ITM Power
Hydrogen Buffer Vessel

As the world seeks alternatives to fossil fuels, hydrogen is emerging as a clean energy solution with the potential to transform transport and power generation. Automotive leaders such as Honda and Toyota are investing in hydrogen-powered vehicles, while governments and universities are funding the development of hydrogen refuelling infrastructure.

LTi Metaltech partnered with ITM Power, a clean energy storage specialist, to manufacture a hydrogen pressure vessel prototype. This vessel was delivered to Keele University as part of a UK programme to test hydrogen refuelling systems for next-generation vehicles.

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The Challenge

The buffer tank had to meet ITM Power’s detailed Product Design Specification (PDS), covering:

  • The ability to withstand high internal pressures.

  • Performance across varying temperature ranges.

  • A design suitable for controlled university-led testing.

Material selection was also key. At the time, carbon steel tanks were commonly used, but they were prone to oxidisation and corrosion. For hydrogen applications, this raised safety and durability concerns. LTi was tasked with finding a more reliable, corrosion-resistant solution that would still be cost-effective to manufacture.

How LTi went about it

LTi’s engineers drew on extensive experience in pressure vessel fabrication to design and manufacture the buffer tank:

  • Material Innovation – Replaced carbon steel with stainless steel, improving corrosion resistance and reducing maintenance risks.

  • Advanced Forming – Used waterjet cutting, edge rolling, and plate rolling to achieve the precise dimensions required.

  • CAD Modelling & Simulation – Designed and digitally tested the tank to confirm its ability to handle operational stresses over its intended service life.

  • Independent Review – Engaged external assessors to validate compliance with EN 13445 European Pressure Vessel Standards.

This process ensured the tank could safely handle the extreme demands of hydrogen storage and refuelling system testing.

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What was the outcome?

LTi Metaltech successfully delivered a hydrogen buffer tank prototype that was:

  • Compliant with EN 13445 pressure vessel standards.

  • Fabricated in stainless steel to avoid corrosion issues associated with carbon steel.

  • Delivered to Keele University, supporting ITM Power’s testing of hydrogen storage and refuelling technologies.

Although developed for research rather than commercial rollout, the project highlighted LTi’s ability to adapt its expertise in high-integrity pressure systems to support emerging clean energy applications.