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Emissionsfreies Fliegen mit Wasserstoff
Prof. Dr.-Ing. Josef Kallo
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University of Ulm –Institute of Energy Conversion and Energy Storage
Department of Hybrid Concepts• Power Electronic Hardware, Controls and
FC/Battery Power Management Systems
Department of Propulsion Research• High power E-Machines, Generators
Applications: Aircraft applications, ….
Hardware/Test bench: • ICE-Battery-E-Machine Hybrid up to MW• Hydrogen infrastructure• Low pressure and temperature chamber for
components and complete systems
Cologne
Oberpfaffenhofen
Braunschweig
Goettingen
Berlin
Bonn
Neustrelitz
Weilheim
Bremen Trauen
Lampoldshausen
Stuttgart
Stade
Augsburg
Hamburg
Juelich
Ulm
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Aerospace Research Center and Space Agency ofthe Federal Republic of Germany (DLR)
• 7.700 employees• 16 national facilities• > 30 institutes and test facilities• offices in Brüssel, Paris, Washington• Test facilities in Almeria/Spain
• ESI Energy System Integration, DLR• Battery Systems and degradation• Fuel Cell Systems and degradation• Aircraft Applications MEA and AEA
Cologne
Oberpfaffenhofen
Braunschweig
Goettingen
Berlin
Bonn
Neustrelitz
Weilheim
Bremen Trauen
Lampoldshausen
Stuttgart
Stade
Augsburg
Hamburg
Juelich
Ulm
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CO2 – Emissionen verändern die Zusammensetzung der Luft in der Atmospäre
820Mt CO2/Jahr
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Energietechnik
9
Auswirkungen Klimaveränderung
Bild: Google Earth
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Energietechnik
H2
H2
H2
H2
Ist es möglich mit regenerativ erzeugtem Wasserstoff ohne CO2 Emissionen zu fliegen?
Wasserstoffantrieb für Flugzeuge
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Potenziale der Brennstoffzelle in der Luftfahrt Elektrochemische Grundlagen der Brennstoffzelle (PEMFC basiert)
Teilreaktion Anode: Teilreaktion Kathode:
2H2 4 H+ + 4 e- 4 H+ + 4 e- + O2 2 H2O
Grundreaktion der Wasserstoff-Brennstoffzelle:
2H2 + O2 2H2O (+ el. Energie / Arbeit + Wärme)
N2 aus der Luft bleibt als Inertgas
Nutzung des produzierten Abwassers
Potential zur CO2 Freiheit
kein Carnotprozess d.h. bei niedrigen Arbeitstemperaturen sind Wirkungsgrade in (kleinen) Systemen bis 55% möglich
Anode Kathode
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Energietechnik
Taxiing & Takeoff
Departure Landing & TaxiingCruise Descent
Technische Randbedingungen und Phasen einer Flugmission
P=1013mbarTambient = 14°C
P=250 – 550mbarTambient = ‐ 60°C ‐15°C
P=1013mbarTambient = 14°C
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Hybrid electric hydrogen propulsion unit – Schematics, simple math for feasible energy capacity
30 - 80 kW electricpower at 350 - 270V
10kWh at 45 - 60kW – 50kg
36kW – 80kg
10kg H2 - 160kWh el. usable200 kg storage unit
Mass balance 50kg + 80kg + 200kg = 330kg
Energy balance 170kWh usable (at 50%eff) 515Wh/kg (Druckwasserstoff)
(622Wh/kg at 20kgH2)
Bei Verwendung von Flüssigwasserstoff erhöht sich die Energiedichte im Quell-System auf bis zu 950Wh/kg
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„More Electric“ and „All Electric“ applications in aviation
History of emission-free aviation at UUlm and DLR
2007-2015• Replacement of the A320 Auxiliary
Power Unit• emission-free taxing Airbus A320
2008-2016• DLR-H2 – first piloted emission-free hydrogen fuel
cell aircraft• HY4 – first 4 seater hydrogen - fuel cell aircraft
• Power source• Electric power distribution• Electric motors for aircraft application
HY4
DLR-H2
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Elektrochemischer Gasturbinen APU Ersatz mit Wasserstoff im A320
Mechanical Strenght Simulation
Aircraft ApplicationFunctionality, Architecture, BOP
FC System from Transport Application
Airworthy technology development platform
- Fuel cell- DC/DC- hydrogen storage
DO16x
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H2 Sensor humid environmentDesign development for hydrogen detection in very humid environments (e.g. cathode exhaust)• Heated control volume to levels above monitored atmosphere• Design validation using CFD tools zusammen
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Hydrogen tank system integration• Enclosure with high pressure (orange) and low pressure (blue) compartment• Compartments are airtight separated by wall (blue)
