Design considerations of hydrogen fuel cell-powered aircraft: Safety risks, hydrogen handling, and barriers to commercialization

Abstract

The aviation industry faces mounting pressure to decarbonize. While sustainable aviation fuel (SAF) and batteries have limitations, hydrogen fuel cells (HFC) propulsion have emerged as a promising solution for zero-emission flight. HFC-powered aircraft could reduce emissions by 75-90%, especially in the CS-23 aircraft category. However, the implementation of HFC technology presents various economic and design challenges, adding a layer of complexity to the problem of renewable hydrogen sources. This paper meticulously presents a comprehensive examination of hydrogen fuel cell-powered aircraft, aiming on three essential areas: system design, safety risks associated with hydrogen handling, and the barriers impending commercial adoption. The technical section looks at the design architecture of fuel cell systems, including liquid hydrogen storage, thermal management, and integration with electric propulsion systems. The safety analysis highlights key risks such as hydrogen leakage, ignition potential, and cryogenic storage challenges, along with mitigation strategies. Finally, the paper discusses the economic, regulatory, and infrastructural challenges that hamper widespread implementation. By bridging engineering insights with policy and safety considerations, this work aims to provide a holistic perspective on the future of hydrogen aviation. The findings revealed that the design of HFC-powered aircraft is significantly impacted by factors such as increased aircraft weight, on-board hydrogen storage, propulsion architecture, and system integration. In conclusion, this review provides a comprehensive and reliable overview and progression of HFC- powered fixed-wing manned aircraft design concepts, highlighting underexplored research areas and offering valuable insights for the industry.