Fuel Cells in Aeronautical Applications Need of Dedicated Balance of Plant

Fuel Cells in Aeronautical Applications
Need of dedicated Balance of Plant
Dr F. Boudjemaa
SAFRAN / MICTROTURBO
Workshop on aeronautical applications of fuel cells and hydrogen

technologies - 15th & 16th September 2015
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AGENDA
 Aircraft requirement for Fuel Cell System certification
 Operational conditions impact Fuel Cell System design
 Fuel Cell and Aircraft Specificities
 Application impacts Fuel Cell System design
 An example : Fuel Cell Emergency Power Unit
 SAFRAN answers
 Fuel Cell System Roadmap
1/ Workshop on aeronautical applications of fuel cells and hydrogen technologies/ 15 th & 16th September 2015
AIRCRAFT REQUIREMENTS FOR FCS CERTIFICATION
 V-type development life cycle
CS25 “Certification ED14/DO-160G  Environmental

specification for large airplane” Conditions and test Procedures for Airborne Equipment
FCS certification
ARP4754  Guidelines For Development Of Civil Aircraft and Systems
ARP4761  Guidelines and Methods for Conducting the Safety Assessment
Process on Civil Airborne Systems and Equipment
S/S PDR SS CDR FCS qualification
DO-178  Software considerations in airborne systems and equipment certification

DO-254  Design assurance guidance for airbone electronic hardware
PDR S/S CDR FCS component qualification

MIL-STD-704-F  Aircraft Electrical Power Characteristics S/S to be validate:
AIR-1168  Aerothermodynamic Systems Engineering and Design - Stack
AIR-2000  Aerospace Fluid System Standards - thermal management S/S
- Reactive alimentation S/S
- C/C
AIR 6464 / EUROCAE ED-219 “Hydrogen Fuel
- mechanical, electrical
Cells Aircraft analysis Fuel cell Safety Guidelines”
interfaces
AIRCRAFT REQUIREMENTS FOR FCS CERTIFICATION
 Design for safety: “how making a safe O2/H2/e- system for aircraft?”
O2 standard known for aeronautic  CS 25
H2 standard to be found for H2 storage sub-system.  SAE AIR 6464
 EN 12245 (DOT-CFFC) targerted for HP H2(O2) bottles (High TRL)
Examples of guidelines
- Robust to single failure + uncontrolled fire on aircraft level is extremely improbable
- HP H2/O2 storages shall be treated similarly regarding safety analysis
- Bottle burst to be extremely improbable by combining qualification and design
Examples of risk mitigation

- Energetic source segregation, FCS ventilation
- Fire resistance proofness (TPRD + venting line)
- Functions of control and security have to be separated
REGULATION
Alim
ANODE NfH2 FC
Alim Stack
CATHODE NfH2 REGULATION
OPERATIONAL CONDITIONS IMPACT FCS DESIGN 1/2
 Operational conditions (DO-160)

 Mechanical solicitations (vibration, shocks) Alim
REGULATION
NfH2
 Shock absorber : mechanical design compliance
ANODE
FC
Alim Stack
 Thermal environment [-55°C ; +85°C] NfH2
CATHODE REGULATION
 Ground survival conditions

 Impact on structure design, alimentation
 Pressure [0.1 ; 1.088] bar abs
design of FCS and component (gas pressure
 Ground conditions regulator, air compressor, gasket and coolant)
 On-board conditions
Altitude
inboard External cond.
41000ft 0,75 bar < 0,2 bar
8000ft 0,75 bar 0,75 bar
ground 0,6 - 1 bar
OPERATIONAL CONDITIONS IMPACT FCS DESIGN 2/2
 Operational conditions (DO-160)

 Explosion proofness
 Define a specific procedure for Hydrogen
 Fire resistant
 Define a specific procedure for Hydrogen
 Additional constraints
 Confined space
 Very low leakage allowable
 Integration of an emergency purge for Hydrogen
FUEL CELL & AIRCRAFT SPECIFICITIES 1/3
Fuel cell system location onto an aircraft

