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(LLNL, Calif., U.S.) and Verne (San Francisco, Calif., U.S.) has recently demonstrated a novel pathway for creating high-density hydrogen through a research program funded by the Department of Energy’s (DOE’s) ARPA-E. The demonstration validated that it is possible to efficiently reach cryo-compressed hydrogen (CcH₂) conditions with liquid hydrogen-like density directly from a source of gaseous hydrogen — substantially reducing the energy input required compared to methods that rely on energy-intensive hydrogen liquefaction.

According to Verne, the energy density of hydrogen on a mass basis is very high. However, at ambient conditions, gaseous hydrogen requires more volume to store an equivalent amount of energy as competing forms of energy storage.

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To reduce the storage volume required, densification of hydrogen is typically accomplished using gas compression or liquefaction. As a result, the hydrogen supply chain has been hindered by a trade-off between compressed gaseous hydrogen — which is cheap to produce, but low in density — and liquid hydrogen — which is high in density, but expensive to densify (via liquefaction). This has led to expensive distribution costs that have limited the adoption of hydrogen solutions.

Verne and LLNL’s work with CcH₂ has demonstrated a pathway that uses both compression and cooling at the same time, each to a lesser degree than when used independently. Moreover, it has validated that this type of hydrogen has the potential to break this trade-off by creating high-density hydrogen without requiring the significant energy inputs required of hydrogen liquefaction.

“This demonstration confirms that CcH₂ can break the current trade-off between density and cost,” says Ted McKlveen, co-founder and CEO of Verne. “Providing a low-cost way to reach high densities will bring down the cost of delivering and using hydrogen, opening up a host of applications for hydrogen across some of the most demanding sectors of the economy from construction to ports to warehouses.

In addition to energy savings, this densification pathway is more modular than hydrogen liquefaction.

CcH₂ was originally investigated at LLNL in the late 1990s by Salvador Aceves, who demonstrated its benefits with his team through thermodynamic modeling and built three generations of tanks.

After its founding at Stanford University in 2020 to explore hydrogen applications in heavy industry, the Verne team began researching CcH₂ and signed Aceves (then retired from LLNL) as a technical adviser.

Verne began working with LLNL in 2021 through a Strategic Partnership Project to test Verne’s tanks at LLNL’s cryogenic hydrogen fueling facility. Collaborations progressed through two cooperative research and development agreements in 2023-2024 facilitated by LLNL’s Innovation and Partnerships Office (IPO). This collaboration has provided Verne with access to the facilities and expertise required to rapidly test and develop its technology.

“Adoption of hydrogen is currently inhibited by its high cost,” says Nick Killingsworth, LLNL principal investigator and mechanical engineer. “The sum of this work demonstrates a promising path to reduce the cost and energy associated with its storage and transportation.”

In 2023, LLNL and Verne announced a record for CcH₂ storage — more than tripling previous records. Verne believes that the densification and hydrogen storage breakthroughs enable 40% cheaper hydrogen distribution costs relative to existing technologies.

The novel hydrogen densification pathway that LLNL and Verne most recently demonstrated produced CcH₂ without requiring a phase change, leading to 50% energy savings relative to small-scale hydrogen liquefaction. Conversion of hydrogen to 81 K (-314°F) and 350 bar (one bar is equivalent to atmospheric pressure at sea level) and densities greater than 60 grams per liter were achieved using a catalyst-filled heat exchanger.

In addition to energy savings, this densification pathway is more modular than hydrogen liquefaction. While hydrogen liquefaction typically requires construction of large, centralized facilities, cryo-compression can be efficiently built at small scale. This means that the hydrogen distribution network can be further optimized, locating densification and distribution hubs closer to the points of use.