Thermo-Mechanical Behavior of Polymer-Sealed Dual-Cavern Hydrogen Storage in Heterogeneous Rock Masses

Underground hydrogen storage (UHS) in geological formations offers a promising solution for large-scale energy buffering, but its long-term safety and mechanical stability remain concerns, particularly in fractured rock environments. This study develops a fully coupled thermo-mechanical model to investigate the cyclic response of a dual-cavern hydrogen storage system with polymer-based sealing layers. The model incorporates non-isothermal gas behavior, rock heterogeneity via a Weibull distribution, and fracture networks represented through stochastic geometry. Two operational scenarios, single-cavern and dual-cavern cycling, are simulated to evaluate stress evolution, displacement, and inter-cavity interaction under repeated pressurization. Results reveal that simultaneous operation of adjacent caverns amplifies tensile and compressive stress concentrations, especially in inter-cavity rock bridges (i.e., the intact rock zones separating adjacent caverns) and fracture-dense zones. Polymer sealing layers remain under compressive stress but exhibit increased residual deformation under cyclic loading. Contour analyses further show that fracture orientation and spatial distribution significantly influence stress redistribution and deformation localization. The findings highlight the importance of considering thermo-mechanical coupling and rock fracture mechanics in the design and operation of multicavity UHS systems. This modeling framework provides a robust tool for evaluating storage performance and informing safe deployment in complex geological environments.