Official opening of the DLR BALIS test centre

Official opening of the DLR BALIS test centre
by Robert Schreiber
Berlin, Germany (SPX) Oct 31, 2024
As part of its BALIS project, the German Aerospace Center (DLR) has inaugurated a pioneering test facility in Empfingen dedicated to advancing fuel cell propulsion systems for various modes of transportation. The BALIS project focuses on developing fuel cell systems with an output of approximately 1.5 megawatts, aimed at future applications in shipping and aviation.

This state-of-the-art facility will enable DLR to work with hydrogen fuel cells powered by renewable energy, also known as green hydrogen, promoting emissions-free transportation aligned with environmental sustainability goals. Situated on the Innovation Campus at the E2U Empfinger Entwicklungszentrum fur Umwelttechnologie (Development Centre for Environmental Technology), the facility officially opened on October 28, 2024, with political, industrial, and public representatives in attendance. The Federal Ministry for Digital and Transport has allocated 26 million euros to fund the BALIS test center.

Unique Facility for Fuel Cell-Based Transportation Powertrains
"The dialogue between research and industry that arises from the construction and use of large-scale facilities like BALIS is invaluable for both sides. This is how we not only jointly demonstrate that new technologies are functional, but also develop them to a size and economic viability that make them an interesting solution for industry," said Karsten Lemmer, DLR Executive Board Member for Innovation, Transfer and Research Infrastructure.

"In aviation in particular, the step up from a stable propulsion system on the ground to qualification for use in aircraft is very complex and takes time. A facility like BALIS provides the basis and reliability needed to transform aviation."

Hartmut Hoppner, State Secretary at the Federal Ministry for Digital and Transport, added, "The opening of the test facility is a decisive step towards achieving climate neutrality by 2045. Transport faces major challenges, and hydrogen offers us the opportunity to develop and implement emission-free propulsion systems for various means of transport. We are providing targeted funding to support research and development for the creation of innovative and ultimately marketable solutions. Together with industry and research, we are laying the foundations for sustainable mobility."

Highlighting the facility's breadth of expertise, Meike Jipp, DLR Divisional Board Member for Energy and Transport, noted, "Hydrogen technologies are central to energy and transport research at DLR. Unlike other research centres, DLR covers the entire process chain with its interdisciplinary expertise in aeronautics, space, energy, transport, security and digitalisation, from materials and processes for producing renewable hydrogen, to applications in mobile and stationary systems, to system analysis. It shows the contexts and conditions under which hydrogen technologies can create an economically viable, safe and sustainable energy and mobility system."

Versatile Test Capabilities for Next-Gen Fuel Cell Systems
The modular BALIS test facility, housed within shipping containers, is designed to evaluate individual components and complete powertrains, including fuel cell systems, electric motors, refueling infrastructure, and control systems. The DLR Institute for Engineering Thermodynamics oversees the project, making BALIS unique in its flexible configuration and advanced research methodology.

As part of this project, DLR is also constructing an innovative megawatt-class electric propulsion system, featuring a fuel cell assembly, hydrogen tank, electric motor, control components, and power electronics. Unlike conventional fuel cells, which produce several hundred kilowatts, the megawatt-capable system integrates multiple modules to reach high power output. Optimizing for high efficiency and stable operation, this development aims to fulfill commercial requirements for heavy-duty transport.

Research Expands to Liquid Hydrogen Applications
BALIS also explores the handling and use of liquid hydrogen (LH2) in large volumes, essential for running entire propulsion systems. Supported by an additional three million euros, DLR is building a test tank and refueling infrastructure for LH2. With a higher density than gaseous hydrogen, liquid hydrogen conserves space but requires storage at extremely low temperatures (below -253 degrees Celsius), adding specific infrastructure challenges for temperature and pressure control.

The BALIS test center is fully booked for the next three years, partnering with a range of industry leaders from start-ups to established companies in energy and aviation. DLR's collaborations include work with its spin-off H2FLY, PowerCell, Compact Dynamics, and Air Liquide, as well as aviation companies like Diehl Aviation, GE Aerospace, and Deutsche Aircraft. AVL partnered with DLR on the design and construction of this versatile testing facility.