FuelCellsWorks

Flying test laboratory will further the development of fuel cells for aerospace applications

On 7 July 2009, Antares DLR-H2, the world’s first piloted aircraft capable of taking off using only power from fuel cells, demonstrated this capability at Hamburg Airport. Antares DLR-H2 has been developed by the German Aerospace Center (Deutsches Zentrum für Luft- und Raumfahrt; DLR). The Antares flies with zero CO2 emissions and has a much lower noise footprint than other, comparable, motor gliders. The propulsion system for this aircraft was developed at the DLR Institute for Technical Thermodynamics (Institut für Technische Thermodynamik – Stuttgart) in collaboration with its project partners – Lange Aviation, BASF Fuel Cells and Serenergy (Denmark). This motor glider achieves new quality standards in the field of high-efficiency, zero-emission energy conversion and clearly demonstrates the progress that has been made in fuel cell technology.

The centrepiece and greatest innovation on the Antares DLR-H2 is the fact that it is powered directly by means of an ultra-efficient fuel cell. “We have improved the performance capabilities and efficiency of the fuel cell to such an extent that a piloted aircraft is now able to take off using it,” stated Prof. Dr-Ing Johann-Dietrich Wörner, Chairman of the Executive Board at DLR. “This enables us to demonstrate the true potential of this technology, also and perhaps specifically for applications in the aerospace sector. Coupled with our expertise in fuel cell technology, DLR’s many years of extensive experience in gaining official approval for aerospace systems are what made the Antares DLR-H2 a feasible proposition.”

Standard motor glider retrofitted with fuel cell drive

The Antares DLR-H2 is based on the Antares 20E motor glider with a wingspan of 20 metres, constructed by Lange Aviation, a company based in the Rhineland-Palatinate region of Germany. With its fuel cell propulsion system, Antares has a cruising range of 750 kilometres, achieved in a flying time of five hours. In order to accommodate the fuel cell and the hydrogen supply on board the aircraft, two additional external load carriers were slung under the specially reinforced wings. Due to the extra 100 kilograms of payload that each of these removable and flexibly interchangeable containers is able to carry, the aeroelastic properties of the wings had to be reconfigured to prevent any adverse impact on the flight stability of the aircraft. Optimisation work at the DLR Institute for Aeroelasticity (Institut für Aeroelastik – Göttingen) now provides the Antares DLR-H2 with an assured capability to fly at speeds of up to 300 kilometres per hour without any wing flutter. The current propulsion system permits maximum flying speeds of approximately 170 kilometres per hour.

A fuel cell system is the centrepiece of propulsion technology

The fuel cell system was developed by the DLR Institute for Technical Thermodynamics in collaboration with BASF Fuel Cells (electrolytic membrane and catalysts) and Serenergy A/S (stack subsystem). The system uses hydrogen as its fuel, and this is converted into electrical energy in a direct, electrochemical reaction with oxygen in the ambient air, without any combustion occurring. During this zero-particulate reaction, the only by-product is water. If the hydrogen fuel is produced using renewable energy sources, then the motor glider genuinely flies without any CO2 emissions whatsoever. The fuel cell is slung under the left wing and the hydrogen tank under the right wing – with a capacity of either 2 or 4.9 kilograms. The fuel cell system used to power the Antares delivers up to 25 kilowatts of electrical power. When flying in a straight line, the aircraft only requires about ten kilowatts of power. In this situation, the fuel cell is operating at an efficiency level of approximately 52 percent.

The total efficiency of the drive system from tank to powertrain, including the propeller, is in the region of 44 percent, making it about twice as efficient as conventional propulsion technologies based on combustion processes. Systems powered by kerosene or diesel only contribute about 18 to 25 percent of their energy to propulsion.

“The top priority in this project is of course the safety and reliability of the fuel cell propulsion system,” stated Antares Project Manager Dr-Ing. Josef Kallo from the DLR Institute for Technical Thermodynamics. However, having the correct architecture for the entire system is just as important for full implementation of this project: ”This includes having an absolutely reliable fuel cell, in conjunction with propulsion system of the aircraft and, last but not least, a fully mature configuration for the aerodynamics and aeroelasticity of the motor glider.”

