Innovative Polymerized Sulfur-Based Composite Material for Underground Storage of Hydrogen

Abstract

Abdel Mohsen O. Mohamed and Maisa M. El Gamal

Underground energy storage in high-pressurized lined rock caverns is emerging as a viable solution for storing large volumes of energy in the form of pressurized gases, such as hydrogen and natural gas. This technology is particularly advantageous due to its potential to ensure the containment of gases with high specific energy in shallow rock formations, while operating under ambient temperature conditions. This paper (a) investigates the development of a novel polymerized sulfur-based composite material (PSCM) made of recyclable materials from oil and gas production industry (i.e., elemental sulfur) and steel manufacturing (i.e., Ladle-Furnace Slag (LFS) and Ground Granulated Blast Furnace Slag (GGBFS)); and (b) optimizes the composite proportions within the formed PSCM to enhance its physico-mechanical properties, such as packing density, compressive strength, and splitting tensile strength, for use to store hydrogen in high-pressurized underground lined rock caverns.

Through an experimental design guided by statistical analysis using Minitab-17 software, various compositions were mixed and tested to identify the optimal PSCM mixture ratios. The findings revealed that maximum compressive strength, reaching up to 58 MPa, and splitting tensile strength of 3.56 MPa were achieved with a mixture containing 34% polymerized sulfur, 36% dune sand, 19% LFS, and 17% GGBFS. The study also confirmed that better aggregate packing reduces voids, thereby minimizing the amount of polymerized sulfur required to fill these voids and increasing the overall strength of the PSCM. These results underscore the potential of PSCM as a sustainable and durable alternative to Portland cement concrete used as a liner material in constructing underground man-made caverns for hydrogen storage.

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