RESEARCH ON THE DESIGN AND PRODUCTION OF TYPE IV COMPOSITE LPG CYLINDERS AND HOW THEY CAN BE IMPROVED
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Abstract
This study investigates the technology employed in the production of Type 4 Liquefied
Petroleum Gas (LPG) composite cylinders and explores potential improvements to enhance
their performance, safety, and cost-effectiveness. Type 4 cylinders, composed of a polymer
liner fully wrapped with fiber-reinforced composites, represent the most advanced generation
of LPG storage vessels due to their lightweight structure, corrosion resistance, and superior
burst strength.
Data for the research were obtained through field observations at Don Mac Limited, review of
standard operating procedures (SOPs), and engineering simulations. The study analyzed
each stage of the production process—from liner molding and surface preparation to filament
winding, curing, testing, and inspection—based on ISO 11119-3 and EN 12245 standards.
Simulation results revealed that substituting high-density polyethylene (HDPE) liners with
polyamide (PA11) and E-glass fibers with hybrid carbon–glass reinforcements increased
burst pressure from 50 bar to 70 bar while maintaining a high factor of safety.
Identified challenges include high material costs, liner gas permeability, and limited local
production capacity. To address these, the research proposes the adoption of nano-filled
epoxy resins, automated filament winding systems, and locally sourced highperformance polymers to optimize strength and reduce cost. These improvements will
advance the development of composite cylinder manufacturing in Nigeria, enabling safer,
lighter, and more sustainable LPG storage solutions
Petroleum Gas (LPG) composite cylinders and explores potential improvements to enhance
their performance, safety, and cost-effectiveness. Type 4 cylinders, composed of a polymer
liner fully wrapped with fiber-reinforced composites, represent the most advanced generation
of LPG storage vessels due to their lightweight structure, corrosion resistance, and superior
burst strength.
Data for the research were obtained through field observations at Don Mac Limited, review of
standard operating procedures (SOPs), and engineering simulations. The study analyzed
each stage of the production process—from liner molding and surface preparation to filament
winding, curing, testing, and inspection—based on ISO 11119-3 and EN 12245 standards.
Simulation results revealed that substituting high-density polyethylene (HDPE) liners with
polyamide (PA11) and E-glass fibers with hybrid carbon–glass reinforcements increased
burst pressure from 50 bar to 70 bar while maintaining a high factor of safety.
Identified challenges include high material costs, liner gas permeability, and limited local
production capacity. To address these, the research proposes the adoption of nano-filled
epoxy resins, automated filament winding systems, and locally sourced highperformance polymers to optimize strength and reduce cost. These improvements will
advance the development of composite cylinder manufacturing in Nigeria, enabling safer,
lighter, and more sustainable LPG storage solutions
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