Launched at the end of 2021, this project brings together Airbus, SEGULA Technologies, Applus Laboratories, Ingeteam, CESA and CiTD with a common goal: to prepare for the arrival of the first commercial aircraft powered by hydrogen, for cleaner and more sustainable aviation.

What are the advantages of liquid hydrogen?

The major advantage of liquid hydrogen (LH2) is its energy density. For the same volume, it contains much more energy than gaseous hydrogen and therefore promises greater autonomy for aircraft. However, this choice poses significant challenges. Hydrogen is highly flammable and must be stored at an extreme temperature of -253°C to remain liquid. In an aircraft, where conditions are particularly demanding, designing reliable and safe systems is therefore a real technological challenge. ‘So far, hydrogen is still at the prototype stage. The challenge is to take a decisive step forward by developing solutions that can operate in such complex environments,’ emphasises Rubén Hernández Librán, Technical Director for Madrid and Sines (Portugal) in the Industry and Energy Division. By focusing on liquid hydrogen, the project is exploring an ambitious path: making hydrogen usable on a large scale in aviation and turning it into a credible alternative to fossil fuels.

Legend : 3D concept image:
the rear compartment
where the entire LH2 energy
production system would be
located.

SEGULA’s contribution: safety and component integration

Legend : Example of a CFD simulation: N2
flow in the evaporator

Within the ZERO project, SEGULA is Working on two missions. The first concerns safety and reliability: analysing the risks associated with the engine and its components, anticipating possible failures and ensuring that the entire system operates safely and is available in all
circumstances. The second mission focuses on component integration. One of the key
elements is the heat exchanger, a device that converts liquid hydrogen into gaseous hydrogen to power either a microturbine or a fuel cell. SEGULA is conducting specialised studies to verify that this process is running correctly and safely. To analyse fluid behaviour, engineers use advanced simulation software (CFD methodology). These calculations not only validate the operation of the heat exchanger, but also study how hydrogen could disperse in the event of a leak in the aircraft. This data is then used to determine the location of detectors, as well as shutdown and emergency protocols, to ensure maximum safety on board.

Full-scale tests

In addition to numerical simulations, SEGULA wants to compare its results with tests carried out in real conditions. The company therefore plans to conduct 1:1 scale tests in collaboration with two specialised centres: the CTA (Aeronautical Technology Centre) and the National Hydrogen Centre. The aim is to reproduce hydrogen leaks in a simulated aircraft cabin
in a controlled manner and to measure their dispersion accurately using sensors. This data will enable the results obtained during the tests to be compared with the numerical simulations (CFD) and the reliability of the models to be validated.

The ZERO project is supported by the CDTI (Centre for Technological Development and
Innovation) as part of the 2021 call for projects aimed at financing strategic sectoral initiatives for entrepreneurial innovation. It is part of the Recovery, Transformation and Resilience Plan,  financed by Next Generation EU funds through the Recovery and Resilience Facility, as well as the National Programme for Entrepreneurial Leadership in R&D&I and the National Plan for Scientific, Technical and Innovation Research 2017-2020.

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