Hydrogen is emerging as one of the most promising energy carriers for a decarbonised global energy system. Transportation and storage of hydrogen are critical to its large-scale adoption and to these ends liquid hydrogen is being widely considered. The liquefaction and storage processes must, however, be both safe and efficient for liquid hydrogen to be viable as an energy carrier. Identifying the most promising liquefaction processes and associated transport and storage technologies is therefore crucial; these need to be considered in terms of a range of interconnected parameters ranging from energy consumption and appropriate materials usage to considerations of unique liquid-hydrogen physics (in the form of ortho–para hydrogen conversion) and boil-off gas handling. This study presents the current state of liquid hydrogen technology across the entire value chain whilst detailing both the relevant underpinning science (e.g. the quantum behaviour of hydrogen at cryogenic temperatures) and current liquefaction process routes including relevant unit operation design and efficiency. Cognisant of the challenges associated with a projected hydrogen liquefaction plant capacity scale-up from the current 32 tonnes per day to greater than 100 tonnes per day to meet projected hydrogen demand, this study also reflects on the next-generation of liquid-hydrogen technologies and the scientific research and development priorities needed to enable them.

A model has been developed and implemented in the software package BoilFAST that allows for reliable calculations of the self-pressurization and boil-off losses for liquid hydrogen in different tank geometries and thermal insulation systems. The model accounts for the heat transfer from the vapor to the liquid phase, incorporates realistic heat transfer mechanisms, and uses reference equations of state to calculate thermodynamic properties. The model is validated by testing against a variety of scenarios using multiple sets of industrially relevant data for liquid hydrogen (LH2), including self-pressurization and densification data obtained from an LH₂ storage tank at NASA’s Kennedy Space Centre. The model exhibits excellent agreement with experimental and industrial data across a range of simulated conditions, including zero boil-off in microgravity environments, self-pressurization of a stored mass of LH₂, and boil-off from a previously pressurized tank as it is being relieved of vapor.