“ZeroAvia Certification-Intent Fuel Cell System, Successfully Replicates Full Flight Profile in Ground Test”
ZeroAvia announced this week it has completed a full flight profile ground test of its certification-intent low temperature proton exchange membrane (LTPEM) fuel cell power generation system (PGS) for the ZA600 hydrogen-electric powertrain, reports a press release.
The release explains, “The test simulated a 250 nautical mile flight in a Cessna Caravan 208b aircraft, equivalent to flying between London Heathrow and Dublin Airport. During the 2 hour and 38 minute test, the fuel cell system demonstrated stable power output and excellent performance of the balance-of-plants, with each 200kW capable module producing 170kW power for take-off, 132kW during a 23-minute climb and 83kW for a 90-minute cruise.”
It continues, “As part of the ZA600 hydrogen-electric powertrain for up to 20 seat planes, four 200kW rated modules of the dual stack PGS will provide electrical power for ZeroAvia’s 600kW electric propulsion system, recently the subject of G‑1 and P‑1 issue papers from the FAA.”
Fuel Cell Power Generation System
Val Miftakhov, Founder & CEO of ZeroAvia, commented, “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.”
Each module is capable of feeding DC electrical power to four ZeroAvia 200kW rated inverters, which in turn provide AC power to one of four segments of the company’s proprietary 600kW motor design. The segregated system enables full power operation of the motor if there is failure in one leg, creating a high degree of fault tolerance.
For the ZA600 engine, ZeroAvia has created a multi-stack balance-of-plant architecture capable of delivering 1.4 kW/kg power density. Since initial breakthrough flight tests, the company has been working to finalise the design of the certification-intent ZA600 as it works to certify with the UK CAA.
Miftakhov continued, “What we have achieved with the Venturi ejector device for the recirculation of hydrogen gas within the fuel cell system, is groundbreaking and further enhances an already commercially attractive, highly efficient and certifiable fuel cell propulsion system.”
The company has brought to its design various innovations including novel humidification approach; novel gas distribution system; and the multistack BoP architecture itself. Importantly, all of these innovations now have a clear and direct path to aviation qualification and certification.
The company also revealed this week it has optimised the weight and operation of its ZA600 power generation system (PGS) through the design and development of the Venturi device in conjunction with supplier The Lee Company.
Val Miftakhov
The release continues, “The latest round of testing has seen the light and compact Venturi emulating the performance of a typical electrically-driven hydrogen blower, but with many advantages. Where the heavy and bulky blower system draws parasitic power from the fuel cells, the Venturi does not, boosting the overall specific power of the system. As a passive mechanical body, the Venturi also promises very low failure rates.”
ZeroAvia’s ZA600 power generation system is the world’s first fuel cell module designed to meet CS‑E and CS-23 certification requirements. The innovative balance of plant is en route to full certification and commercialisation and is well advanced in the requirements validation testing campaign.
Meanwhile, ZeroAvia aims to full engine ground testing of the final design in the next few weeks. The company has already extensively tested a prototype of its first ZA600-engine aboard a Dornier 228 aircraft at its UK base.
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(Top image: ZA600 Aircraft)
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