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A Study on Thermal Management Systems for Fuel-Cell Powered Regional Aircraft

Author

Listed:
  • Manuel Filipe

    (Instituto de Engenharia Mecânica, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1049-001 Lisboa, Portugal)

  • Frederico Afonso

    (Instituto de Engenharia Mecânica, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1049-001 Lisboa, Portugal)

  • Afzal Suleman

    (Instituto de Engenharia Mecânica, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1049-001 Lisboa, Portugal
    Department of Mechanical Engineering, University of Victoria, Victoria, BC V8W 2Y2, Canada)

Abstract

This work studies the feasibility of integrating a hydrogen-powered propulsion system in a regional aircraft at the conceptual design level. The developed system consists of fuel cells, which will be studied at three technological levels, and batteries, also studied for four hybridization factors (X = 0, 0.05, 0.10, 0.20). Hydrogen can absorb great thermal loads since it is stored in the tank at cryogenic temperatures and is used as fuel in the fuel cells at around 80 °C. Taking advantage of this characteristic, two thermal management system (TMS) architectures were developed to ensure the proper functioning of the aircraft during the designated mission: A1, which includes a vapor compression system (VCS), and A2, which omits it for a simpler design. The models were developed in MATLAB ® and consist of different components and technologies commonly used in such systems. The analysis reveals that A2, due to the exclusion of the VCS, outperformed A1 in weight (10–23% reduction), energy consumption, and drag. A1’s TMS required significantly more energy due to the VCS compressor. Hybridization with batteries increased system weight substantially (up to 37% in A2) and had a greater impact on energy consumption in A2 due to additional fan work. Hydrogen’s heat sink capacity remained underutilized, and the hydrogen tank was deemed suitable for a non-integral fuselage design. A2 had the lowest emissions (10–20% lower than A1 for X = 0), but hybridization negated these benefits, significantly increasing emissions in pessimistic scenarios.

Suggested Citation

  • Manuel Filipe & Frederico Afonso & Afzal Suleman, 2025. "A Study on Thermal Management Systems for Fuel-Cell Powered Regional Aircraft," Energies, MDPI, vol. 18(12), pages 1-21, June.
    • Handle: RePEc:gam:jeners:v:18:y:2025:i:12:p:3074-:d:1676221
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    References listed on IDEAS

    as
    1. Qian Wu & Zhiliang Dong & Xinfeng Zhang & Chaokai Zhang & Atif Iqbal & Jian Chen, 2025. "Towards More Efficient PEM Fuel Cells Through Advanced Thermal Management: From Mechanisms to Applications," Sustainability, MDPI, vol. 17(3), pages 1-26, January.
    2. Wu, Wei & Zhai, Chong & Sui, Zengguang & Sui, Yunren & Luo, Xianglong, 2021. "Proton exchange membrane fuel cell integrated with microchannel membrane-based absorption cooling for hydrogen vehicles," Renewable Energy, Elsevier, vol. 178(C), pages 560-573.
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