zepp.solutions has an Aeronautical Solution

Dean Sigler Announcements, Electric Aircraft Components, Electric Powerplants, Fuel Cells, hydrogen, Hydrogen Fuel, Sustainable Aviation Leave a Comment

Working With the NLR

zepp.solutions is a multi-faceted Dutch firm intent on finding ways to apply hydrogen propulsion systems to sea, land, and aeronautical applications.  Their ultimate product will be the conversion of an eighty-passenger fossil-fuel powered commuter liner into a zero-emission vehicle that loses a few paying passenger to the goal of flying in clean air.  Working with the The Netherlands Aerospace Center (NLR), zepp will start with a Pipistrel Electro Velis as a proof-of-concept machine that will test new fuel cells and associated gear.

zepp describes the large-scale partnership of which it is a part.  “This major Dutch partnership aims at building a hydrogen system for aircraft, completely green, from fuel to propulsion. The system will be scalable to larger aircraft. And it is entirely of Dutch origin. This will make the Netherlands the world’s leading supplier of hydrogen-powered aircraft,” according to zepp.

“Hydrogen Aircraft Powertrain and Storage System (HAPSS)* is an entirely Dutch public-private partnership, set up by Unified International and InnovationQuarter with 17 companies, including FokkerTU Delft, the Dutch government, the Royal Dutch Aerospace Center and zepp.solutions. From the National Growth Fund, €383 million ($398 million) was allocated to the Aviation in Transition program, of which the HAPSS project is the largest component.”

Starting Small

Starting with a student group at AeroDelft, part of the technical university at Delft, zepp will help develop a small, carbon-fiber H2 tank, fuel cell, and power delivery system that will fit in a container under the Velis’ fuselage.   Some of this seems based on similar units developed for drone-size craft created by AeroDelft.  This range extender will augment the existing battery system.  zepp seems happy with battery-hydrogen hybrid systems in its many applications.  zepp will integrate all aspects of the fuel cell system into the Velis.  zepp will make the test flights and work with the NLR on subsequent assessments.

zepp.solutions hydrogen system would act as range extender for existing battery

Arjen Kloosterman is NLR project leader of the project.  “With this project, NLR aims to gain knowledge and experience in the development and integration of hydrogen components and drivetrains for manned aviation. The biggest challenges, in addition to the physical integration, are the airworthiness and safety aspects associated with the introduction of hydrogen on board an aircraft. The entire process, up to the demonstration flight that is now planned for 2026, provides us with valuable knowledge and insights for the integration of hydrogen technology…”  The project will be a big part of the NLR’s, “‘ Climate-neutral aviation ‘, which focuses on the development of innovative and sustainable technologies with the aim of making aviation climate neutral by 2050 at the latest.”

Jan Bot, co-founder of zepp.solutions, is ready to make it happen. “Our fuel cell technology has already proven itself in various sectors. We bring a lot of knowledge and experience when it comes to developing efficient and compact fuel cell systems. However, aviation offers completely different challenges. This collaboration, and being able to learn from each other in this way, is therefore incredibly valuable. In the development of the hydrogen system for the Pipistrel, we will not only demonstrate the possibilities of hydrogen in aviation together with NLR, but we will also learn lessons that can be of great value to this sector.”

zepp’s Hydrogen Background

As noted earlier, zepp has a varied background in H2 applications, included those on land, sea, and now in the air.

By Land

Land-based power systems seem to include every type of wheeled or tractor vehicle.  Liebherr excavators, for instance, use a zepp.solutions Y50 power system to run a formerly polluting Diesel-powered rig.   zepp powers the Terberg Benschop B.V. fuel cell yard tractor, the YT203-H2, a clean way of moving things like cargo containers around a marshalling yard.

For cross-country transport of goods, zepp offers the Europa hydrogen-powered truck.  zepp is developing  DREAMH2AUL – Hydrogen-electric semi trucks,  “A hydrogen fuel cell system with an extremely high power density. This system will be integrated into 2 semi-trucks that will carry enough hydrogen tanks for a range of at least 600 km. These trucks will refuel green hydrogen at a public filling station that will be realized within the project on the important North Sea-Baltic TEN-T Corridor.”

zepp TULIPS ground power unit in action at Schipol Airport

By Sea

zepp powers SWIM. an H2-powered water taxi in Rotterdam.  Delivered in mid 2022 and christened on August 30, SWIM began hauling passengers in the second half of 2022 and has been in commercial operation ever since.

zepp.solutions’ SWIM water taxi provides clean transport in Rotterdam Harbor

Ab-Initio is a training ship with a combination of electric and fuel-cell propulsion.  Over 200 square meters (2,153 square feet) of solar panels help provide current to the ship, coupled with a zepp maritime 50kW system.  Its maker describes it thus: “Overall, what makes Ab Initio a leader in sustainability? The 67-meter-long, 8.2-meter-wide vessel, with a maximum draft of 1.8 meters, features multiple generators, a lithium-ion battery pack, a 50 kW fuel cell module that can run on hydrogen, 200 m² of solar panels and a wind turbine. It also has a wastewater treatment plant on board. The ship can run emission-free for 4 hours at a time and can carry 39 passengers.

ISHY – Implementation of Ship Hybridization

An ambitious project to overcome the barriers of low return on investment (ROI) for new vessels, long service life for existing vessels, and reluctance to retrofit or try new technology, zepp is working to develop a maritime fuel cell module to be used in different pilot vessels.  This means working on related solutions for alternative fueling and creation of new infrastructures.  Said to have been completed in 2022, things like the SWIM harbor transport  and Ab Initio may be early signs of interest in the industry.

With so many successful projects and a firm understanding of fuel cells and electric propulsion, one can hope for and anticipate further success with the HAPPS program and cooperation from the NLR.  Competition from firms like ZeroAvia, Universal Hydrogen and even Airbus will add impetus to their efforts.

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