Multiphysical Coupling Analysis of Sealing Performance of Underground Lined Caverns for Hydrogen Storage

The accurate analysis of the sealing performance of underground lined cavern hydrogen storage is critical for enhancing the stability and economic viability of storage facilities. This study conducts an innovative investigation into hydrogen leakage behavior by developing a multiphysical coupled model for a composite system of support structures and surrounding rock in the operation process. By integrating Fick’s first law with the steady-state gas permeation equation, the gas leakage rates of stainless steel and polymer sealing layers are quantified, respectively. The Arrhenius equation is employed to characterize the effects of temperature on hydrogen permeability and the evolution of gas permeability. Thermalmechanical coupled effects across different materials within the storage system are further considered to accurately capture the hydrogen leakage process. The reliability of the established model is validated against analytical solutions and operational data from a real underground compressed air storage facility. The applicability of four materials— stainless steel, epoxy resin (EP), ethylene–vinyl alcohol copolymer (EVOH), and polyimide (PI)—as sealing layers in underground hydrogen storage caverns is evaluated, and the influences of four operational parameters (initial temperature, initial pressure, hydrogen injection temperature, and injection–production rate) on sealing layer performance are also systematically investigated. The results indicate that all four materials satisfy the required sealing performance standards, with stainless steel and EP demonstrating superior sealing performance. The initial temperature of the storage and the injection temperature of hydrogen significantly affect the circumferential stress in the sealing layer—a 10 K increase in initial temperature leads to an 11% rise in circumferential stress, while a 10 K increase in injection temperature results in a 10% increase. In addition, the initial storage pressure and the hydrogen injection rate exhibit a considerable influence on airtightness—a 1 MPa increase in initial pressure raises the leakage rate by 11%, and a 20 kg/s increase in injection rate leads to a 12% increase in leakage. This study provides a theoretical foundation for sealing material selection and parameter optimization in practical engineering applications of underground lined caverns for hydrogen storage.