The INLINE project aims at the solution of key challenges to enable the implementation of a scalable manufacturing process for fuel cell systems. Current manufacturing processes rely on manual work that has substantial limits in terms of cycle times, costs and scalability. Developments will start with the re-design and optimization of two key components: the media supply unit and the tank valve regulator. Both are components that are currently difficult to manufacture and are perceived as bottlenecks in the production process. Based on these new designs, an integrated production line will be planned using simulation tools. These tools will enable the evaluation of different layouts, part flow strategies and for different production scenarios. In terms of manufacturing tools, the end of line test will be improved to reduce cycle times by a factor of 3 and assistance systems for assembly stations will be developed that will enable scalability by reducing the need for training of workers. The overall target is to reduce the cycle time for production of a whole fuel cell system from 15 hours to less than 2.5 hours. Data gathering and analysis methods will be developed to enable the tracking of parts through the production line and - through a correlation of process and quality data - the continuous improvement of the production process. Demonstration of the end of line test and the assistance system will be done in hardware. The whole production line will be evaluated using a simulation tool that has been verified on the current production process. A set of engineering samples of the re-designed tank valve regulator and the media supply unit will be produced and used for tests of the integrated fuel cells and for assessment of the whole production process.A potential of 250 new jobs in manufacturing of fuel cells and for production of the key components will be generated by the project.

The TROPHY project, which stands for “Technological Research On Propulsion by HYdrogen”, aimed at supporting the Clean Aviation HYDEA funded project (HYdrogen DEmonstrator for Aviation), which proposes a technology maturation plan to develop an H2C (Hydrogen Combustion) propulsion system compatible with an Entry Into Service of a zero CO2 low-emission aircraft in 2035. TROPHY supported design activities related to the development of an H2 engine fuel system as well as the investigation of integration aspects between engine and aircraft. Decision was made by the consortium to close TROPHY grant agreement as it turned out that key objectives as initially envisaged were no longer relevant.

The goal of the SH2APED project is to develop and test at TRL4 a conformable and cost-effective hydrogen 70 MPa storage system with increased efficiency and unprecedented safety performance. The innovative storage system is composed of the assembly of 9 tubular vessels fitting into a design space of 1800x1300x140 mm used for the battery pack. Fire resistance and mechanical robustness are drastically improved while the cost is decreased by 20% compared to the state-of-the-art Type IV tanks. This architecture allows a modular system configuration fitting into the flat space of light-duty car underbodies. All the vessel and the system elements are being manufactured using know-hows and high-throughput processes. Performance parameters and KPIs are monitoring in compliance with the current regulations, codes and standards (RCS) aiming the update of RCS by new knowledge and technological breakthroughs and simplification of certification. Economic assessment for industrial mass manufacturing is in line with the expectations of the automotive industry. The SH2APED consortium is a strong partnership of two industrials, one federal institute and one university. Optimum CPV - Plastic Omnium is the leader in hydrogen vessels fabrication for the automotive industry. Misal Srl is the highly skilled on mechanical components machining. BAM is the expert on safety and reliability of high-pressure composite cylinders. Ulster University is one of key providers of hydrogen safety research globally. In addition, a vital contribution to the project is expected from the Advisory Board comprising vehicle manufacturers including Daimler, Toyota, Audi, Geely, FIA, GreenGT. They will advise the project on the SH2APED system integration in light-duty fuel cell vehicles and validate the project results.

The HYDEA project, which stands for “HYdrogen DEmonstrator for Aviation”, proposes a robust technology maturation plan to develop an H2C (Hydrogen Combustion) propulsion system compatible with an Entry Into Service of a zero-CO2 low-emission aircraft in 2035, consistently with the expected timeframe of the European Green Deal and CA SRIA objectives. The project aims to address fundamental questions related to the use of hydrogen as an aviation fuel, concentrating on the development and testing in relevant conditions of an H2 combustor and H2 fuel system, also including emission studies and further technologies which will serve as an outlook to future engines, i.e. NOx optimization studies, potential contrails emissions and investigating integration aspects between engine and aircraft. HYDEA results will be core for the ZEROe technology exploration project, launched by Airbus in 2020. The revolutionary technologies in scope call for an early engagement and dialogue with EASA (European Union Aviation Safety Agency) within HYDEA, starting from phase 1.

In MARANDA project an emission-free hydrogen fuelled PEMFC based hybrid powertrain system is developed for marine applications and validated both in test benches and on board the research vessel Aranda, which is one of about 300 research vessels in Europe. Special emphasis is placed on air filtration and development of hydrogen ejector solutions, for both efficiency and durability reasons. In addition, full scale freeze start testing of the system will be conducted. When research vessels are performing measurements, the main engines are turned off to minimize noise, vibration and air pollution causing disturbance in the measurements. The 165 kW (2 x 82.5 kW AC) fuel cell powertrain (hybridized with a battery) will provide power to the vessel's electrical equipment as well as the dynamic positioning during measurements, free from vibration, noise and air pollution. One of the major obstacles for wider implementation of fuel cells in the marine sector is the hydrogen infrastructure. To alleviate this problem, a mobile hydrogen storage container, refillable in any 350 bar hydrogen refuelling station will be developed in this project. This novel solution will increase hydrogen availability to marine sector as well as many other sectors. The consortium of this project contains companies from the whole fuel cell value chain, from balance-of-plant components to system integrator and end user. The fuel cell system will be tested in conditions similar to arctic marine conditions before implementation to the target vessel. In addition, long-term durability testing (6 months, 4380 operating hours) of the system will be conducted at an industrial site. The project will increase the market potential of hydrogen fuel cells in marine sector, which have for long lagged behind road transportation. General business cases for different actors in the marine and harbor or fuel cell business will be created and therefore the impacts in the whole industry will be notable.