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Hydrogen tank system integration• Redundant hydrogen detection in each enclosure compartment with two sensors
in each (red)• Permanent enclosure ventilation (yellow) into discharge line (green)
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Hydrogen tank qualification tests• Vibration test according to RTCA-DO160E (1h/direction)• Bonfire test and pressure burst test according to ISO15869 (performed by
manufacturer)
FC-System on shaker
Hydrogen tank on shaker
RTCA-DO160E vibration profile
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Fuel cell technology transfer to aircraft application
System Voltage and Power before and after transfer to aircraft architecture
28
32
36
40
44
48
52
56
60
0 50 100 150 200 250 300 350 400
I [A]
U [V
]
0
2
4
6
8
10
12
14
16
Pow
er [k
W]
Voltage originalVoltage A/CPower OriginalPower A/C
No power loss by transfer to airworthy architecture
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Overview emission free taxi with fuel cell and e-NWD
Multifunctional fuel cellsystem in cargo bay
Fully integrated e-NWD
Motorelectronics
ControlBox and Data
Aquisition
High Torque 11.000Nm
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Emission free taxi - system installation in A320
Fuel cell system and electrical nose wheel drive installationin cooperation with Airbus (Hamburg/Toulouse/Lutton) and Lufthansa Technik
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A320 emission free taxi with fuel cell and e-NWD
Test DLR + Airbus + LHT
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Emission free taxi – fuel cell + el. drive (Frankfurt Airport)Fuel Burn A320 + B737 conv. Fuel Burn A320 + B737 el. FC Taxi
Savings A320 + B737 ca. 44t Kerosene/day = 136t CO2/dayAequivalent Hydrogen ca. 2,4 t (332 Landings, 334 Starts, 4.4.2009)
700 -1000h Engine Saving Time/Year/Plane
20
380
[ kg
/ m /
Day
]
20
380
[ kg
/ m /
Day
]
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Energietechnik
Wasserstoff-SpeichersystemBrennstoffzellensystem
DLR‐H2 – erstes Brennstoffzellenflugzeug
Einsitziges Flugzeug mit elektrischem Propellerantrieb
Leistungsquelle:
Brennstoffzellen-Batterie Hybrid
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Fuel Cell Technology Antares DLR H2 – Gen 2
Modular hybrid fuel cell system with cooling booster
Fuel Cell System Powerup to 33kW, Hybrid up to 55kW
modular system with high redundancy
Medium active area(ca. 230cm2)
High voltage auxiliarycomponents
System efficiency up to 52%
reliable, redundant, modular
FC Stacks
FC Air BlowerCooling Unit
Air Intake
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Hydrogen storage system Gen 2
- Tank: Dynetec W205
- Dimensions 415mm x 2110 mm
- Weight 99,5 kg
- Volume 205 Liter, H2 capacity 4,89 kg
at 350 (425) bar 5 h flight time
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Energietechnik
Übersicht Antriebsstrang BZ‐ AntriebWasserstoff - Speicher
Kompaktes Brennstoffzellensystem
Leistungsmanagement
Batterie10kWh
=
Elektromotor
‐ Technologische Herausforderung aufgrund gravimetrischer und volumetrischer Anforderungen‐ Systemzuverlässigkeit hat stets erste Priorität
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Energietechnik
Integration Brennstoffzelle in DLR H2
EASA – Permit to flynach CS 23
Systemeffizienz >50%
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Energietechnik
Erstflug DLR‐H2 (25.05.2009)
www.DLR.de • Folie 42
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Energietechnik
Lärmemission DLR‐H2• Messung in Anlehnung an ICAO Annex 16 Vol.1
30,0
35,0
40,0
45,0
50,0
55,0
60,0
19:31:35 19:31:44 19:31:52 19:32:01 19:32:10 19:32:18 19:32:27 19:32:36 19:32:44 19:32:53
Uhrzeit [hh:mm:ss]
SPL
[dB
(A)]
Umgebung2. Überflug 1000m mit MotorMin SPL [dB(A)]Max SPL [dB(A)]
Antares direkt über der Messstelle
Geringe bis keine Lärmwahrnehmung im Überflug
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Energietechnik
1: Zweibrücken
EDRZ
2,4: Hof-
Plauen EDQM
3: Berlin
Schönefeld
EDDB
5: Stuttgart
EDDS
Zweibrücken – Hof
2 Stunden 47 Minuten
378,4 km
ca. 2,5 kg Wasserstoff
Hof - Berlin
2 Stunden 36 Minuten
367,0 km
ca. 2,2 kg Wasserstoff
Berlin - Hof
2 Stunden 42 Minuten
271,4 km
ca. 2,6 kg Wasserstoff
Hof - Stuttgart
2 Stunden 18 Minuten
295,5 km
ca. 2,2kg Wasserstoff
Gesamt: 11 Stunden 42 Minuten, 1483,9 km
Langstreckenversuch DLR- H2
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Energietechnik
Herbst 2015: DLR‐H2 Projekt beendet
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Energietechnik
Wo ist die Grenze des Machbaren?
