IZMIR KATIP CELEBI UNIVERSITY

FACULTY OF ENGINEERING AND ARCHITECTURE

DEPARTMENT OF METALLURGICAL AND MATERIALS ENGINEERING

CRYOGENIC GAS TANK DESIGN AND MATERIALS

SELECTION

Gökçe DUNLU
İlkim TUNCER
Buse UĞURLU
Hilal ÇİĞDEM

20.12.2023

IZMIR
 ABSTRACT

The purpose of this research is to evaluate the crucial necessity of material selection for
cryogenic gas storage tanks. Cryogenic tanks are specialized storage systems meant to work at
low temperatures, and the material used greatly determines the tank's safety, longevity, and
performance. This report describes the material selection process in depth, analyzing the
benefits and drawbacks of various material possibilities. The material selection procedure
takes into account elements such as the stored gas's characteristics, tank size, cost-
effectiveness, durability, and thermal conductivity. The combination of these criteria
complicates finding the best material. The report will discuss how different material
possibilities react to these elements and how they affect performance in a cryogenic
environment. The beneficial aspects and drawbacks of using different materials will be
extensively analyzed in the findings section, taking into account the properties and uses of
each material. This research attempts to assist designers make educated decisions by
understanding the complexities of the material selection process for cryogenic gas storage
tanks. The report's conclusion section is intended to identify areas where further research on
the development and optimization of cryogenic gas storage technologies might be focused.
This section will thoroughly examine the obstacles, accomplishments, and potential
improvements in the material selection process, directing readers for future research attempts.
1. INTRODUCTION

Cryogenic gas tanks are special containers designed for the storage and transportation of
gases at very low temperatures (below -150 degrees Celsius). The term "cryogenic" originates
from the Greek word "kryos" meaning cold. These tanks are designed to transport gases in
their cryogenic state, such as liquefied gases or cold gases under high pressure. With its
special structure, insulation and pressure control systems, it ensures that the gases in the tank
remain in liquid form. For example, industrial gases such as liquefied natural gas (LNG),
liquefied oxygen, nitrogen, hydrogen, argon are often stored in cryogenic tanks.

1.1 USAGE AREAS OF CRYOGENIC TANKS

Cryogenic gas tanks play important roles in various areas of industrial applications.
These tanks are used for various purposes in industrial sectors as they have the capacity to
liquefy and store gases by operating at low temperatures. Here are some industrial uses and
roles of cryogenic gas tanks:

 Power Plants and LNG Storage: Cryogenic gas tanks play an important role in
storing fuels such as liquefied natural gas (LNG) used in power plants. These tanks reduce
the volume of natural gas by liquefying it and enable it to be stored more easily and
economically.

 Metallurgy and Metal Processing: In the metallurgical industry, cryogenic gases are
used in metal processing processes. In particular, cryogenic nitrogen or argon is used in the
cooling and shaping stage of metals.

 Health and Medicine: Cryogenic gases are important in medical applications. For
example, liquefied oxygen, nitrogen, and argon are used for medical imaging devices and
surgical procedures.

 Food Industry: Cryogenic gases are used in cooling and freezing processes in the
food industry. In particular, liquefied nitrogen or carbon dioxide is used in freezing,
preserving or packaging foods.

 Chemical Industry: Cryogenic gases are used to maintain low temperatures and
control reactions in chemical production processes. Some chemical processes are carried
out in cryogenic conditions, which can increase the efficiency of certain chemical
reactions.

 Space and Aviation: In the space industry, liquefied oxygen, hydrogen, or other
cryogenic fuels are used as rocket fuel. These fuels provide the propulsion power of
spacecraft and rockets.
 Figure.1 Cryogenic liquid vacuum storage tank

1.2 ADVANTAGES AND DISADVANTAGES OF CRYOGENIC GAS TANKS

Cryogenic gas tanks have some advantages and disadvantages that need to be considered
and determined depending on the area in which they will be used.

