Hydrogen at Scale: Liquid Hydrogen Systems and Vacuum Technology from Aerospace to Industry July 30, 2025
10 MIN READ
Table of content
1. Aerospace: The Origin of Modern Hydrogen Systems
2. Real-World Adoption in Industry and Transport
3. Why Liquid Hydrogen? Performance and Storage Density
4. Cryogenic System Design: Challenges and Innovations
5. Unlock the Full Insights
Liquid Hydrogen Systems and the Role of Vacuum Jackets
As the world accelerates its transition to cleaner energy, hydrogen—particularly in its liquid form—is stepping into the spotlight. Far from being an experimental technology, liquid hydrogen (LH₂) has a long, proven track record, especially in aerospace. Now, that legacy is powering a new wave of industrial and transportation applications that demand high energy density, safety, and scalability.
Aerospace: The Origin of Modern Hydrogen Systems
The U.S. Department of Energy (DOE) has designated hydrogen as a critical element of the energy transition. But long before the term “energy transition” was coined, hydrogen had already made its mark.
- 1930s–1950s: Early use of hydrogen in jet engine research.
- 1960s: NASA’s Centaur upper stage became the first space vehicle powered by liquid hydrogen and liquid oxygen (LOX), offering unmatched thrust-to-weight performance.
- Apollo missions & Space Shuttle era: Hydrogen powered main engines, while hydrogen fuel cells generated electricity, potable water, and heat.
This aerospace use wasn’t just theoretical—it involved large-scale production, transport, storage, and handling of cryogenic hydrogen, establishing engineering standards and safety practices that the world is now leveraging.
Real-World Adoption in Industry and Transport
Hydrogen is already integrated into several industries, not just as a fuel but also as a process enabler:
- Industrial use: Hydrogen plays a vital role in steel production (as a reducing agent), semiconductor manufacturing, and chemical synthesis.
- Mobility: LH₂ is gaining traction in sectors where battery electric options face range, weight, or refueling limitations.
Real examples include:
- Heavy-duty trucking: Daimler’s GenH2 trucks and Hyundai’s XCIENT Fuel Cell.
- Mining: Anglo American’s hydrogen-powered haul trucks.
- Maritime: Norway’s MF Hydra ferry (LH₂ powered) and Kawasaki’s Suiso Frontier (LH₂ carrier).
- Aviation: Airbus’s ZEROe program, Rolls-Royce and Linde’s cryogenic test flights, and ZeroAvia’s LH₂ propulsion systems.
These deployments underscore a clear message: liquid hydrogen is viable today, not decades away.
Why Liquid Hydrogen? Performance and Storage Density
While gaseous hydrogen is easier to handle at small scales, liquid hydrogen is preferred when volume efficiency and mass-specific energy are crucial.
- Energy density: LH₂ has ~2.4 times the energy per unit mass compared to compressed hydrogen.
- Storage efficiency: Liquid storage allows for smaller, lighter tanks—a major advantage for mobility and aerospace.
However, these benefits come with complexity. Hydrogen becomes a liquid at –253°C and must be stored at low pressure in highly insulated systems to prevent boil-off and pressure buildup.
Cryogenic System Design: Challenges and Innovations
Designing systems for LH₂ storage and transport involves multiple interlocking disciplines:
- Vacuum-jacketed insulation: Most LH₂ tanks use a double-wall design with high vacuum and multilayer insulation (MLI) to reduce thermal conductivity.
- Thermal modeling: Engineers must predict heat ingress and manage pressure rise due to evaporation (boil-off gas or BOG).
- Structural design: The outer tank is built to resist atmospheric pressure trying to crush the inner vacuum.
- Ventilation and safety: Proper purging, ventilation, and sensor placement are critical for leak detection and ignition prevention.
- Material selection: Hydrogen embrittlement, thermal contraction, and low-temperature behavior must be considered when choosing materials (e.g., stainless steel, aluminum alloys, composites).
- Refueling infrastructure: Hydrogen requires advanced interfaces for cryogenic transfer, vapor management, and system cooldown, all while maintaining safety.
Unlock the Full Insights
This article provides a high-level view of what was covered in our expert webinar:
“Liquid Hydrogen Systems and Role of Vacuum Jackets.”
In the full session, we explore:
- Engineering design principles for LH₂ storage
- Lessons from decades of NASA and commercial aerospace use
- Case studies from maritime, aviation, and industry
- Practical safety measures and real-world implementation
- Future outlook: mobility, hydrogen hubs, and global infrastructure
