Hydrogen tank leaks threaten fuel supply, study suggests fixes

A recent study by researchers at Washington State University addresses the significant challenge of hydrogen fuel loss due to evaporation in liquid hydrogen storage tanks. Liquid hydrogen, favored for industrial use and clean energy applications, must be kept at extremely low temperatures, but even brief exposure to air causes rapid evaporation, leading to substantial fuel losses. The team developed an efficient mathematical model that simulates tank behavior over extended periods, enabling operators to identify conditions that trigger hydrogen boil-off and adjust operational parameters accordingly. For example, by simply modifying the pressure limits of relief valves during hydrogen transfer, the researchers demonstrated a 26% reduction in fuel loss, highlighting that straightforward operational tweaks can yield major efficiency improvements. This advancement holds considerable real-world implications, especially for companies like Plug Power, which operates hundreds of liquid hydrogen tanks fueling tens of thousands of forklifts critical to supply chains. Even small efficiency gains at this scale can translate into significant cost savings and reduced emissions. The new model, calibrated with real-world data and capable of simulating hundreds of