Table.1 Cryogenic tanks advantages and disadvantages

Advantages
High Energy Density: Liquefying gases
greatly reduces their volume. This provides
greater energy density in terms of storage
and transportation. Liquefaction of natural
gas (LNG), in particular, can be transported
over longer distances and takes up less
space.
Storage at Low Temperatures: Cryogenic
tanks have the ability to preserve liquid
gases at low temperatures. This feature is
important for use in industrial, medical and
research fields.
Disadvantages
High Energy Consumption: Storing and
maintaining cryogenic gases in liquid form
generally requires high energy consumption.
This can increase operational costs and lead
to environmental impacts.
Safety Risks: Cryogenic systems operating
at low temperatures and under high pressure
have safety risks. Situations such as gas
leaks and explosion risks can pose serious
dangers.
Various Application Areas: Cryogenic gas
tanks are used in many different areas, from
the energy sector to the healthcare industry.
The storage and transportation of liquefied
gases is vital for a variety of applications.
Rapid Cooling and Process Control:
Cryogenic technology provides rapid
cooling capability and may be advantageous
for process control in some industrial
processes.
Requires Maintenance and Expertise:
Maintenance of cryogenic systems requires
special training and expertise. Maintenance
and operation of such systems must be
carried out by expert technicians and
engineers.
Cost: Cryogenic tanks are costly because
they are made of special materials and must
withstand high pressure and low
temperatures.

1.3 CRYOGENIC TANK PROPERTIES

Cryogenic tanks have a number of features that make them stand out compared to other
alternative gas storage methods. These;

 High Insulation Capacity: Cryogenic tanks have high levels of insulation to maintain
the low temperature inside. This insulation minimizes heat transfer from the external
environment.

 Low Temperature Endurance: These tanks have the ability to operate at low
temperatures (usually below -150°C) and high pressure.

 Made from Special Materials: Cryogenic tanks are usually made from special alloy
steel or other durable materials. These materials must be resistant to low temperatures
and high pressure.

 Pressure and Capacity Diversity: Tanks can be produced in different pressures and
sizes depending on storage capacity and intended use. This provides flexibility for a
variety of industrial and medical applications.

 Special Valves and Connections: Cryogenic tanks have specially designed valves and
connections for the intake, evacuation and transfer of gases.

 Safety Features: These tanks include safety measures as they operate under high
pressure and low temperatures. Additionally, precautions must be taken against gas
leaks.

 Corrosion Resistance: Special coatings or materials can be used to prevent corrosion

on internal surfaces.
 Low Heat Transfer: Cryogenic tanks prevent heat transfer to the outside to ensure
that the liquefied gas inside is maintained at a low temperature.

1.4 CRYOGENIC TANKS COMPONENTS

Cryogenic tanks consist of various special components that require resistance to low
temperature and high-pressure conditions. The inner vessels of cryogenic tanks are the
innermost container where liquefied gas is stored. It is made of special materials such as
stainless steel, aluminum or other alloys that can withstand extremely low temperatures.
There is a layer surrounding the inner container called the outer vessel, which provides
structural support and acts as a secondary barrier for insulation. This outer layer is usually

made of durable materials and helps protect the inner container from external damage.
Annular space is filled with insulation material between the inner tank and the outer
vessel, which will minimize heat transfer and protect the low temperature environment
inside the tank. Common insulation materials include perlite, vacuum insulated panels,
foam insulation or multilayer insulation systems. For some larger tanks, pressure-
generating coils are mounted inside the tank. These coils help regulate and maintain the
pressure of the stored liquefied gas by allowing some of it to evaporate and increase the
pressure as needed. Cryogenic tanks are equipped with special valves, fittings and
connections designed to withstand extreme temperatures and pressures. These components
enable controlled filling, withdrawal and transfer of liquefied gas. Cryogenic tanks have a
variety of safety features such as relief valves, rupture discs, pressure relief devices and
emergency shutdown systems. These safety measures help prevent overpressure situations
and ensure safe operation, especially in emergency situations.
 1.5 COMMONLY USED MATERIALS IN CRYOGENIC TANKS

Cryogenic tanks are designed to withstand extremely low temperatures and high pressure
conditions associated with storing liquefied gases. Various materials are used in their
construction to ensure durability, strength, and resistance to these demanding conditions.
Some commonly used materials include:

Stainless Steel: Stainless steel, particularly grades that offer good low-temperature
toughness and resistance to corrosion, is a common material for cryogenic tanks due to its
durability and reliability.

Aluminum Alloys: Aluminum alloys are also used in cryogenic tanks due to their
lightweight nature and reasonable strength at low temperatures. These alloys are often
employed in inner tank structures.