E40E6HY4
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HY4 – Aircraft Integration overview
H2FLY
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General Aviation - Emission free passenger flight – HY4 as AIRTAXI
Cruising altitude 10000 ft (3000 m)
Cruising speed 140 km/h ‐200 km/h
Range 750‐1500km
Souls on board 4
Maximum weight 1500 kg
Net weight approx. 1100 kg
Engine power 80 kW (120 kW)
Fuel cell power 45 kW
Battery power 45 kW (80 kW)
Battery capacity 21 kWh@75 A
Hydrogen storage 300 kWh
Wingspan 21.36 m
Length 7.4 m
H2FLY
Show feasibility, demonstrate key features
Emission free hydrogen fuel cell plane
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Flight Friedrichshafen-StuttgartSimulation of a flight with 200km/h airspeed
Car: 180km
2h:20min
HY4:120km 37min
90%H2
36% SOC
Source: Google MapsPdrivetrain approx. 48kW
Pow
er /
kWC
urre
nt/ A
Alti
tude
/ mL
evel
/ %
Traveled distance / m
SOC of battery Remaining hydrogen mass
Battery Fuel cell Hybrid (total)
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Flight Friedrichshafen-StuttgartSimulation of a flight with 160km/h airspeed
Car: 180km
2h:20min
HY4:120km 46min
88%H2
66% SOC
Source: Google MapsPdrivetrain approx. 37kW
RecuperationPo
wer
/ kW
Cur
rent
/ AA
ltitu
de/ m
Lev
el /
%
Traveled distance / m
SOC of battery Remaining hydrogen mass
Battery Fuel cell Hybrid (total)
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Flight Friedrichshafen-StuttgartRecharge battery from the fuel cells, 200km/h (including DC/DC Boost)
Car: 180km
2h:20min
HY4:120km 37min
86%H2
80% SOC
Source: Google Maps
Charging at maximumcurrent
Pow
er /
kWC
urre
nt/ A
Alti
tude
/ mL
evel
/ %
Traveled distance / m
SOC of battery Remaining hydrogen mass
Battery Fuel cell Hybrid (total)
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Noise perception on electric propulsion for aircraftapplication
Noise production frequency for 2016 HY4
- Noise level perception betterdue to low frequencies
High torque electric motorsrequire low rpm propellerat high speed!
Noise production frequency for 2017 HY4
Turboprop
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Go4H2– Airtaxi Motivation, Potential• Demand: Regional air traffic (60 Airports in BW,
aprox. 300 in Germany and 1200 in Europe)
Hy4 ‐ 0,4kg H2/paxC 182 ‐ 5 kg Avgas/pax
37min ‐ Hy42h 9 min – car2h 14 min – train
30min ‐ Hy41h 12 min – car3h 14 min – train
Example routes:
Walldürrn – Stuttgart Airport
Friedrichshafen – Stuttgart Airport
Hy4 ‐ 0,36kg H2/paxC 182 – 4,5 kg Avgas/pax
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Go4H2 – Airtaxi Motivation, Potential, Infrastructure
Hy4 ‐ 0,4kg H2/pax37min ‐ Hy4
1:06 h:min ‐ Hy4
- Small investment for initial hydrogen infrastructure expected
- Synergies with automotive refuelingstations should be used
Hy4 ‐ 0,36kg H2/pax
25min ‐ Hy4
30min ‐ Hy4
38min ‐ Hy4 Hy4 ‐ 0,4kg H2/pax37min ‐ Hy4
25min ‐ Hy4
30min ‐ Hy4
40min ‐ Hy4
37min ‐ Hy4
• Demand: Regional air traffic (60 major airports in Germany, aprox. 300 adequate airfields in Germany and 1200 in Europe)
ACARE Goals: 4 hour „door to door“ inside Europe
- Technology developmentfor worldwide market!
