German Aerospace Center (DLR)
Commissioning of the Balis test environment
The German Aerospace Center (DLR) put the Balis test field into operation on October 28, 2024. DLR is using this test infrastructure to develop and test innovative propulsion systems based on hydrogen fuel cells with an output in the megawatt range.
In the Balis project, the German Aerospace Center (DLR) is building a unique scientific test field in Empfingen. DLR is using it to develop and test fuel cell drives for various modes of transportation. The Balis project focuses on fuel cell systems with an output of around 1.5 megawatts, which will power ships, for example, and could be used in aviation in the future. Such systems are not yet available on the market. If hydrogen from renewable sources - so-called green hydrogen - is used in fuel cells, they enable CO2-free and therefore climate and environmentally friendly mobility. The plant is located on the innovation campus of the E2U Empfingen Development Center for Environmental Technology. The Federal Ministry for Digital and Transport Affairs is funding the Balis test field with 26 million euros.
The complex and modular test field makes it possible to comprehensively examine individual components as well as entire drive trains: These include the fuel cell system itself, electric motors, tank infrastructure as well as control and regulation technology. Due to its flexible design and the associated research methodology, the facility is unique in the world. All parts of the system are housed in containers. The DLR Institute of Technical Thermodynamics is responsible for the project.
New generation of fuel cell systems for climate-friendly mobility
In addition to setting up and operating the test field, DLR is also building its own electric drive system in the megawatt performance class. It consists of a fuel cell system, hydrogen tank, electric motor, control components and power electronics. This makes DLR one of the first facilities to have such a system. It can be used to fundamentally record, understand and qualify all process steps of a fuel cell drive system. The largest commercially available fuel cells for mobile applications have an output of up to several hundred kilowatts. In order to reach the megawatt range, the fuel cell systems must be constructed from several interconnected fuel cell modules. This results in high operating voltages and currents. These must be optimally controlled to ensure stable and efficient operation. At the same time, a low weight and high efficiency of the drive system are crucial for commercial applications in the heavy-duty sector. The initial focus of the work is therefore on the behaviour and optimization of this megawatt drive system for stable operation under different load scenarios.
Handling and use of liquid hydrogen
Another research focus of the Balis test infrastructure is the handling of large quantities of liquid hydrogen for the operation of the entire propulsion system. To this end, DLR is currently building a test tank and the necessary refueling infrastructure with additional funding of around 3 million euros. In terms of storage volume, liquid hydrogen has a higher storage density than gaseous hydrogen. Hydrogen only becomes liquid at very low temperatures from -253 °C. This is why liquid hydrogen is also referred to as cryogenic hydrogen. For this reason, liquefying, storing and transferring the hydrogen places special demands on the infrastructure in order to keep the pressure and temperature constant.
Close links with the industry
For the next three years, Bali's test environment is already fully occupied with research projects and cooperation projects with industrial partners. The companies with which DLR is working on this include innovative start-ups, established SMEs and global players from the energy and aviation sectors. These include the DLR spin-off H2FLY as well as the fuel cell manufacturer PowerCell, the specialist for electric drives Compact Dynamics and the manufacturer and supplier of technical gases Air Liquide. From the aviation sector, DLR works together with companies such as Diehl Aerospace, GE Aerospace and Deutsche Aircraft. The system partner with whom the system was designed and realized is the company AVL.
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