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The Fuel Cell and Hydrogen Energy Association (FCHEA) is the trade association for the fuel cell and hydrogen energy industry, and is dedicated to the commercialization of fuel cells and hydrogen energy technologies. Fuel cells and hydrogen energy technologies deliver clean, reliable power to leading edge corporate, academic and public sector users, and FCHEA members are helping to transform our energy future. FCHEA represents the full global supply chain, including universities, government laboratories and agencies, trade associations, fuel cell materials, components and systems manufacturers, hydrogen producers and fuel distributors, utilities and other end users.

Fuel Cell Aviation Update

Transitions

Fuel Cell Aviation Update

Connor Dolan

Recent “In Transition” updates have outlined developments across a range of transportation methods. Today, we highlight the exciting announcements that have arrived this year from FCHEA members involved in hydrogen and fuel cell aviation. Aviation is a hard-to-decarbonize industry, and hydrogen can be used to fuel aerial vehicles both through direct use in fuel cell electric powertrains and in the creation of synthetic fuels that reduce carbon emissions from traditional aircraft fuel. Due to a high energy density, hydrogen provides a robust source of lightweight energy that allows air travel without carbon emissions.

Since our prior update on this topic, two major players in this emerging sector, ZeroAvia and HyPoint, have both joined FCHEA as members focused solely on the aviation market.

ZeroAvia, based both in California and the United Kingdom, develops fuel cell-electric powertrains for aircraft, ranging in size from 20-seat regional aircraft to long-distance planes. As noted in our previous update, ZeroAvia conducted successful tests of a six-seat plane in 2020 and has continued that momentum in 2021. Throughout the year, multiple commercial airlines and plane manufacturers have been announced as partners for larger integration projects, including Alaska Airlines and United Airlines, and ZeroAvia successfully carried out ground tests on their 19-seat fuel cell module in August and continued advanced testing in partnership with fellow FCHEA member Hyzon Motors. The company plans to carry out commercial flights between the Hague, the Netherlands and the United Kingdom in 2024.

ZeroAvia’s developmental Dornier 225 aircraft. (Source: ZeroAvia)

Also based in California, HyPoint is another company that develops fuel cell electric modules designed for aviation. The company aims to provide hydrogen solutions for drones, air taxis, and vertical takeoff vehicles, alongside fixed-wing aircraft. HyPoint partnered with global chemicals giant BASF to develop a cutting-edge fuel cell membrane which provides a 50% increase in power, ideal for narrow-body aircraft. Through a partnership with Piasecki Aircraft, a helicopter company, HyPoint aims to produce five full-scale fuel cell systems for use with Piasecki’s PA-890 eVTOL (electric vertical take-off and landing vehicle), which will become the first hydrogen-powered manned helicopter when it becomes available in 2024.

HyPoint’s Air-Cooled Aviation Fuel Cell Systems. (Source: HyPoint)

Commercial Aircraft Development Partnerships

Throughout 2021, ZeroAvia collaborated with FCHEA member PowerCell Sweden and ZeroAvia on the continued development of aviation powertrains of increasing sizes. The PowerCell fuel cell modules are used  by ZeroAvia, including in the module designed for powering a 19-seat aircraft. ZeroAvia also collaborated with FCHEA member Hyzon Motors on advanced ground tests for larger powertrains, using heavy-duty fuel cell modules.

Based in the United Kingdom (UK), Intelligent Energy is another FCHEA member working on hydrogen-powered aircraft, partnering with fellow UK company GKN Aerospace to lead the H2GEAR program. H2GEAR is a UK government supported collaborative group, through which companies are planning a liquid hydrogen fuel cell system that will power commercial subregional aircraft by 2026 and scale the power requirements after that point.

FCHEA member Plug Power announced in March 2021 an expanded partnership with aviation company Universal Hydrogen also aimed at further development of hydrogen-powered regional aircraft. The companies plan experimental flights of 40-60 seat aircraft in 2023 and revenue service in 2025.

In June 2021, FCHEA member General Motors partnered with Liebherr-Aerospace to jointly adapt and develop GM’s Hydrotec fuel cell technology for aviation purposes. The modules will be constructed in France and tested in several aviation scenarios.

Successful Test Flights

FCHEA member Cummins powered the four-seat HY4 airplane that was unveiled and flown in Stuttgart, Germany, in December 2020. In April 2021, Cummins announced the aircraft had completed 30 separate 2-hour flights. With these test flights completed, the H2FLY project that Cummins participated in to develop the airplane will consider scaling the design to carry 40 passengers.

Hydrogen has significant potential to decarbonize the aviation sector. Along with reducing flight carbon emissions, the many vehicles used in airport operations, including cargo haulers and baggage trains, can utilize hydrogen and fuel cells to decrease overall airport emissions.