The global transition away from fossil fuels is one of the most pressing challenges of our time, with the civil aviation industry identified as the second-largest source of transport-related greenhouse gas emissions. Emissions from aviation could potentially triple by 2050, prompting efforts to develop liquid hydrogen (LH2)-powered aircraft as part of the sector’s ambition to achieve net-zero emissions by mid-century. A critical barrier to the adoption of LH2 aviation is the readiness and cost of the supporting infrastructure, particularly storage facilities at airports.

This research addresses the design, cost, and optimization of LH2 storage facilities, focusing on reducing uncertainties in cost estimates while ensuring operational feasibility. The study begins with a comprehensive literature review of LH2 supply chain technologies and associated levelized costs, which revealed significant knowledge gaps and high variability in cost estimates for on-site LH2 storage facilities, exceeding a factor of 200. Expert interviews complemented the literature review, providing updated insights and validation for realistic assumptions in cost modeling.

A case study was conducted for Rotterdam The Hague Airport (RTHA) in 2040, evaluating three storage tank types: trailer, cylindrical, and spherical. Storage facilities were sized to accommodate three days of peak LH2 demand, estimated at 120 tonnes. The cost model calculated levelized costs, capital expenditure (CAPEX), and land footprint for each tank configuration. Large spherical tanks emerged as the most cost-effective solution, offering the lowest levelized cost (€1.22/kg LH2), smallest land usage (598 m²), and moderate upfront investment (€18.1M). However, the analysis highlighted the importance of modularity and adaptability to prevent oversizing, which could lead to significant increases in levelized costs.

Sensitivity analyses identified key cost drivers, including facility usage, tank CAPEX, pump CAPEX, boil-off losses, and LH2 procurement costs. Strategies for cost reduction include modular designs to optimize facility utilization, CAPEX reduction through batch production or technological improvements, and recovery or utilization of boil-off gas. Storage topology recommendations were derived: trailer tanks are optimal for capacities under 30 tonnes due to modularity and low initial investment despite higher levelized costs; cylindrical tanks suit 30–100 tonnes, balancing cost, land use, and modularity; and spherical tanks are preferred for capacities exceeding 100 tonnes, achieving the lowest cost and land footprint while maintaining scalability.

This study significantly reduced the uncertainty in LH2 storage cost estimates from a factor of over 200 to less than 20, providing a systematic and data-driven framework for facility design and cost assessment. The research contributes practical guidance for airport planners, policymakers, and industry stakeholders, supporting the transition to hydrogen-powered aviation by ensuring economically feasible and technically robust storage solutions. ... Read more