Hydrogen Systems in Aviation: Top 10 Projects & Companies

Green Hydrogen Takes Flight: Powering the Future of Aviation

Imagine a world where airplanes soar through the sky powered not by fossil fuels, but by clean, green hydrogen. This vision is rapidly moving closer to reality, fueled by innovative projects and massive investments worldwide. From sprawling green hydrogen hubs in Texas to cutting-edge fuel cell testing labs, the aviation industry is undergoing a significant transformation, embracing hydrogen as a key element in its quest for sustainability. Let’s explore some of the largest hydrogen systems in aviation, showcasing the scale and diversity of this growing sector.

Installations: Fueling the Aviation Revolution

Below are some of the most significant green hydrogen projects focused on powering aviation. These installations highlight the different approaches being taken, from direct hydrogen production to the creation of sustainable aviation fuels (SAF) using hydrogen as a key ingredient.

1. Hydrogen City, Texas: Integrated Green Hydrogen Hub

Company: Green Hydrogen International
Installation Capacity: Growing to 60 GW in size, producing over 2.5 billion kilograms of green hydrogen annually.
Applications: Production, storage, and transport hub for green hydrogen.
Source: Green Hydrogen International Announces Hydrogen City, Texas

2. China Green Hydrogen-to-Aviation Fuel Plant

Company: Not specified
Installation Capacity: 300,000 tons of green aviation fuel annually.
Applications: Production of green aviation fuel.
Source: Launch of China’s First Major Green Hydrogen-to-Aviation Fuel Plant

3. Power2X, Advario e-SAF Facility in Rotterdam

Company: Power2X, Advario
Installation Capacity: Over 250,000 tonnes of e-SAF per year.
Applications: Production of Electric Sustainable Aviation Fuel (e-SAF).
Source: Power2X, Advario to build ‘largest’ green hydrogen SAF facility in Rotterdam

4. World Energy and Air Products SAF Facility

Company: World Energy, Air Products
Installation Capacity: 340 million gallons (almost 1.3 billion liters) of SAF annually.
Applications: Production of Sustainable Aviation Fuel (SAF).
Source: World Energy teams with Air Products in new $2 billion SAF …

5. DG Fuels SAF Production Facility in Louisiana

Company: DG Fuels, Johnson Matthey, bp
Installation Capacity: 13,000 barrels per day of FT SAF.
Applications: Production of Sustainable Aviation Fuel (SAF).
Source: Johnson Matthey and bp technology chosen for the world’s largest …

6. ZeroAvia’s HyFlyer II Project

Company: ZeroAvia
Installation Capacity: Developing a certifiable hydrogen-electric powertrain for airframes carrying up to 19 passengers, with a 300 nautical mile flight.
Applications: Hydrogen-electric powertrain for aviation.
Source: ZeroAvia Makes Aviation History, Flying World’s Largest Aircraft …

7. Avina’s Southern California Clean Hydrogen Project

Company: Avina
Installation Capacity: 1,400 metric tons of compressed clean hydrogen per annum.
Applications: Fueling nearly 100 fuel cell heavy-duty trucks and supporting aviation fuel.
Source: Avina’s Southern California Clean Hydrogen Project Hits Major …

8. OMV Green Hydrogen Production Plant

Company: OMV
Installation Capacity: 10 Megawatts
Applications: Green hydrogen production plant.
Source: OMV unveils Austria’s largest green hydrogen production plant

9. Accelera by Cummins hydrogen production facility

Company: Accelera by Cummins, Gevo, Zero6 Energy
Installation Capacity: 20 MW
Applications: Hydrogen production facility.
Source: Accelera by Cummins partners with Gevo and Zero6 Energy for first …

10. ZeroAvia Fuel Cell Testing Lab

Company: ZeroAvia
Installation Capacity: Over 1 MW capacity
Applications: Hydrogen fuel cell testing capabilities.
Source: Jingle Bells and Hydrogen Fuel Cells – 2024 a Year in Review

Table: Green Hydrogen Installations in Aviation

A Symphony of Applications: Hydrogen’s Diverse Role

The beauty of green hydrogen lies in its versatility. The installations listed reveal a multifaceted approach to decarbonizing aviation. We see large-scale hydrogen production hubs like “Hydrogen City, Texas,” aiming to become epicenters for green hydrogen production, storage, and transportation, servicing multiple industries including aviation. Then there are dedicated plants focused on producing Sustainable Aviation Fuel (SAF), such as the projects by World Energy and DG Fuels, showcasing the vital role hydrogen plays as a feedstock in SAF production through processes like Fischer-Tropsch synthesis. Even more groundbreaking is ZeroAvia’s HyFlyer II project, which directly integrates hydrogen into aircraft propulsion systems using fuel cells, representing a direct replacement for conventional jet fuel. This diversity demonstrates that green hydrogen is not just a niche solution, but a comprehensive enabler for a sustainable aviation future, adapting to different needs and scales within the industry. Avina’s Southern California project further highlights this, aiming to support both heavy-duty trucking and aviation with its hydrogen production.