Nickel Steel Alloys: Certain nickel-based alloys, such as Invar (an iron-nickel alloy),
possess low coefficients of thermal expansion, making them suitable for cryogenic
applications where dimensional stability is crucial.

Titanium: Titanium and its alloys exhibit excellent strength-to-weight ratios and corrosion
resistance, making them suitable for specific components or structures within cryogenic
tanks.

Composite Materials: Some modern cryogenic tanks might utilize advanced composite
materials that offer a combination of strength, lightness, and resistance to extreme
temperatures. These composites could be used for insulation or specific structural
components.

2. MATERIAL SELECTION PROCESS

The selection of materials for cryogenic gas vessels is a careful procedure that is critical
for guaranteeing safety, performance, and efficiency. It begins with determining the precise
cryogenic gas and operating conditions, followed by a thorough grasp of the appropriate
design norms and standards. Material qualities, such as low-temperature toughness and
corrosion resistance, must be evaluated, as well as weldability and simplicity of
manufacturing. Historical performance assessments give useful information, allowing for
more educated judgments. Calculating thermal insulation requirements and optimizing for
weight and cost, as well as investigating the potential use of composite materials, are critical
steps. Material compatibility testing ensures that there are no adverse reactions, and extensive
documentation, validation, and continuous improvement all contribute to a systematic
approach to selecting materials designed for cryogenic gas vessels, assuring their
dependability and integrity in specialized applications.
 2.1 DESIGNING OF CYROGENIC VESSELS

The thickness of the product vessel, diameter of the product vessel, thickness of the
outershell, diameter of the outershell, and thickness of the stiffners are all calculated factors.
These estimates are affected by the design codes used.

2.1.1 Design Codes

A design code is a document that establishes guidelines for the creation of a new
development. It is a tool for use in the design and planning processes. Pressure vessels are
designed and manufactured in accordance with certain standards and codes.They ensure
operational safety, quality control, and assurance. Pressure vessel manufacturers follow the
following codes:

ASME selection VIII division- I & II (American codes)

PD 5500 (British code)

AD Merkblatter (German code) and

IS 2825 (Indian code)

The underlying goals of the codes are the same, but their approaches are not. For distinct
codes in different countries, their raw material consumption, historical background, design,
and production varied. The characteristics and restrictions of codes are listed below.

ASME Section VIII Division-1: This code is essential for the safe and efficient design and
construction of pressure vessels. It includes thickness and stress calculation methods, as well
as design techniques. The thickness of the wall is calculated using particular assumptions to
ensure that it conforms with maximum permitted stresses, uniform stress distribution, and a
greater safety factor. The code sets constraints: pressure should not exceed 3000 Psi, vessels
with working pressures less than 15Psi have no size requirements, and vessels with a nominal
water capacity of 120 gallons or less and an internal diameter less than 6 inches have
particular limitations. ASME Section VIII Division-1 is a critical reference for pressure vessel
design that is industry-standard compliant, dependable, and efficient.

ASME Section VIII Division-2: This code takes a different approach, allowing for higher
permissible stresses in vessel design by taking into account lower safety factors. It is still
committed to assuring safety, good design, efficient manufacture, and strict quality control.
Notably, this regulation only applies to stationary vessels with no pressure restrictions.

PD 5500: This code specifies the standards for welded pressure vessels' design, construction,
inspection, and testing. It excludes vessels that have been exposed to directly produced heat or
flame impingement during the firing process. The pressure within the vessel must not exceed
140m bar above atmospheric pressure and must not go below 6m bar below atmospheric
pressure, according to the restrictions. Low-pressure vessels, single vertical axis of revolution,
multi-layer vessels, and transport pressure vessels are not covered by PD 5500.
AD Merkblatter: Compiled by a collaboration of seven trade groups in Germany, the AD
codes cover safety criteria critical for typical functioning settings. The successful design,
production, and operation of pressure vessels are required requirements. The AD Merkblatter
code is heavily influenced by DIN standards (German standards). Organized into many series,
each concentrating on a different component or issue of pressure vessel safety and
performance.

