Large-scale underground hydrogen storage is expected to play an important role in balancing variable renewable energy supply and future hydrogen demand. In regions dominated by hard rock, lined rock caverns (LRCs) provide a potential storage solution. Repurposing existing underground oil storage caverns could further reduce the need for new excavation; however, these caverns were not originally designed for high-pressure gas storage and commonly have shallow cover and elongated geometries that differ substantially from conventional LRCs. This thesis investigates the feasibility and key engineering considerations of converting such oil storage caverns into LRCs for underground hydrogen storage.
The research is developed through three interconnected numerical studies. The first provides a geological foundation by investigating how in-situ stress and rock mass discontinuities influence anisotropic cavern deformation during excavation. The results demonstrate that joint orientation and stiffness can substantially modify both the magnitude and spatial distribution of cavern deformation, highlighting the importance of geological structures in assessing existing caverns. The second study serves as a pilot geometric-design investigation, examining the effects of cavern-bottom geometry and sliding layer stiffness on steel liner stress and interface displacement. Smoother bottom transitions generally reduce local liner demand, particularly when interface restraint is high, although reductions in stress and interface displacement do not necessarily coincide. These two studies provide geological and geometric understanding for the central investigation of oil-cavern repurposing.
Building on these preliminary studies, the main investigation evaluates two concepts for converting shallow, elongated oil storage caverns into hydrogen-storage LRCs: a Multi-cavern scheme, in which the existing excavation is divided into multiple lined sub-caverns, and a Single-cavern scheme, in which one continuous lined volume occupies the existing cavern. A modified uplift failure model is used to obtain a preliminary maximum operating gas pressure estimate, after which numerical analyses evaluate liner stress, yielding of the concrete and surrounding rock, storage capacity, material demand, and sensitivity to key geological and design parameters. Short-term cyclic thermo-mechanical analyses are additionally performed to examine the implications of hydrogen injection and withdrawal.
The results reveal a clear trade-off between structural performance and storage/material efficiency. At the benchmark pressure of 3.3 MPa, the Multi-cavern scheme reduces the maximum steel liner tensile stress from 32.4 MPa to 25.4 MPa and has a total plastic-zone volume approximately 18% of that of the Single-cavern scheme. In contrast, the Single-cavern scheme provides approximately twice the effective gas-storage volume and a substantially lower indicative material cost per unit mass of stored hydrogen. Rock mass quality strongly influences structural response, demonstrating the importance of geological conditions in retrofit assessment. The cyclic analyses further show that static loading at the maximum operating gas pressure does not conservatively bound all response quantities: compared with the cyclic cases examined, it produces higher steel liner stress and concrete yielding but lower rock mass and total yielding.
Overall, the thesis demonstrates that repurposing existing oil storage caverns using LRC technology is a technically promising option, but that retrofit feasibility cannot be assessed from storage volume or pressure capacity alone. Geological conditions, LRC geometry, global uplift resistance, liner response, material demand, and operational loading need to be considered together. The work establishes a preliminary assessment framework and identifies the principal issues requiring further development toward project-specific design. In particular, the continuing PhD research will extend the geological investigation to construction and pressurized operational stages and develop more detailed performance-based and coupled analyses for shallow LRC hydrogen storage.