Composite Type 3 Cylinders VS Type 1 Steel Cylinders
As India builds out its gas infrastructure, natural gas can find multiple uses in India’s energy system, including to help meet air quality and near‐term emissions goals as promised in the Paris Agreement. The CNG vehicle market in India is growing rapidly and has witnessed a yearly growth of 35% from 2023 to 2024. According to sources, the vehicle industry is expected to grow at 7% CAGR.
Composite Type 3 and Steel Type 1 cylinders are both widely used for storing gases, but they differ significantly in terms of materials, construction, and performance characteristics. This article focuses on comparing the use of Composite Type 3 and Steel Type 1 cylinders, using a practical example from the current truck market in India.
Truck Market Overview
In the current truck market, Type 1 steel cylinders with an 80-liter capacity are commonly used. The number of cylinders on a vehicle typically ranges from 2 to 8, depending on the truck’s size and application. Larger trucks, in particular, predominantly feature about 8 cylinders of 80-liter capacity.
For this discussion, we will analyse and compare the performance and practicality of Composite Type 3 versus Steel Type 1 cylinders in the context of such configurations.
Let us dive into the numbers. All data have been taken from market information available.
If a truck has 8 steel cylinders of 80 litres capacity, each cylinder weighing about 82 Kilogram. Size 267MM diameter * 1720 MM long. 200 BAR design pressure storing about 11.5 Kilogram of GAS
8 cylinders * 82 KG = 656 KG dead weight of the cylinders in the truck
Gas storage = 11.5 * 8 = 92 Kilograms
Range (assumed for 10 Ton truck) mileage is 6 KM per Kilogram = 90*6 = 540 Kilometres
Now let us compare the numbers with Composite Type 3 cylinders
Vinjamuri Innovations (VIPL) composite type 3 cylinders (patent protected) are at least 45% to 50% lighter than steel cylinders, depending on design and configuration. It is designed for 230 BAR storage pressure, meaning higher storage compared to existing steel cylinders.
Therefore,
8 cylinders * 40 KG = 320 KG dead weight of the cylinders in the truck
Gas storage = 13.3 * 8 = 106 Kilograms
Range (assumed for 10 Ton truck) mileage is 6 KM per KG = 100*6 = 600 Kilometres
Additionally:
VIPL composite cylinders are fast fill cylinders.
Fast Fill and Composite Cylinders
1. Lightweight Design: Composite materials like carbon fibre and fiberglass dissipate heat more efficiently than metal, allowing for faster pressure stabilization during rapid gas filling.
2. Temperature Management: While fast filling generates heat due to gas compression, the design of composite cylinders helps mitigate extreme temperature rise compared to all-metal cylinders. This ensures a safer and more consistent fill.
3. Durability Under Pressure: Composite cylinders are designed to handle high pressures up to 700 bar, making them ideal for quick fills at high-pressure public refuelling stations.
Conclusion
1. VIPL Composite cylinders, due to superior design provide extra range of about 60 KMS per filling.
2. Being light weight, the dead weight of cylinders is almost 330 KGS less than steel cylinders, the truck can carry 330 KGS of excess luggage per trip. As per calculations detailed below
Chennai to New Delhi – 330 * Rs10 per KG -= Added Revenue per trip is Rs.3300/-
Assumed travel time is 4 Days / trip – No of trips per year on 300-day basis = 70 trips
Total additional revenue possible = 70 * 3300 = INR 231000/-
This revenue is far higher than the difference in the initial cost of the Composite cylinder. Therefore, a truck owner can recover the difference in cost of composite cylinder well within 8 to 10 months.
3. Composite cylinders due to their lightweight and high-pressure capabilities make them particularly well-suited for fast fill applications where speed and efficiency are prioritized.
From an innovation perspective, VIPL Composite Type 3 cylinders fulfill the growing demand by combining advanced materials and engineering to enhance efficiency, reduce weight, and improve gas storage capacity. Their lightweight, high-pressure capabilities not only align with the expanding CNG market’s requirements but also enable faster refueling and increased payload capacity, making them a forward-thinking solution for the transportation industry. Wishing you the very best in showcasing their outstanding research work, driving innovation and paving the way for achieving greater milestones in the near future.