Hydride Flow Reactor for On-Demand Hydrogen Without High-Pressure Tanks

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Solution Overview

Problem

Hydrogen storage remains a challenge, limiting the scalability and design flexibility of hydrogen fuel cell systems, particularly in medium and small scales, due to the high weight and space requirements of existing high-pressure storage methods.

Innovation Solution

A hydride flow reactor that converts metastable hydride fuels like lithium aluminum hydride into hydrogen gas on demand using a tubular member, auger, and heater system, allowing for efficient production of hydrogen gas without high-pressure storage tanks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If high-pressure hydrogen storage tanks are used, then hydrogen storage capacity is improved, but system weight and volume increase significantly

Engineering Contradiction:

Improvehydrogen storage capacityVSAvoidsystem weight

Core Design Contradiction:

Quantity of substanceVSWeight of moving object

Solution Approach 1:

The invention changes the storage parameter from high-pressure gaseous hydrogen to solid-state hydride materials. The hydride flow reactor converts solid hydride fuels (like lithium aluminum hydride) into hydrogen gas on-demand through controlled thermal decomposition, eliminating the need for high-pressure storage tanks while achieving higher specific energy densities up to 1500 Wh/kg

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system utilizes phase transition of hydride materials from solid to gas state through controlled heating. The heater converts solid hydride fuel into hydrogen gas and solid byproducts, providing a lightweight hydrogen supply solution that transitions from solid storage to gaseous delivery without requiring high-pressure containment

Inventive Principle:

Principle #36Phase transitions

2Quantity of substance

If high-pressure hydrogen storage tanks are used, then hydrogen storage capacity is improved, but system volume increases

Engineering Contradiction:

Improvehydrogen storage capacityVSAvoidsystem volume

Core Design Contradiction:

Quantity of substanceVSVolume of moving object

Solution Approach 1:

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system uses composite hydride materials such as lithium aluminum hydride that provide high hydrogen content in a compact solid form. The tubular reactor design with integrated heating and auger transport creates a space-efficient system that converts solid hydride to gas without requiring large high-pressure vessel volumes

Inventive Principle:

Principle #40Composite materials

3Use of energy by moving object

If metastable hydride fuels are used, then specific energy is improved, but thermal stability decreases

Engineering Contradiction:

Improvespecific energyVSAvoidthermal stability

Core Design Contradiction:

Use of energy by moving objectVSStability of the object's composition

Solution Approach 1:

The system dynamically controls the thermal decomposition process through regulated heating in the tubular reactor. The auger transport mechanism continuously moves hydride material through the heated zone, controlling the rate of decomposition and hydrogen generation. This dynamic control allows the system to utilize the high specific energy of metastable hydrides (up to 1500 Wh/kg) while managing thermal stability through controlled residence time and heating rate

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The continuous flow reactor design maintains steady-state operation with continuous feeding, heating, and discharge of reaction products. This continuous action prevents thermal runaway by maintaining controlled conditions throughout the decomposition process, allowing efficient utilization of metastable hydride energy content

Inventive Principle:

Principle #20Continuity of useful action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The reactor achieves specific energies up to 1500 Wh/kg, providing a lightweight and efficient hydrogen supply for vehicles, including electric and hybrid-electric vehicles, and other applications.

Implementation Method 1

heating a reaction zone within the tubular member using a heater to convert the hydride fuel into hydrogen gas and a reacted byproduct

Methodology Applied

Scientific EffectThermal decomposition: Pyrolysis

Implementation Method 2

moving the hydride fuel within the tubular member using an auger positioned within the tubular member

Methodology Applied

Scientific EffectMechanical conveyance: Archimedes Screw

Data Source

PatentEP4026798B1Solid hydride flow reactor

Publication Date: 2025.06.25 THE BOEING CO

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AI summary

A hydride flow reactor includes a tank configured to receive a hydride fuel. The reactor also includes a tubular member coupled to the tank and configured to receive the hydride fuel from the tank. The reactor also includes a transporter positioned at least partially within the tubular member and configured to transport the hydride fuel through the tubular member. The reactor also includes a heater positioned at least partially around the tubular member and the transporter. The heater is configured to heat the hydride fuel in the tubular member to convert the hydride fuel into hydrogen gas and a reacted byproduct.