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Revolutionary Fuel Cell Power System Passes Ground Testing
ZeroAvia, a pioneering aviation company, has made a significant breakthrough in its mission to develop a sustainable and efficient alternative to traditional fossil fuel-powered aircraft. The company’s certification-intent low temperature proton exchange membrane (LTPEM) fuel cell power generation system (PGS) for the ZA600 hydrogen-electric powertrain has successfully replicated a full flight profile in ground testing.
The test, which simulated a 250 nautical mile flight in a Cessna Caravan 208b aircraft, equivalent to flying between London Heathrow and Dublin Airport, demonstrated stable power output and excellent performance of the balance-of-plants. Each 200kW capable module produced 170kW power for take-off, 132kW during a 23-minute climb, and 83kW for a 90-minute cruise. This achievement is a significant milestone in ZeroAvia’s journey to commercialize its hydrogen-electric powertrain technology.
The ZA600 power generation system is designed to provide electrical power for ZeroAvia’s 600kW electric propulsion system, which will be installed on up to 20-seat planes. The system consists of four 200kW rated modules, each capable of feeding DC electrical power to four ZeroAvia 200kW rated inverters. These inverters then provide AC power to one of four segments of the company’s proprietary 600kW motor design, enabling full power operation of the motor if there is failure in one leg. This design creates a high degree of fault tolerance and ensures the reliability of the system.
One of the key innovations in ZeroAvia’s ZA600 power generation system is the use of a bespoke passive Venturi ejector device for the recirculation of hydrogen gas within the fuel cell system. This design optimizes the weight and operation of the system, reducing parasitic power consumption and boosting overall specific power. The Venturi also promises very low failure rates due to its passive mechanical nature.
The company’s Venturi design simplifies the certification process, as it is reliant on the DO160G environmental qualification, rather than the more stringent DO254 for complex hardware that would face a system utilizing an electric blower. This innovation has enabled ZeroAvia to accelerate the certification and commercialization of its power generation system.
The ZA600 power generation system is the world’s first fuel cell module designed to meet CS-E and CS-23 certification requirements, marking a significant achievement in the development of hydrogen-electric propulsion systems for aviation. With both core components of the powertrain now in bench testing, ZeroAvia will move to full engine ground testing of the final design in the next few weeks.
ZeroAvia’s strategy to invest in world-class in-house testing facilities has played a crucial role in the rapid progression to this milestone. The company has built a 2MW capable fuel cell test lab at its Gloucestershire R&D center, equipped with two bays that enable testing in an open frame environment. This facility has enabled ZeroAvia to progress the volume-constrained certification-intent system and advance the development of its pioneering fuel cell propulsion technology.
Val Miftakhov, Founder & CEO of ZeroAvia, stated: “We have shown the possibilities by flying a prototype of the ZA600 system on shorter range missions, and we are now seeing the final design replicating customer needs in ground testing, and pushing the boundaries of performance with new innovations.” He further emphasized that the Venturi innovation is “genuinely groundbreaking” and enhances an already commercially attractive, highly efficient, and certifiable fuel cell propulsion system.
ZeroAvia has also extensively tested a prototype of its first ZA600-engine aboard a Dornier 228 aircraft at its UK base. The company has also performed advanced ground tests in the US and UK for the key building block technologies for the ZA2000 system, including cryogenic tanks or LH2 and proprietary high-temperature PEM fuel cell and electric propulsion systems. ZA2000 will support up to 80-seat regional turboprop aircraft such as the ATR72 or the Dash 8 400.
The successful ground testing of ZeroAvia’s certification-intent power generation system marks a significant step towards the development of sustainable aviation fuels (SAF). The company’s mission is to make hydrogen-electric propulsion accessible and affordable for airlines, enabling them to reduce their carbon footprint and operate more sustainably. With its innovative technology and commitment to testing and validation, ZeroAvia is poised to play a leading role in shaping the future of aviation.
The use of hydrogen-electric propulsion systems has the potential to revolutionize the aviation industry by reducing greenhouse gas emissions and operating costs. As the demand for sustainable aviation fuels continues to grow, companies like ZeroAvia are at the forefront of developing the necessary technologies to support this transition.
ZeroAvia’s achievements demonstrate the company’s commitment to innovation and its ability to push the boundaries of what is possible in the development of hydrogen-electric propulsion systems. With its successful ground testing of the ZA600 power generation system, the company has taken a significant step towards commercializing its technology and making it available for widespread adoption.
As ZeroAvia continues to develop and refine its power generation system, the aviation industry can look forward to a more sustainable and efficient future. The company’s pioneering work in hydrogen-electric propulsion has the potential to transform the way we fly, reducing our carbon footprint and operating costs while maintaining the reliability and performance of aircraft. With ZeroAvia at the forefront of this revolution, the future of aviation looks brighter than ever.