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Build up schematics and boundary conditions 6 seater FC-Hybrid
DLR.de • Folie 61 > Vortrag > Autor • Dokumentname > Datum
H2
Fuel Cell
Battery
el. Motor
Power electronics
Compact integration architecture withhigh redundancy
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Range [m]
Payl
oad
[kg]
Design pay-load
Liquid hydrogenMax. range at MTOW with liquid hydrogenPressurized hydrogenMax. range at MTOW with pressurized hydrogenGasolene (95 RON)Max. range at MTOW with gasolene (95 RON)DieselMax. range at MTOW with Diesel
Vision: 6 seat fuel cell powered aircraft (DLR-TT+IFB Stuttgart)
Goal: Intermediate, financial atractive demonstration platform
Felix Frey IFB, Josef Kallo DLR 2014
-1000km range with pressurized hydrogen-2000km range with liquid hydrogen
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Electric plane study (M. Hepperle, DLR, 2012-2014)
ES= 360Wh/kgR = 711km
ES= 720Wh/kgR = 1455km
28 seater
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Vision: electric, emission-free flightPassenger airplane (up to 40 Seats) FC+Battery+H2
• 40 seat regional aircraft• > 2 MW – combined hybrid propulsion
power • approx. 1.3 MW cruise • 230-280kts• 400-1000km range feasible
Study is focused on • Propulsion power, • Weight distribution, • Flight stability• Aspects of integrationRather on component integration and thermal managment, not on aerodynamic optimization! Further optimization ofaircraft concept can be expected.
Felix Frey, Josef Kallo 2015
Goal: show feasibility: emission free flight is possible
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Power electronics
Batteries
Electric Motor
Power electronics
Hydrogen tank
RadiatorCoolant reservoir Compressor
Fuel CellsCoolant pump
Outline of an 40 seater regional aircraft with fuel cellpropulsion system
Fuel cell modules with 4 parallel strings, total power >1,3 MwelFuel cell module string voltage ca. 900V
Thermal managementcrucial !
Felix Frey, Josef Kallo 2015
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Electric regional aircraft scenario
ETE 2:15
Stuttgart – Leipzig – Paderborn – Stuttgart
ca. 920 km round trip 2:15
(including takeoff and descent ca. 3:00 in plane)
Stuttgart – Leipzig – Paderborn – Stuttgart
ca. 1245 km round trip 12h:22 min
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Hydrogen consumption and fuel cost
0
0,2
0,4
0,6
0,8
1
1,2
1 seater 4 seater160 km/h
4 seater200 km/h
6 seater280 km/h
40 seater400km/h
H2 Consumption [kg/100km/PAX]
H2 Consumption[kg/100km/PAX]
EE- Hydrogen aprox. 5-7Euro/kg
Conventional Hydrogen produced byMethane processing 2-4 Euro/kg
Taking advantage ofspeed and seat capacity
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• 2013 – overall kerosene and equivalent energy amount used in Germany:
8,8 Mio. tons*
eq.
377 PJ ( at 42,8MJ/kg) **
eq.
105 TWh
Energy amount used in Germany for kerosene fuels2013
* http://www.mwv.de/index.php/daten/statistikeninfoportal** http://www.exxonmobil.com/AviationGlobal/Files/WorldJetFuelSpec2008_1.pdf
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• Based on the 2013 BEE e.V. papera cumulative 34,5 TWh/a surplus energyamount from renewables is expected in 2030(total renewable electrical energy prospectedin 2030 ca. 450TWh/a)
> Vortrag > Autor • Dokumentname > DatumDLR.de • Folie 69
Expected residual energy amount in Germany 2030 fromrenewable energy converters
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Energietechnik
70
• Beispiele für Innere Energie und ArbeitEnergiewandlung
ΔU12 = Δ Q12 + ΔW12
1 m
U1, Q1, W1
U2, Q2, W2
Wärme Mechanische Arbeit
Innere Energie
Bierkisteneinheit (BKE) = m(19,7kg) * g(9,81m/s2) * h(1m) = 193 Joule
‐ Potentielle Energie
Ca. 2 900 000 BKE Stuttgart nach Berlin
Ca. 53 000 000 000 000 000 BKE Weltweit für Luftfahrt
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Energietechnik
Zusammenfassungelektrisches Fliegen mit H2
E40E6HY4
HY4 ‐ AIR TAXI Konzept technologisch realisiert
E6 – Konzept technologisch realisierbar
E40 – Konzept technologisch realisierbar jedoch finanzielle Herausforderungen
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Stellenausschreibungen HY4 – Universität Ulm
3 Stellen Wissenschaftlicher Mitarbeiter/Promotion/Postdoc3 + 2 Jahre Leistungselektronik, Hybridisierung, elektrische Antriebe
Kontakt: [email protected] oder [email protected]
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Energietechnik
Danke für Ihre Aufmerksamkeit!
DLR.de • Folie 73 > Vortrag > Autor • Dokumentname > Datum