 Thermal management Cold source
Cooling loop
FC
Stack
from airplane
 Waste heat from depleted-air and cooling loop
 Thermal power to evacuate depends on FCS electric
performance (stack design) & operational condition (H2
purity, temperature, pressure)
 Design of cooling loop
‒ Air cabin: limitation by ECS
‒ Exterior air: external temperature variation with altitude, no
control of air flow rate
‒ Specific Equipment: power regulation depends on mission
profile
 Specific exchanger design vs localization
 /!\ Compatibility coolant vs operational temperature
Airbus A320 Fuel Cell-Demonstrator
Fuel cell system location onto an aircraft

 The localization of FCS on airplane would be
mainly influenced by the relative proximity
between FC hardware and public
 Different options :
 FCS near to the load
 FCS in tail cone
 FCS in fairing
 The issues that influence the choice Thermal

manageme
 Availability space nt
 Safety REGULATION
 Tubing, wire mass & volume Alim

ANODENfH2 FC
 Rejection of waste Alim
NfH2
CATHODE
Stack
REGULATION
 FC waste heat
FCESS
 Optimizations of FCS design and location vs application
 Equipment integration (design) into aircraft = certification specification

 Safety assessment early in development phase
 Operational environment
 Integration requirements
 Automotive-based fuel cell system solutions could not be adapted to

aeronautical environment
 Specific development
 Energetic source segregation
 H2 fuel cell standards under evolution
 System and component development needed
APPLICATION IMPACTS FCS DESIGN
 FCS Design criteria

 Mission/cycle : long mission (compressor); short mission (O2 tank)
 Location : air cabin, atmosphere
 Life time  fuel cell stack size, reactive purity (filtering)
EPU
~15 kW
1 kg H2
APU Galleys Entertainment

50 - 200 kW ~30 kW ~30 kW
50 kg H2 10 kg H2 10 kg H2
Special aircraft
~15 kW
10 kg H2
J. Fuel Cell Sci. Technol. 2010;8(1):011014-011014-7. doi:10.1115/1.4002400
EXAMPLE : FUEL CELL EMERGENCY POWER UNIT
 Stack - PEM High Temperature
 Accept non pure H2
 No humidification system
 Facilitate thermal integration
 Solid Hydrogen Gas Generator

 Low pressure (20 bar max)
 Long life Storage
 Easier transportation
 Simplify logistic
 Air Compressor with Air Bearings

 No air pollution
 High ratio compression
 Electrical pump
10 / Workshop on aeronautical applications of fuel cells and hydrogen technologies/ 15 th & 16th September 2015
HYDROGEN POWER UNIT: SAFRAN ORGANIZATION
• Integration
• Safety
• Certification
CGH2 – 350 bar
H2 solid P < 20 bar

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Fuel Cells in Aeronautical Applications

Need of dedicated Balance of Plant

Workshop on aeronautical applications of fuel cells and hydrogen

 Aircraft requirement for Fuel Cell System certification

 Operational conditions impact Fuel Cell System design

 Fuel Cell and Aircraft Specificities

 Application impacts Fuel Cell System design

 An example : Fuel Cell Emergency Power Unit

 Fuel Cell System Roadmap

 V-type development life cycle

CS25 “Certification ED14/DO-160G  Environmental

S/S PDR SS CDR FCS qualification

DO-178  Software considerations in airborne systems and equipment certification

PDR S/S CDR FCS component qualification

Examples of risk mitigation

 Operational conditions (DO-160)

 Ground survival conditions

8000ft 0,75 bar 0,75 bar

ground 0,6 - 1 bar

 Operational conditions (DO-160)

Fuel cell system location onto an aircraft

Airbus A320 Fuel Cell-Demonstrator

Fuel cell system location onto an aircraft

 The issues that influence the choice Thermal

 Tubing, wire mass & volume Alim

 Optimizations of FCS design and location vs application

 Equipment integration (design) into aircraft = certification specification

 Automotive-based fuel cell system solutions could not be adapted to

 FCS Design criteria

APU Galleys Entertainment

J. Fuel Cell Sci. Technol. 2010;8(1):011014-011014-7. doi:10.1115/1.4002400

 Solid Hydrogen Gas Generator

 Air Compressor with Air Bearings

CGH2 – 350 bar

H2 solid P < 20 bar

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