4. April 2022
On the path to climate-neutral flight

The Fed­er­al Min­istry for Eco­nom­ic Af­fairs and Cli­mate Ac­tion is fund­ing a project to fur­ther de­vel­op hy­dro­gen fu­el cell tech­nol­o­gy

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Aeronautics
Engine of a Do 328 in the hangar
En­gine of a Do 328 in the hangar
Image 1/2, Credit: Deutsche Aircraft

Engine of a Do 328 in the hangar

In the 328H2-FC project, a fu­el cell sys­tem with one and a half megawatts of pow­er is be­ing de­vel­oped for the first time for use in flight.
Hydrogen aircraft with fuel cell
Hy­dro­gen air­craft with fu­el cell
Image 2/2, Credit: DLR (CC BY-NC-ND 3.0)

Hydrogen aircraft with fuel cell

The 328H2-FC project opens up a tech­no­log­i­cal per­spec­tive for fu­ture cli­mate-neu­tral re­gion­al air­craft in the 40-seater class.
  • An important step towards climate-neutral passenger aircraft.
  • Promising hydrogen fuel cell system in the megawatt range is being developed and will be demonstrated in flight by 2025.
  • Ten partners from science and industry are jointly promoting flying with hydrogen.
  • A Dornier 328 will become a demonstration aircraft for climate-neutral flights in the EASA large aircraft class ('CS25').
  • Participation of the DLR spin-off H2FLY strengthens DLR's strategic position in technology transfer.
  • Focus: Aeronautics, emission-free flight

The future climate-neutral air transport system needs carbon-dioxide-free propulsion technologies. For regional aircraft, hydrogen-electric propulsion systems with hydrogen fuel cell technology offer a promising option. This is now receiving a strong boost from the '328H2-FC' project. Led by the German Aerospace Center (Deutsches Zentrum für Luft- und Raumfahrt; DLR) in cooperation with H2FLY, Deutsche Aircraft, Diehl Aviation and six other partners, the project is the first to develop a fuel cell system with a power output of one and a half megawatts for use in flight. The project opens up a technological perspective for future regional aircraft with 40 seats. The Federal Ministry for Economic Affairs and Climate Action (Bundesministerium für Wirtschaft und Klimaschutz; BMWK) presented the funding notification at the beginning of 2022. The BMWK is funding the realisation of the first megawatt hydrogen fuel cell system for air transport with approximately 30 million euros.

Within the scope of the partnership, a Dornier 328 aircraft will be converted to be used for hydrogen-electric passenger flights for the first time. This involves the electrification of the powertrain and the integration of a fuel cell system, including a cooling system and a liquid hydrogen tank. The '328H2-FC' project paves the way for proving the potential of hydrogen for climate-neutral air transport. The unique hybrid-electric powered demonstration aircraft for EASA’s large aircraft class ('CS25') is scheduled to take off for the first time in 2025. Before that, tests of the fuel cell system that is to be developed are planned, using a new ground-based test facility at DLR.

André Thess, Director of the DLR Institute of Engineering Thermodynamics says: "With a fuel cell that generates more than one megawatt of power, we are opening the door to climate-neutral passenger air transport without carbon dioxide emissions. At DLR's Stuttgart site, we will test the new technology extensively before moving on to aircraft integration and initial flight tests. By the end of the decade, such passenger aircraft could already be in commercial operation."

Technology development and transfer

DLR is coordinating the project. To this end, DLR is responsible for the fuel cell test stand, the tank system, its testing and the interface between fuel cells and tank system, as well as the fuel cell housing with integrated sensors, safety components and their cooling system. The BALIS research infrastructure is used for testing the drive train. In addition, DLR is analysing emission data and investigating the overall climate impact of a possible 328H2-FC fleet, focusing on contrail formation and its impact. Furthermore, the project brings in DLR spin-off H2FLY as a partner, thus consolidating DLR's strategic position in the field of technology transfer.

Anna Christmann, Member of the Bundestag (Federal Parliament) and Federal Government Coordinator of German Aerospace Policy: "H2FLY is an important building block for the future strategy of emission-free air transport. With this project funded by the BMWK, we have a unique opportunity to extend the technological lead in hydrogen-powered flight here in Germany. With our funding, we are making it possible for researchers to overcome the technical challenges involved in using hydrogen in air transport."

Josef Kallo, co-founder and CEO of H2FLY: "With this funding, H2FLY will consolidate its position as a global technology leader in hydrogen-electric propulsion. Flying with hydrogen without carbon dioxide emissions will become a reality." In cruise flight, the use of a hydrogen fuel cell energy system enables the aircraft to operate without emitting carbon dioxide, which means that a large part of the flight distance can be covered in a completely climate-neutral manner. For the energy-intensive take-off, a gas turbine will provide additional thrust as part of the testing of the hybrid-electric concept.

Martin Nüßeler, CTO of Deutsche Aircraft: "Our Dornier 328 is the optimal platform for demonstrating the new fuel cell technology. We can use this to bring the technology into real-world conditions and accelerate our progress towards climate-neutral air transport."

Benno Petersen, Head of Innovation and R&T at Diehl Aerospace: "Our company is participating in the '328H2-FC' project through extensive research programmes. This is a clear signal of our interest in this future-facing propulsion technology and underscores the important role that the supplier industry plays in the development of such innovative systems."

