Fuel Cells in the Aircraft Industry: Concepts and

Development Progress
K.A. Friedrich, J. Kallo, J. Schirmer, G. Schmithals
Deutsches Zentrum für Luft und Raumfahrt (DLR), Institut für Technische Thermodynamik,
Pfaffenwaldring 38-48, D-70569 Stuttgart
International Symposium: Introduction of Fuel Cell Systems to Early
Markets
Motivation for Fuel Cell Aircraft Application

Fuel cell technology offers a chance to improve

environmental impact of aircraft:

enhanced energy efficiency especially for inefficient

aircraft operating modes, e.g. on ground
emission free and low noise ground operation
emission reduction during whole flight cycle
additional synergy benefits through fuel cell by-products
(inert gas, water)

International Symposium: Introduction of Fuel Cell Systems to Early Markets,

13th July, 2010
Possibilities to Reduce Emissions
Propulsion – Aerodynamics – Flight Control – Mass – Periphery

International Symposium: Introduction of Fuel Cell Systems to Early Markets,

13th July, 2010
Airport Emissions: Study at Zürich Airport

Within the handling emissions, APU emissions can contribute significantly to the overall airport
emissions as well as to the local pollution concentrations. In 2003, APU contributed with 18.5% to
the NOx handling emissions Source: Study of Aircraft APU Emissions at Zürich Airport

International Symposium: Introduction of Fuel Cell Systems to Early Markets,

13th July, 2010
Motivation for Fuel Cell System Application
Ecological and Economical A/C Operation Aspects
Ecological Aspects:
 Emission reduction
 Higher fuel economy
 Noise reduction

Economical Aspects:
Weight Reduction
Low Maintenance
Mission Improvements
Elimination of RAT and APU
BatteryReduction
APU ~ 20 % APU ~ 40 %
idle ~ 10 %  ~ 50 %
International Symposium: Introduction of Fuel Cell Systemsidle
to Early Markets,
13th July, 2010
 Low Emissions System : Fuel Cells
Hydrogen supplied fuel cell
Fuel and CO2: No pollutants :
(HC, NOx, CO, SO2)
Reduced fuel burn
Less noise
= lower CO2 emissions

Batteries Emergency Power

Auxiliary Power

Ground Support
Equipment Water Refilling Truck

Fuel Tank
inerting system

Source: Airbus
International Symposium: Introduction of Fuel Cell Systems to Early Markets,
13th July, 2010
 Airbus Fuel Cell Strategy:
Each development step contains the functions of the previous step

Increased Benefit on Aircraft Level

Vision 2020

Multifunctional Fuel Cell

 Power for all loads on ground

To enable low or even no
Additional Functions
Function:  Flammability Reduction (Inerting) emission ground operation
 Emergency Power  Continuous Supplemental Power  Water Generation
Flight Test successfully
performed

+ +
Source: Airbus
International Symposium: Introduction of Fuel Cell Systems to Early Markets,
13th July, 2010
FCEPS –Fuel Cell Emergency Power System
Test Flight

Provides immediately Power after failure of power generation

Integration into the aircraft body -> independent of flight velocity
Benefits compared to Ram air turbine
Possible weight reduction without influence on flow resistance
Switch-off and reactivation of system is possible
Maximum power independent of flight phase
(flight velocity and flight height)
Less maintainance (no moving parts)

International
Constant Symposium:
PowerIntroduction of Fuel Cell Systems
during acceleration in toflight
Early Markets,
(30.000ft)!
13th July, 2010
 Development Multifunctional Fuel Cell System
Technology Platform

Flight certified architecture Load calculation for

and components mechanical set up
ABD 100 und DO160E

Integration and Test in

A320 D-ATRA
Qualification tests and documentation

Inclination Vibrations Temperature Low pressure

International Symposium: Introduction of Fuel Cell Systems to Early Markets,

13th July, 2010
Fuel Cell Technology Transfer to Aircraft Application
Aircraft Application
Functionality, Architecture, BOP

Airworthy technology
development platform
FC System from Transport
Application

Mechanical Strenght Simulation

International Symposium: Introduction of Fuel Cell Systems to Early Markets,

13th July, 2010
 New System for Flight Testing Fuel Cell System

Air Fuel Cell System for multifunctional use: Power > 12.5 kW
Water generation and inerting function demonstrated

International Symposium: Introduction of Fuel Cell Systems to Early Markets,

13th July, 2010
Technology Transfer to Aircraft Application

System Voltage and Power before and after transfer to aircraft architecture

60 16
Voltage original
Voltage A/C
56 14
Power Original
Power A/C
52 12

48 10

Power [kW]
U [V]

44 8

40 6

36 4

32 2

28 0

0 50 100 150 200 250 300 350 400

I [A]
 No power loss by transfer to airworthy architecture
International Symposium: Introduction of Fuel Cell Systems to Early Markets,
13th July, 2010
Vibration test for system qualification
Vibration test according to RTCA DO 160E Standard
Vibration Fixed Wing
• Qualification H2-Tank pressurised with 350 bar
(intank valve)
• Retested by manufacturer
• Test succesfull

Prequalification Flying Development Platform

• Equipped with componets
• No significant mechanical failures detected
(Main component stack ok!)