Global Hotspots: Where is Hydrogen Aviation Taking Off?

A clear geographic pattern emerges: North America and Europe are leading the charge in developing green hydrogen solutions for aviation, followed by China. The sheer scale of “Hydrogen City, Texas,” points to the United States’ ambition to become a global leader in green hydrogen production. Simultaneously, Europe is heavily invested in e-SAF production, as evidenced by the Power2X and Advario facility in Rotterdam and OMV in Austria, reflecting the region’s strong commitment to decarbonizing the transportation sector. The presence of a major green hydrogen-to-aviation fuel plant in China signals the country’s increasing focus on sustainable aviation and its willingness to invest in innovative technologies. This geographical spread indicates that the transition to hydrogen-powered aviation is not confined to a single region, but is a global movement driven by environmental concerns, policy incentives, and technological advancements.

From R&D to Reality: Assessing Technology Maturity

The installations provide insights into the maturity levels of different hydrogen-based aviation technologies. ZeroAvia’s HyFlyer II project, focused on developing a certifiable hydrogen-electric powertrain, represents a pioneering effort in directly electrifying aircraft using hydrogen fuel cells, it has demonstrated technology but awaits further development. Projects focused on SAF production, such as those by World Energy, DG Fuels, Power2X, and the Chinese plant, are closer to commercial deployment as they leverage existing infrastructure and established refining processes, while integrating hydrogen as a clean feedstock. The Avina and OMV Projects showcase green hydrogen production for multi-vector applications, including aviation, implying a commercially ready solution with room to scale up. The diverse range of projects, from early-stage technology development to large-scale SAF production, indicates a multi-faceted approach to integrating hydrogen into aviation, with varying degrees of technological readiness across different applications.

Cleared for Takeoff: The Future of Hydrogen in Aviation

These installations paint a compelling picture of the future of aviation, where green hydrogen plays a pivotal role in decarbonizing the industry. The focus on SAF production suggests that this will be an early adoption pathway, leveraging existing infrastructure while reducing the carbon footprint of jet fuel. Simultaneously, the development of hydrogen-electric powertrains by companies like ZeroAvia represents a long-term vision of zero-emission flight, potentially disrupting the industry with entirely new aircraft designs. The strategic partnerships between energy companies like Air Products, bp, and technology providers like Johnson Matthey signify a growing recognition of the importance of collaboration in accelerating the transition to hydrogen-powered aviation. As technology matures, costs decrease, and regulations evolve, green hydrogen is poised to become an increasingly viable and attractive alternative to conventional jet fuel, paving the way for a cleaner, more sustainable aviation future.

Frequently Asked Questions

What are some of the main applications of green hydrogen in the aviation industry?
Green hydrogen is being used for a variety of applications, including the production of Sustainable Aviation Fuel (SAF), powering hydrogen-electric powertrains for aircraft, and fueling ground support vehicles. Large-scale green hydrogen production and storage hubs are also being developed to support the broader hydrogen economy, including aviation.

Where are the leading regions in the development of green hydrogen for aviation?
North America and Europe are currently leading the development of green hydrogen solutions for aviation. China is also showing increasing interest and investment in this area. ‘Hydrogen City, Texas’ and the Rotterdam e-SAF facility are good examples of the commitment in the US and Europe respectively.

How is hydrogen being used to create sustainable aviation fuel (SAF)?
Hydrogen is a crucial component in the production of Sustainable Aviation Fuel (SAF). It is often used as a feedstock in processes like Fischer-Tropsch synthesis, where it combines with captured carbon dioxide to create synthetic hydrocarbons that can be used as SAF.

Are hydrogen-powered aircraft commercially available yet?
While not yet commercially available, hydrogen-electric powertrains are under development, with companies like ZeroAvia making significant progress in testing and certification. Projects focused on SAF production, which incorporate hydrogen, are closer to commercial deployment as they can utilize existing infrastructure.

What is the overall outlook for green hydrogen in the aviation industry?
The future of aviation looks promising with the integration of green hydrogen. SAF production is likely to be an early adoption pathway. Hydrogen-electric powertrains represent a longer-term goal for zero-emission flight. As technology improves, costs decrease, and regulations adapt, green hydrogen is expected to become a viable and attractive alternative to conventional jet fuel.