Series A Equipment Series B Design

Series C Fundamentals Series H Manufacture
Series HP Manufacturing and Testing Series N Nonmetallic Materials
Series S Special Cases Series W Metallic Materials

IS 2825: The IS 2825 code specifies the minimum construction criteria for the design,
fabrication, inspection, testing, and certification of welded unfired pressure vessels made of
ferrous and nonferrous metals. Certain exceptions apply, including vessels designed for
pressures exceeding 200 kgf/cm2 when the ratio of outside to inside diameter of the shell
exceeds 1.5, hot water supply storage tanks heated by steam or any other indirect means,
vessels with an internal operating pressure not exceeding 1 kgf/cm2 with nominated size, and
vessels with an internal diameter not exceeding 150 mm with no size limitation.

2.2 DESIGN CALCULATIONS

Several calculations of various variables are provided below.

2.2.1 Capacity Calculations

Net capacity Q1 = 65 m³
Vapour space provided in tank = 5% of capacity
Gross capacity of cold converter Q = net capacity + vapour space = 68.25 m³
Inner diameter of inner cylinder Di = 2698 mm
Radius of inner dished end ri =1350 mm
Volume of two dished ends Vd = 4/3 πri³ = 10.277 m³ – both = 5.138 m³ – each dished
ends volume of cylindrical shell = LD²π/4
Volume of cylindrical shell = gross capacity – volume of dished ends = 57.98 m³
From the above two equations

LD²π/4 = 57.98 m³
Length of cylindrical shell L (TL to TL) = 10.14 m
Height of the shell (HD²π/4) =59.85 m³
H = 10.473 m
Height of the liquid shell = height of shell – one dished end = 10.473 + 1.350 = 11.823 m³
Pressure due to static head= height of liquid × density of flu id/10 = 0.957 kg/cm²
Hence design pressure = working pressure × 1.1 + atmospheric pressure + pressure due to
static head = 18.5×1.1 + 1.0332 +0.957 = 22.3402 kg/cm²
2.2.2 Design of Inner Shell

Design of inner cylindrical shell (under internal pressure) thickness of shell (as per
ASME SEC VIII DIV 1)

T = PRi / (SE- 0.6P) + C.A + T. A

Where P = design pressure = 22.3402 kg/cm²
S = allowable stress = 1406.14 kg/cm²
Ri = radius of inner shell = 1350 mm
E = joint efficiency = 1
C.A = corrosion allowance = 0
T.A = thinning allowance = 0
Hence thickness T = 20.13 mm ≈ 20.2 mm
Adopted thickness = 20.2 mm

2.2.3 Design of Inner Dished Ends

Dished ends are of spherical type thickness of dished end is.

T = PRi / (2SE- 0.2P) + C.A + T.A

P = design pressure = 22.3402 kg/cm²
Ri = 1350.33 mm
S = 1406.14 kg/cm²
C.A = 0
T.A = 1
Hence thickness of inner dished end Td = 11.74 mm ≈ 12 mm
Adopted thickness Td = 12 mm

2.2.4 Inner cylindrical shell design (under external pressure)

External diameter Do = 2698+ (2×20.2) = 2738.4 mm

Thickness of inner shell t =20 .2mm
Length of inner cylindrical shell = 10140.23 mm
Effective length L = 10140.23 + 2(rd/3) Where rd = radius = 1350 mm
L = 11040.23 mm
Do/t = 135.564
From ASME SEC VIII DIV 1

From graph factor A = 0.00008

Since the graph (HA- 1) is falls on left side
Pressure Pa = 2AE / 3(Do/t) = 5.34 psi
External pressure P=atmospheric pressure = 15 psi
Since Pa < P the design is not safe, so we use stiffener rings

2.2.5 Design of outer cylindrical shell design (under external pressure)

SA 516 TP 70 carbon steel is used.

 Inner diameter of outer cylindrical shell = 3050 mm
Thickness of outer cylindrical shell = 20.2 mm
Outer diameter of outer cylindrical shell Do= 3074 mm
Corrosion allowance C.A = 3.0
Effective length L =1240.23 mm
L/Do = 3.65
Do/t = 152.1782
From ASME SEC VIII DIV 1

From graph factor A = 0.00009

Because the graph is tilted to the left, the factor 'B' value cannot be obtained.
Pressure Pa = 2AE / 3(Do/t) = = 9.448 psi
External pressure P= 15 psi
Because Pa P, the adopter dimensions are insufficient to withstand external pressure. We must
provide stiffener rings on the external cylindrical shell for this purpose.

