An Airbus A320 that was used for almost 31 years in commercial flights, is now being converted to be a test laboratory, by Lufthansa Technology.
The aircraft registration D-AIQF, manufactured in 1991 and equipped with CFM 56 engines, will receive a kit to change the fuel from kerosene to hydrogen, this includes new fuel tanks where previously there were seats for engers. These will store liquid hydrogen (LH2).
The focus of this experiment is not to use the A320 to carry out hydrogen-powered flights, but to optimize the ground structures to receive this type of propulsion in the future in several different aircraft.
With current technology, it takes several hours to fill an aircraft the size of the A320 with Liquid Hydrogen, due to the condensation factors and the safety of injecting fuel under pressure. With the A320 these processes will be optimized.
For this reason, the Hydrogen Aviation Lab will often be deployed on the apron at Hamburg Airport to assess ground operations on a number of different issues.
Parallel to the research carried out with the physical hardware of the Hydrogen Aviation Lab, the project also involves the creation of the so-called digital twin of the Airbus A320. In it, simulations will allow researchers to develop and test predictive maintenance methods for systems and components of future generations of aircraft. Using targeted data analysis, component and hydrogen system failures can be predicted prior to their failure in the physical system, allowing for timely replacements before component failures affect aircraft operation.
The project, which is being funded by the Hamburg Ministry of Economic Affairs and the IFB Hamburg development bank, is a partnership between Lufthansa Technik, Hamburg Airport, the German aerospace center DLR and the ZAL Center for Applied Aeronautical Research.
Key research topics and core questions that will be researched using the Hydrogen Aviation Lab
Refueling with liquid hydrogen:
- How can hydrogen be optimally integrated into existing airport infrastructure?
- How do we ensure competitive replenishment times and processes?
- How do we avoid overfilling and wasting hydrogen?
Cooling, insulation and safety at work:
- How do we prevent ice buildup on components and surfaces?
- What additional protection requirements may arise in the work area
- (e.g. No Step / No Grab, personal protective equipment)?
Hydrogen gas leak, called “Boil-Off”:
- How do we prevent uncontrolled LH leakage? 2 when it becomes gaseous (GH 2 )?
- What safety protocols are required for handling hydrogen, for example during refueling and storage?
- How can we recover GH 2 escaped and make it usable again?
Making stored hydrogen inert:
- What protective measures need to be taken to mitigate hydrogen fire hazards?
- What might the proper security protocols look like?
- What training needs to be developed for ground or maintenance personnel?
