In today’s episode of the “Start-up of the Week,” International Finance will talk about ZeroAvia, which in March 2024, got listed at the top of TIME Magazine’s list of “America’s Top Greentech Companies 2024.” The venture edged past some 250 odd United States-based clean technology companies based on “environmental impact, financial strength, and innovation.”
Founded in California and having its presence in the United Kingdom, ZeroAvia has emerged as a leader in zero-emission aviation with the mission of delivering a hydrogen-electric engine in every aircraft as the most environmentally and economically friendly solution for addressing the industry’s climate impact.
A Glorious Journey So Far
Having established in 2018, the company is now focussing on hydrogen-electric propulsion and fuelling solutions to address a variety of markets, from 300-mile range in 9–19 seat aircraft by the 2025 end, to up to 700-mile range in 40–80 seat aircraft by 2027.
The company first grabbed the headlines in December 2021, by initiating the first spin of the propeller on its in-house Dornier 228 testbed using electric power. The test was designed as a functional check of the fully integrated and flight-ready Electric Propulsion System aboard the testbed aircraft at the United Kingdom’s Cotswold Airport.
In 2022, the aircraft achieved another milestone, in the form of the first outdoor ground testing after the full installation of the hydrogen-electric powertrain. The Dornier 228, in the following months, made its first movements on the runway, in the form of medium power taxi testing. By the year end, ZeroAvia’s prototype aircraft completed all the ground tests.
In 2023, the 19-seat testbed aircraft took to the skies with its left side propeller powered by a hydrogen-electric powertrain, making this the largest aircraft flown with hydrogen-electric propulsion at the time. The milestone also ensured that ZeroAvia was well on the way to meeting the target of commercial flights using only hydrogen fuel cell power by 2025.
The venture then took things forward with the aircraft performing a levelled flight using only the ZA600 prototype engine. The test crew flew with zero thrust from the conventional turbine engine as the ZA600 entirely powered the testbed aircraft. As the tests progressed, the testbed aircraft reached its highest speed yet (140 knots), with the fuel cell and electric propulsion systems increasing their performance envelopes. The speed further increased to 150 knots and in the subsequent tests, the aircraft reached a height of 3,000, while flying for 16 minutes.
As the tests progressed, the aircraft soared to 4,000 feet, making it the highest-flying commercial-scale aircraft powered by fuel cells. The aircraft also flew for 22 minutes, making it the longest-duration flight yet. On the ninth flight, the aircraft reached its highest altitude yet, ascending to 5,000 feet and flew for 20 minutes in total. In January 2024, the same Dornier 228 flew above 5,000 feet, apart from successfully passing an endurance test lasting some 23 minutes. In the most recent test flight, undertaken on April 18, 2024, the aircraft flew for some 35 minutes.
While the fuel cell power generation and electric propulsion system, the core components of the novel zero-emission engine, have been performing at or above expectations throughout the flight tests, ZeroAvia wants to fine-tune things further.
Being A Revolutionary Force
ZeroAvia’s standout product has been its ZA600 engine, which has been tailored for 10-20 seat aircraft. The 500 to 750 Kw hydrogen-electric powertrain is fuelled by gaseous hydrogen tanks, apart from being capable of carrying passengers up to 300 nautical miles. The engine is perfect for airframes like the DHC-6 Twin Otter, Dornier 228 and Cessna 208B Grand Caravan.
Next is ZA2000, a 2-5 megawatt modular hydrogen-electric powertrain, that will power 40-80 seat regional turboprop by 2027. Fuelled by liquid hydrogen tanks, the engine will be capable of carrying passengers up to 1000 nautical mile. This particular powerplant will power bigger regional aircraft like the DHC Dash 8 Series and ATR 42/72.
In pursuit of its first engines, ZeroAvia has developed high-performance and high-efficiency aviation components that offer a step change to existing technologies in the market. One such innovation is the ZeroAvia SuperStack Flex, which is a modular fuel cell power generation platform with up to 150kW net total continuous power and lightweight, aviation-optimised balance-of-plant, developed as a best-fit approach for drones with further potential applicability in marine and ground vehicle use cases.