2.2.6 Stiffener ring calculations under external pressure,

Inner shell

Provide two stiffener rings, resulting in three equal spaces

Outside diameter of cylindrical shell Do = 2722 mm

Provided thickness t = 20.2 mm
Corrosion allowance C.A = 0
Length between stiffener rings Ls =3680.076mm
(Assuming 2 stiffener rings)
L/Do = 1.35
Do/t = 137
From ASME SEC VIII DIV 1

From graph factor A = 0.00023

From graph factor B = 3000
Pressure Pa = 4B / 3(Do/t) , Pa = 29.684 psi
External pressure P = 15 psi

Because Pa > P, the adopted dimensions are insufficient to withstand external pressure. As a
result, our design is secure.

Outer Shell

Outside diameter of cylindrical shell Do =3074 mm

Provided thickness t = 20.2 mm
Corrosion allowance C.A = 3 mm
Length between stiffener rings Ls = 3740 mm
L/Do = 1.218
Do/t = 152.17
From ASME SEC VIII DIV 1
 From graph factor A = 0.00025
From graph factor B = 3400
Pressure Pa = 4B / 3(Do/t) = 29.79 psi
External pressure P = 15 psi

Because Pa > P, the adopted dimensions are insufficient to withstand external pressure. As a
result, our design is secure.The vessel is designed under these geometry conditions.Some
dimensions are calculated, some are assumed, and some are derived from design standard
codes and graphs.

3. CRYOGENIC MATERIALS

Austenitic steels, stainless steels, fine grain double normalized and tempered nickel steels,
copper, and aluminum are excellent cryogenic temperature resistant materials.

3.1 Stainless steels

Austenitic stainless steels are ideal for cryogenic applications because they remain tough
and ductile at temperatures as low as -269°C.

3.2 9% Nickel steels

9% nickel steels are typically classified as ferrite steels, but they also include austenitic
ferrite and magnetite. Austenitic has provided excellent strength and resistance to brittle
fracture. At -200°C, the decrease in ductility with decreasing temperature below zero is
very gradual, with chirpy v notch values exceeding 25 Ft lbs (346 or 4.4 kg/cm2).In terms
of fabrication, its proven safety and low cost have led to its widespread use in cryogenic
equipment for storing and transporting liquefied gases such as nitrogen, methane, and
ethylene.

Extensive tests on tanks filled with liquid nitrogen have shown that quenching and
tempering, as well as post-weld treatment, are not beneficial. The ASME code states that
heat treatment up to and including 2 inches thickness (about 50mm) is not required.

3.3 Aluminium alloys

Aluminium alloys like 5083 (Mg 0.445%, Mn 0.6%, and Cr 0.15%) and 6003 (Mn 1.26%,
Cu 0.12%, and Cr 0.15%) are used to make cryogenic storage vessels, columns in air
separation plants, and brazed aluminum heat exchangers. Even at liquid helium
temperatures of -269°C, these show no ductile to brittle transformation. Because the
toughness properties of aluminum are well known, it was not thought necessary to specify
 a minimum value in ASME or ASTM codes. The notch yield ratio, tear resistance, and
critical stress intensity are all high. The fatigue strength increases as the temperature drops.

3.4 Copper alloys

Copper alloys such as alpha brass and phosphorous-dioxide, copper were simple materials
to fabricate for cryogenic equipment. Copper tubes are still used for trays in small air
separation plants today. Copper has a low yield strength when annealed. Copper alloys
have lower yield strength than steel and are not affected by temperature changes.

RESULTS AND DISCUSSION

SUMMARY AND CONCLUDING REMARKS

In summary, this report focuses on the design, analysis and material selection process of
cryogenic gas tanks. Cryogenic gas tanks are containers used to handle liquids that are
compressible, have highly toxic properties and operate at extremely high pressures. There are
many parameters in the design of these tanks. These design parameters include material
durability, temperature tolerance, pressure resistance, resistance to cracking and other physical
properties. These properties should be selected taking into account how cryogenic liquids
behave at low temperatures and under high pressure.

The report examines the design parameters of cryogenic gas tanks, highlighting that these
tanks comply with the necessary standards to ensure safe storage and handling processes. This
design and analysis plays an important role in meeting industrial safety standards.

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REFERENCES