead to irreversible damage of complex hydride under the current experimental condition. Thus, after 10 cycles with 0.1 vol % CO + 99.9 vol %H2 and 1 vol % CO + 99 vol %H2, the dehydrogenation storage capacity of the composite material decreased by 17.2% and 57.3%, respectively. In the case of investigation of 10 cycles with 1 vol % CO2 + 99 vol % H2 gas mixture, the capacity degradation was 53.5%. After 2 cycles with 10 vol % CO +90 vol % H2, full degradation was observed, whereas after 6 cycles with 10 vol % CO2 + 90 vol % H2, degradation of 86.8% was measured. While testing with the gas mixture of 1.5 vol % CO + 10 vol % CO2 + 27 vol % H2 + 61.5 vol % N2, the degradation of 94% after 6 cycles was shown. According to these results, it must be concluded that complex aluminum hydrides cannot be used for the absorption of hydrogen from syngas mixtures without thorough purification.