Another new feature of the Antares is the way its fuel cell is connected to the main electric motor that powers the aircraft. The motor controller, developed jointly with Lange Aviation and with the College of Advanced Technology in Berne/Biel, is capable of taking in and controlling voltages from 188 to 400 V. Through the direct link between fuel cell and motor, efficiency, costs, reliability and maintenance costs are minimised.

Fuel cell as future energy source for air transport

“With our successful first flight, we have verified the feasibility of fuel-cell powered flight and our next steps will focus on improving efficiency levels and on extending the service life of these systems”, stated Dr Kallo.  This could, for example, make it possible to significantly improve performance by optimising the cooling concepts, fuel cell architecture and components such as the air supply system. “At this stage, we have only tapped into a fraction of the performance capabilities of this technology for aerospace applications. The Antares DLR-H2 will help us to make much greater use of these areas of potential.”

Although the fuel cell may still be a long way from becoming the primary energy source for the propulsion of commercial aircraft, it does already constitute an interesting and important alternative to existing energy systems as a form of reliable on-board power supply. High efficiency levels go hand in hand with minimum pollutant emissions, lower noise levels, safe flying operations and high standards of passenger comfort. The aim of the research work being conducted by DLR is to employ fuel cells in real-life applications for commercial air transport – as a reliable supply source for on-board power. In an initial stage of development, DLR collaborated with Airbus Germany on a fuel cell system for providing an emergency power supply to the hydraulic pumps used to control the DLR research aircraft – the Airbus A320 ATRA. In a second step, the ongoing use of a fuel cell system to provide an on-board supply in large-volume transport aircraft is firmly on the drawing board. In future, the Antares DLR-H2 motor glider will provide a cost-effective platform for testing fuel cell systems for aerospace. Among other things, this optimises the test time of the DLR Airbus A320 ATRA.

Flying test laboratory will in future be teaming up with the Fuel Cell Lab in Hamburg

The Antares DLR-H2 will be based at Lufthansa Technik in Hamburg where, over the next three years, it will be acting as a flying test platform for the fuel cell test activities of DLR as part of its Fuel Cell Labs project. The Fuel Cell Lab was brought into being by the City of Hamburg on a joint basis with DLR and Airbus/EADS and is intended to ‘bundle’ a high proportion of the hydrogen and fuel cell activities being conducted in the greater Hamburg region. By stationing this research aircraft on the premises of Lufthansa Technik, direct contact can be established with an experienced technical development and maintenance operation in the air transport business. This linkage will also help to enhance the ease of operation and maintenance of the future fuel cell systems designed for use in large-volume air transport and developed by DLR in its capacity as a development partner for Airbus. To safeguard and further develop the level all-round flying expertise for this new fuel cell application, DLR and Lange Aviation GmbH have co-signed a cooperation agreement. Other partners who have already joined include BASF Fuel Cell GmbH, Serenergy A/S and Lufthansa-Technik AG, who came on board in the course of 2008.

LATHAM, N.Y., July 7, 2009 (GLOBE NEWSWIRE) — Plug Power Inc. (Nasdaq:PLUG), a leader in providing clean, reliable energy solutions today announced that they have received a $1.4 million award from the New York State Energy Research and Development Authority (NYSERDA) to install and operate three combined heat and power (CHP) GenSys(r) fuel cell systems in New York State homes. These systems will allow Plug Power to validate and enhance product features in preparation for broad scale product commercialization. The first system is scheduled to be installed this summer with all three units expected to be operational this year.

A residential GenSys unit will be installed in the basement of each home and will operate in conjunction with the electric grid, running on natural gas. The fuel cell will produce electricity and high-quality heat to satisfy the home’s heating and domestic hot water demands. Plug Power estimates that GenSys will save the homeowner approximately 30% on their monthly utility bill.

