{"id":12492,"date":"2023-11-01T10:00:00","date_gmt":"2023-11-01T10:00:00","guid":{"rendered":"https:\/\/zbt.de\/projects\/kt2gp-keytechtogreenpower\/"},"modified":"2025-08-19T13:48:36","modified_gmt":"2025-08-19T13:48:36","slug":"kt2gp-keytechtogreenpower","status":"publish","type":"project","link":"https:\/\/zbt.de\/en\/projects\/kt2gp-keytechtogreenpower\/","title":{"rendered":"KT2GP - KeyTechToGreenPower"},"content":{"rendered":"
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KT2GP \u2013 KeyTechToGreenPower<\/h2>\n

Flying is set to become more environmentally friendly. However, the requirements for alternative propulsion systems in aviation<\/strong> are very high. Above all, they must be particularly light and powerful. Together with its partners, ZBT is developing an optimised fuel cell<\/strong> stack for hydrogen propulsion in aircraft<\/strong>. The goal of the project, known as KT2GP (KeyTechToGreenPower), is to achieve a power density of more than 6 kW\/kg. <\/p>\n

To achieve this, the weight of the stack must be significantly reduced. To this end, the project partners are analysing and optimising the entire process chain for the manufacture of titanium bipolar<\/strong> plates, from forming and cutting to joining and sealing, in order to identify and exploit potential for optimisation. For example, the heavy stainless steel used in the bipolar plates is to be replaced by lightweight materials such as titanium. To this end, all project partners are investigating the entire manufacturing technologies for titanium bipolar plates. <\/p>\n

ZBT optimises seal application<\/h4>\n

Within the project, ZBT is focusing on the process of seal application<\/strong> using dispenser technology for the robust use of extremely compact bipolar plates. To this end, a highly integrated sealing system is being developed, taking into account minimal cord thicknesses with optimised materials, optimised media tunnelling concepts and the integration of the sealing groove on the weld contour for the bipolar plate. <\/p>\n

In addition, ZBT is developing suitable qualification concepts<\/strong> to monitor process quality and ensure the long-term stability of components at the seal and bipolar plate level \u2013 always with the specific requirements of aviation applications in mind, of course. To analyse the sealing materials, hydrogen permeation<\/strong> is measured. On the other hand, the materials on the bipolar plate are evaluated using a newly developed optical quality assurance system<\/strong>. In addition, the coatings for the bipolar plate are examined at ZBT by means of corrosion current measurements (ex-situ), resistance measurements and in single-cell fuel cell operation (in-situ) with aviation-specific operating behaviour. <\/p>\n

Two stacks and fully automated assembly<\/h4>\n

A total of two complete stacks with a power density of more than 6 kW\/kg<\/strong> are to be manufactured in this project. In addition, an assembly island for stack assembly<\/strong> will be set up to assemble the fuel cells into a stack fully automatically. <\/p>\n

After the project, the fuel cell system will be validated and verified in a ground test<\/strong>. It should thus demonstrate its suitability for aviation applications with hydrogen as an energy carrier. <\/p>\n

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Project title:<\/strong><\/h5>\n

Manufacturing technologies for titanium bipolar plates (BPP) and stack assembly as enabler technology for fuel cell systems in aviation<\/p>\n

Project acronym:<\/strong><\/h5>\n

KT2GP (KeyTechToGreenPower)<\/p>\n

Approval period:<\/strong><\/h5>\n

01.11.2023 to 31.12.2026<\/p>\n

Funding code:<\/strong><\/h5>\n

20N2204E<\/p>\n

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Department Fuel Cells and Stacks<\/a><\/p>\n<\/div>\n<\/section>\n

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PEMELYonROLL: Scalable roll-to-roll production for PEM electrolysis MEAs<\/h4>\n

The PEMELYonROLL project is developing scalable manufacturing processes for high-performance CCM and MEA for PEM water electrolysis. The aim is to develop material-efficient, quality-assured and industry-oriented manufacturing processes. <\/p>\n <\/div>\n

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NEREUS – Next-Generation Scalable AEM Electrolysers as Sustainable Hydrogen Production System<\/h4>\n

NEREUS develops next-generation anion exchange membrane electrolysers (AEM electrolysers) for high-performance, long-lasting and cost-efficient hydrogen production.<\/p>\n <\/div>\n

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FeNCy-PEM – Production and use of precious metal-free Fe-N-C catalysts<\/h4>\n

FeNCy-PEM develops scalable, precious metal-free Fe-N-C catalysts and integrates them into the production and application of PEM fuel cells.<\/p>\n <\/div>\n

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HyQualityLab4NRW – Laboratory for AI-supported quality control and assurance in H2 research<\/h4>\n

With the “HyQualityLab4NRW”, a high-performance AI-supported material analysis laboratory is being set up at the ZBT to enable research institutions and industry to carry out comprehensive quality control of their products.<\/p>\n <\/div>\n

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PARZELL: Qualitative and quantitative PFAS analysis in realistic PEM electrolysis and fuel cell operation<\/h4>\n

The PARZELL research project systematically investigates the release of PFAS from PEM electrolysers and PEM fuel cells and develops methods to realistically measure, evaluate and reduce emissions in the long term.<\/p>\n <\/div>\n

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HiHyPe: New AEM technology for electrochemical hydrogen compressors<\/h4>\n

The HiHyPe project is developing a low- to non-precious metal AEM technology for electrochemical hydrogen compressors, thereby strengthening the future of the hydrogen economy.<\/p>\n <\/div>\n

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HY-Infra \u2013 Cross-border Project to analyse Hydrogen Infrastructure in the Meuse-Rhine Region<\/h4>\n

Hy-Infra strengthens the cross-border hydrogen infrastructure in the Rhine-Meuse region. The interregional project creates transparency about future hydrogen requirements and derives the necessary infrastructure by 2030\/2035. <\/p>\n <\/div>\n

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