Another good example is ZeroAvia’s high temperature (HTPEM) fuel cell stacks, which, once fully developed, will support electric propulsions of larger aircraft, as well as rotorcraft and eVTOL applications. ZeroAvia has also developed its own continuous power silicon carbide inverters which bio-directionally convert high-voltage DC into three-phase AC to power electric motors. These advanced components, once integrated with aircraft, will enable reliable high-altitude performance. The company is progressing with the optimised integration of the inverters with electric motors.
Decoding The ‘Hydrogen Fuel’ Challenge
ZeroAvia’s dedicated Hydrogen Infrastructure team has been partnering with leading energy players and innovators, apart from advancing the underlying technologies to support airport H2 operations. Realising the potential of green and other low-carbon hydrogen as cost-effective options than jet fuel, airports have started working towards the transition. And ZeroAvia is emerging as the agent of change here.
The start-up is working with energy majors and hydrogen innovators to develop the refuelling infrastructure and operations to enable clean aviation, apart from exploring novel technologies for optimal hydrogen storage and aircraft refuelling.
ZeroAvia’s “Hydrogen Airport Refuelling Ecosystem” works on four pillars: Electrolyzer (modular components to produce hydrogen on-site, supplemented by partnerships with Shell, ZEV Station and others, to ensure supply of low-carbon hydrogen), Mobile Refuellers, Hydrogen Pipeline (world’s first hydrogen airside to landside pipeline at its Cotswold Airport location) and Liquid Hydrogen Development-related projects, which will enable further infrastructure builds to demonstrate LH2 refuelling operations.
Prominent among ZeroAvia’s industry partners, we have energy giants like Masdar, ScottishPower and Fortum, while NEOM, the futuristic urban area being built by Saudi Arabia, has also invested in ZeroAvia, to explore the development of clean hydrogen generation.
Talking about ZeroAvia-Masdar partnership, the UAE-based renewable energy giant entered into the arrangement in 2023, with the goal of exploring hydrogen production and supply at key locations. The stakeholders will focus initially on projects in North America and Europe, while also looking at the opportunities to establish clean flight operations in the UAE. Masdar, which aims to be a global green hydrogen leader through a “smart first mover” approach, is developing and investing in strategic projects and building scalable platforms in key markets.
In collaboration with ScottishPower, ZeroAvia will explore airport hydrogen supply models and financing, apart from investing in clean power requirements and hydrogen production infrastructure for potential future ZeroAvia sites within ScottishPower’s distribution network areas across Scotland, North West England and North Wales.
ZeroAvia recently announced a 70 engine agreement with Scottish headquartered Ecojet. The company also has a longstanding partnership with AGS Airports, including Glasgow and Aberdeen to explore the hydrogen infrastructure requirements for airports to support hydrogen-electric flight and other potential use cases.
With the Fortum partnership, ZeroAvia has expanded its hydrogen production and refuelling infrastructure-related activities at Nordic airports. The companies will investigate the potential development of on-the-ground hydrogen infrastructure at airports with the aim of removing emissions from both flights and the wider airport ecosystem.
Making Impacts In The Market
American Airlines has signed a pact with ZeroAvia for the opportunity to order 100 ZA2000 RJ, hydrogen-electric engines, targeting regional jets. Similarly, United Airlines and ZeroAvia have entered into an agreement anticipating 50 ZA2000 RJ engines, with an option for an additional 50. Alaska has secured options for up to 50 powertrains to begin converting its regional aircraft to hydrogen-electric power through ZeroAvia’s zero-emission powertrain.
The start-up is also working with operators to extend the life of existing fleets via retrofit programmes, along with bringing new zero-emission aircraft into service via ZeroAvia’s line-fit agreements with the original equipment manufacturers. Additionally, the venture has entered into business arrangements with prominent lessors to enable zero-emission aircraft options for their operator customers.
ZeroAvia is also helping forward-thinking airports in adopting hydrogen, while also advancing the underlying technology to support airport H2 operations. Using its experience in operating hydrogen production and refuelling facilities in airport environments, ZeroAvia is working with some of the leading airports and fuel providers to build out the infrastructure for powering hydrogen flights.