ignore quantum tunnelling and ignore the massive predictive value of Quantum theory
Don't know much about quantum tunneling other than it is thought to be related to superconductivity. Mills discusses how superconductivity arises classically and produces equations for the transition thresholds for high temperature superconductors (see Eq 25-45). So I don't agree with your claim that he has ignored quantum tunneling.
With regard to predictive value of QM - can I assume you are referring to the calculation of the anomalous electron dipole moment? Yes, QM/QFT produces a very accurate figure. However, when I go through the derivation, it seems less than convincing and depending on who's calculation you choose, can involve thousands of non-physical constants. In contrast, Mills produces the following equation which arises from first principles and the Poynting Power Theorem has the same 11 figures of accuracy:
g/2 = 1 + alpha/2pi + (2/3)*alpha^2*(alpha/2pi) - (4/3)*(alpha/2pi)^2
(where alpha^1 = 137.03604 from CRC)
So in terms of predictive powers, I would side with Mills in this example.
Again, as I mentioned to markie, the effects Mills claims to predict are SO much more energetic than any known chemical or nuclear effects, and are so easy to achieve that the universe should shine with an amount of energy we could not possibly explain. In fact, given Mills' water catalyist idea for liquid silver, and the fact that the mid atlantic rift effortlessly reproduces those conditions, according to Mills our oceans should not exist.
If on the other hand the hydrino reaction is lost in barely detectable energy levels as you claim here, his energy machine is doomed from the start as it will never produce measurable amounts of energy. So which is it?
This is not my understanding. The hydrino reaction (lets take the standard H -> H[1/4] one associated with HOH catalyst), produces 204 eV per hydrino, which is roughly 200 times the equivalent energy you get from burning gasoline. Nuclear reactions are in the MeV range. Hydrino reactions are intermediate between chemical and nuclear reactions, not more powerful than nuclear as you claim.
But that does not explain why the magical hydrino orbital is not found in any other element. So again, his theory un-explains current explanations but gives nothing better.
I think you may be mistaken here about hydrinos and the orbitsphere. Under GUTCP, whenever the electron is bound in a stable orbit to a nucleus, the orbit can be described as an orbitsphere. That applies to regular hydrogen, helium, and all the way up, as well as when the hydrogen is shrunk into a hydrino. The same math and force balance equations are used in both situations. Each electron in a multi-electron atom has it's own orbitsphere. If you study the periodic chart, there are some diagrams that show how the different orbital (s, p, d, f) are expressed as orbitspheres but modulated with spherical harmonics. There nothing magical about above ground and below ground states - Mills still uses the orbitsphere to describe the orbit in all of them.