International Symposium: Introduction of Fuel Cell Systems to Early Markets,

13th July, 2010
 Qualification Multifunctional Fuel Cell System
5 Test Stands: Operation at different inclinations, climatisation, thermomanagement
modularity, performance, drying of exhaust

Shakeproof test at Rheinmetall

Sep08
International Symposium: Introduction of Fuel Cell Systems to Early Markets,
13th July, 2010
Aircraft Application an Early Market?

Technology introduction with new aircraft generation – long service

and development periods

Airbus A350 under development; scheduled to enter service in 2013

next aircraft model at earliest in 2017 – Early market?

Possibility to retrofit APU and emergency power system (e.g.160 kW for

APU and 60 kW for emergency power)
A320 family in service: ca. 4,200 (2300 on order)
A330 in service: ca. 654 (1,035 on order)
A340 in service ca. 385 (400 on order)

400 Systems per year for both application seems to be possible

International Symposium: Introduction of Fuel Cell Systems to Early Markets,

13th July, 2010
 Unmanned Aerial Vehicles (UAV)

Horizon Singapur

Protonex and Aeroenvironment

USA

Ion Tiger / USA

Civil Application

International Symposium: Introduction of Fuel Cell Systems to Early Markets,

13th July, 2010
Unmanned Aerial Vehicles (UAV) Civil Market

Source: Frost and Sullivan

International Symposium: Introduction of Fuel Cell Systems to Early Markets,
13th July, 2010
Unmanned Aerial Vehicles (UAV) Military Market

Source: Frost and Sullivan

International Symposium: Introduction of Fuel Cell Systems to Early Markets,
13th July, 2010
New flying test bed Antares DLR H2

Motor glider based flying test bed with combined test capability for real
life low pressure, acceleration, humidity and outside temperature
conditions: system, subsystem + component test
Based on Antares 20 E from Lange Aviation  5000 starts on battery
Payload ca. 200 kg, optional battery on board for subsystem operation
Load simulation trough fine adjustable motor load
First test of a high temperature fuel cell under aeronautical conditions

Antares DLR H2 Integrated fuel cell system 25kW

(BASF/Serenergy)
International Symposium: Introduction of Fuel Cell Systems to Early Markets,
13th July, 2010
 Experimental Low Pressure Performance
Investigations
Low Pressure System Performance
Fuel cell stack characterization for varying
pressure, humidity, flow rate and temperature
Humidification determined by the performance of
the passive membrane counter flow humidifier

p = 1bar p = 0.7 bar

p = 0.8 bar p =0.62 bar
35 70,00
U-I-Kennlinie - 660mbar
U-I-Kennlinie - 700mbar
/ V [v]

30 1 bar 0,8 bar 0,7 bar 0,62 bar 60,00 U-I-Kennlinie - 806mbar

/V
U-I-Kennlinie - 1000mbar
potential

25 50,00

Voltage
Voltage
Spannung [V]

[V]
20 40,00
1 bar 100%
StackSpannung
Stack Stack

15 30,00
0.8 64.5
10
0.7 56.2 20,00

5
0.6 44.1 10,00

0 0,00
0 2 4 6 8 10 12 14 16 0 5 10 15 20 25 30 35
Strom [A]
Current
Current [A]/ A Current
Current/[A] A
Stromstärke [A]

International  Underpressure
Symposium: Introduction ofbehaviour Antares
Fuel Cell Systems technology
to Early Markets,
13th July, 2010
 Optimized Electrical Network

 Up to 44% overall efficiency (from chemical energy to movement)

Hydrogen Storage

Batteries
(optional)

=

High efficient power grid
200-450V DC

Fuel Cell System

High power, high torque
electrical actuators
International Symposium: Introduction of Fuel Cell Systems to Early Markets,
13th July, 2010
New Testing Platform for Aviation
Antares DLR-H2
Presentation of the fuel
cell powered Antares
DLR-H2 in Hamburg in
July 2009

8000
2500

7000

2000
6000

Height / Feet
Height / m
5000
1500

4000

1000
3000

500 2000

10:30 11:00 11:30 12:00

01.01.1904
Time on 21.November 2009

International Symposium: Introduction of Fuel Cell Systems to Early Markets,

13th July, 2010
Summary

Fuel cells as aviation systems can significantly reduce

emissions and improve efficiency of air transportation
In near future the application of fuel cells will be on board supply
of power, water and other functions
First successful demonstration of the technology achieved!
The integration of fuel cell technology in A/C will bring more
improvements ....
A certified design organization for aviation is required for
product development
Development times and efforts are long / certification

International Symposium: Introduction of Fuel Cell Systems to Early Markets,

13th July, 2010
 Thank you for your attention !

Acknowledgement: DLR Team, Airbus, Michelin

and BMWi for funding

International Symposium: Introduction of Fuel Cell Systems to Early Markets,

13th July, 2010