The GenSys solution is expected to achieve an overall combined efficiency of 85%. Currently, homes utilizing grid electricity and typical heating systems average 44% household efficiency. “This increased efficiency level yields an annual CO2 reduction roughly equivalent to not driving your car for six months,” said Mark Sperry, Vice President of Plug Power’s Continuous Power Division. “The residential GenSys solution will allow for tremendous reductions in monthly energy bills and greenhouse gas emissions.”

“This project marks another step toward the commercialization of our residential GenSys product,” said Andy Marsh, CEO at Plug Power. “GenSys’s state-of-the-art technology has moved out of the labs and into real homes — homes with families, pets and swimming pools. This product will revolutionize the way energy is used around the world.”

Other partners on this project include:

  * National Grid for site selection and grid interconnection
  * CSA Engineering Services, LLC for mechanical integration to the
    home heating system and grid interconnection design
  * Chuck Russo Heating and Air Conditioning, LLC for mechanical
    installation of GenSys fuel cell systems
  * Socaris Electric for electrical installation of GenSys fuel cell
    systems

NYSERDA has funded several projects to advance the development of Plug Power’s high-temperature fuel cell system, and this milestone project marks the culmination of many years of collaboration.

NYSERDA President and CEO Francis J. Murray, Jr. welcomed the demonstration: “Plug Power’s continuing leadership in developing residential fuel cell units has been demonstrated through its GenSys program. NYSERDA is pleased to match Plug Power’s $1.44 million investment in its development, and we look forward to receiving its operating results as a step toward commercialization of a unit that could dramatically reduce a homeowner’s energy bill and carbon footprint at the same time.”

About Plug Power Inc.

Plug Power Inc. (Nasdaq:PLUG), an established leader in the development and deployment of clean, reliable energy solutions, integrates fuel cell technology into motive, continuous and backup power products. The Company is actively engaged with private and public customers in targeted markets throughout the world. For more information about how to join Plug Power’s energy revolution as an investor, customer, supplier or strategic partner, please visit www.plugpower.com.

Demonstration of “zero carbon” home energy system and agreement to supply demonstration kitchens and electricity storage systems to showcase housing development

ITM announces that, in line with the strategy set out in June 2009, it is today launching and demonstrating the equipment needed to realise a “zero carbon” home power system aimed at taking commercial advantage of UK legislation on emissions from new homes.

Housing currently contributes just under half of the UK’s carbon emissions and the Government’s July 2007 Building A Greener Future – Policy Statement announced that all new homes will be zero carbon from 2016. ITM has applied its patented technology to designing and building a zero carbon domestic energy system providing heating, lighting, and electric power plus the storage needed to allow this to operate from renewable resources. The system makes and stores non-polluting hydrogen which is then used in specially adapted household appliances. This system is being launched and demonstrated today to media, local authorities, potential commercial partners and potential joint-venture partners. The system has been designed to run from renewable sources of power as well as the national grid.

In addition, ITM announces that it has agreed to participate in the building of an innovative demonstration housing development in South Shields, supplying its expertise and technology, in order to show that affordable housing can be made a net producer, rather than a net consumer of energy. The housing development is being built by a partnership between Groundwork South Tyneside & Newcastle with ONE Northeast, Four Housing Group, and South Tyneside Council. The development is being financed by the partners. These houses and apartments will incorporate the best and most practical aspects of building design commensurate with the cost of the properties still allowing for their designation as affordable homes and will be no less comfortable or convenient to live in than a conventional dwelling.

In addition to ITM’s hydrogen technology, the site will feature state of the art heat pumps, solar energy, renewable wind energy, and modern low energy lighting. ITM will fit two of the properties with hydrogen powered kitchens while hydrogen will also be used as an energy store and for provision of electricity to the properties and for the site lighting. The site will be connected to the grid with energy flows in and out from a 225KW wind turbine. Final designs for the development are now being completed and it is expected that application for full planning permission will be made in late August 2009. If successful, Groundwork envisages rollout of the ITM energy package throughout projects in the North East region.

Commenting on today’s news, Dr Graham Cooley, ITM’s newly appointed CEO, said, “I am committed to pursuing multi-market routes to commercialisation with the best strategic fit to the Company’s technology.  Today’s demonstration and the showcase agreement with Groundwork will bring us to the attention of potentially one of the most important of these markets.”