The project thrives on the cooperation between DLR, H2FLY, Deutsche Aircraft and Diehl Aviation (incl. Diehl Aerospace). Other project partners are AKG Verwaltungsgesellschaft mbH, Bauhaus Luftfahrt e.V., GE Aviation, HS Elektronik GmbH, Industrieanlagen-Betriebsgesellschaft mbH and Premium Aerotec GmbH. The Federal Ministry for Economic Affairs and Climate Action is providing funding for the 328H2-FC project within the framework of the aeronautics research programme (LuFo VI-2). The joint project leader is DLR. The project builds on the predecessor projects 328eHY-LAB and 328eHY-TECH (LuFo VI-1) led by Deutsche Aircraft.

DLR - Research for emission-free flying with fuel cells

The German Aerospace Center (DLR) is pursuing the vision of emission-free aviation. In the future, alternative climate-friendly propulsion systems will make a significant contribution to this. For regional aircraft, electric drives in combination with fuel cells and hydrogen offer a promising perspective. Specifically, DLR is researching two approaches in two different size classes with partners from the aviation industry. In the D328H2-FC project, a hybrid-electric system is to be developed and tested for aircraft with up to 40 passengers, consisting of a hydrogen fuel cell in the power class of over one megawatt and a gas turbine. In the Do-228FFC project, a 600-kilowatt engine combined with a hydrogen fuel cell is being developed and tested for flights with up to 18 passengers.

DLR at a glance

DLR is the Federal Republic of Germany's research centre for aeronautics and space. We conduct research and development activities in the fields of aeronautics, space, energy, transport, security and digitalisation. The German Space Agency at DLR plans and implements the national space programme on behalf of the federal government. Two DLR project management agencies oversee funding programmes and support knowledge transfer.

Climate, mobility and technology are changing globally. DLR uses the expertise of its 55 research institutes and facilities to develop solutions to these challenges. Our 10,000 employees (as of February 2021) share a mission – to explore Earth and space and develop technologies for a sustainable future. In doing so, DLR contributes to strengthening Germany's position as a prime location for research and industry.

About H2FLY

Founded in 2014 by five engineers from the German Aerospace Center in Stuttgart and the University of Ulm, H2FLY GmbH is paving the way to emission-free, sustainable aviation. The company develops hydrogen-electric propulsion systems for aircraft and is a global leader in the development and testing of such systems. The HY4, the world's first hydrogen-electric passenger aircraft, took off in 2016, demonstrating both the feasibility and potential of this technology for the aviation of the future. H2FLY has a powerful network of partners in industry and science, and is currently working to scale up its technology with the aid of German and European funding. In just a few years, hydrogen-electric aircraft will be able to transport 40 passengers over distances of up to 2000 kilometres (1240 miles). H2FLY successfully closed a major funding round in April 2021, securing its growth and enabling the company to begin scaling its technology and solving the related challenges.

For more information, please visit: www.H2FLY.de

About Deutsche Aircraft

Founded on the proud heritage of Dornier and Germany's reputation for engineering design, quality and innovation, Deutsche Aircraft is the new purpose-driven German OEM. As Dornier 328 type certificate holder, Deutsche Aircraft will enable future development of the Do328 platform, and exploit future technologies and capabilities to produce a more efficient, economic and environmentally friendly aircraft, and to drive the future of aviation towards climate-neutral flight. Together with the participation of the German Government, Deutsche Aircraft is leading the way in a new era of a cleaner, safer and more efficient aviation.

For more information, please visit: www.deutscheaircraft.com

About Diehl Aviation

Diehl Aviation is one of the largest aviation suppliers in Germany and also participates in the field of hydrogen-based power generation systems. The system supplier is included in the 328H2-FC research project with different focus points. These entail solutions for hydrogen distribution and high-performance cooling for the hydrogen-based energy system. They also include highly reliable control of all system components and power switching in the megawatt class. Diehl Aviation - including Diehl Aerospace (a joint venture with Thales) - is a division of Diehl Stiftung & Co. KG and combines all aviation activities of Diehl Group under one roof. The company is a leading systems supplier of aircraft systems and cabin solutions. Diehl Aviation currently has more than 4,000 employees. Its clients include leading aircraft manufacturers, manufacturers of eVTOL aircraft, and airlines and operators of commercial and business aircraft worldwide.

For more information, please visit: www.diehl.com/aviation

Contact
  • Falk Dambowsky
    Ed­i­tor
    Ger­man Aerospace Cen­ter (DLR)

    Com­mu­ni­ca­tions and Me­dia Re­la­tions
    Telephone: +49 2203 601-3959
    Linder Höhe
    51147 Cologne
    Contact
  • Prof. Dr. André Thess
    Di­rec­tor
    Ger­man Aerospace Cen­ter (DLR)
    In­sti­tute of En­gi­neer­ing Ther­mo­dy­nam­ics
    Pfaffenwaldring 38-40
    70569 Stuttgart
    Contact
  • Deutsche Aircraft
    Press Of­fice
    Deutsche Air­craft
    Oberpfaffenhofen Airport
    82234 Wessling
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  • Hartmut Schultz
    Press Of­fice
    H2FLY
    Telephone: +49 89 99249620
    Augsburger Straße 293
    70327 Stuttgart
    Contact
  • Guido van Geenen
    Vice Pres­i­dent Cor­po­rate Com­mu­ni­ca­tions
    Diehl Avi­a­tion
    Telephone: +49 69 5805 1724
    An der Sandelmuehle 13
    60439 Frankfurt
    Contact
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