For further information please visit www.itm-power.com or contact:

Melbourne-based clean energy company Ceramic Fuel Cells Limited (ASX/AIM: CFU), a global leader in fuel cell development, today announced it had appointed Mr. Roy Rose to its board.

Mr. Rose, based in Melbourne, will be a non-executive director of the company and will join the board’s Technical Committee.

Mr. Rose, aged 62, has 30 years experience in the paint, chemicals, fertilizer and medical products industries and brings to Ceramic Fuel Cells strong skills in technology and innovation, including experience commercialising and manufacturing innovative technologies.

Mr. Rose has held non-executive directorships of Incitec Limited, CRC for Environmental Biotechnology and Qenos Pty Ltd.  Mr. Rose has also held senior management positions at Orica Australia.

He is currently chairman of CSIRO’s Future Manufacturing Flagship Advisory Committee and is a non-executive director of ITL Limited, a rapidly growing medical technology company specializing in innovative medical devices, hospital equipment and pre-sterilized surgical procedure packs. Mr. Rose chairs ITL’s Audit & Risk Management Committee.  ITL Limited is based in Australia, with manufacturing facilities in Malaysia and customers in 35 countries.

Mr. Rose has a B.Sc with a major in chemistry from Monash University and is a member of the Australian Institute of Company Directors.

Mr. Rose has also served on the following industry groups:

Member & Past President – Australian Industrial Research Group

Member – Green Chemistry Centre Advisory Board, Monash University

Member – Industrial Advisory Group, Faculty of Science, Melbourne University

Member – Intellectual Property Research Institute of Australia Advisory Board

Member – Prime Minister’s Science, Engineering & Innovation Council Working Group “Australia’s Science & Technology Priorities for Global Engagement” (2006)

Member – Energy Futures Forum (2005-2006)

Member – National Nanotechnology Strategy Taskforce Reference Group (2005)

Member – Low Energy Technology Action Group (2005)

BOULDER, Colo. — Fuel cells have long represented an elusive opportunity, literally a technology in search of a market, with hockey stick growth curves perpetually only a few years away. However, according to a new report from Pike Research, the key to fuel cells’ adoption lies in the tactical alignment of their capabilities with the growing need for reliable, long-lasting, affordable alternatives to conventional batteries and small generators for many different portable device categories.

“There is no one killer app for fuel cells. Instead, there are dozens of niche applications that have an increasing need for the clean, reliable power that fuel cells can provide,” says industry analyst Bill Matvichuk. “Over the next several years, fuel cell manufacturers must tailor their offerings to serve the specific requirements of a multitude of consumer and industrial products.”

Matvichuk argues that these applications will be determined largely by the power level capabilities of the fuel cells themselves. A few examples for each of the power level segments are as follows:

1-20 watts – consumer electronics, small appliances, toys, remote sensors 20-100 watts – unattended sensors, video surveillance, medical devices, military electronics 100-500 watts – first responder battery charging, power tools, unmanned vehicles Sub 2 kilowatts – replacement for gasoline and diesel generators, watercraft, combat support systems, auxiliary power units 2-7 kilowatts – materials handling such as forklifts, weapon systems, causeway systems

Pike Research’s report, “Fuel Cells for Portable Power Applications”, provides a tactical, applications-oriented analysis of the emerging market for portable fuel cells. It examines the market opportunity for specific niche applications within five key power level segments: 1-20W, 20-100W, 100-500W, 1-2 kW, and 2-7 kW. The report also includes profiles of key industry players and global market forecasts through 2017. An Executive Summary of the report is available for free download on the firm’s website.

Pike Research is a market research and consulting firm that provides in-depth analysis of global clean technology markets. The company’s research methodology combines supply-side industry analysis, end-user primary research and demand assessment, and deep examination of technology trends to provide a comprehensive view of the Renewable Energy, Clean Transportation, Clean Industry, Green Consumers, and Environmental Management sectors. For more information, visit www.pikeresearch.com or call +1.303.997.7609.