Following a Scandinavian test run last year, the Lufthansa Group has launched its ‘Green Fares’ offering by all its six airlines on more than 730,000 flights per year within Europe and North African destinations Morocco, Algeria and Tunisia. Under its “more climate-friendly pledge”, the fares have already built in the extra cost of offsetting all flight-related CO2 emissions, with 20% of the contribution being used to purchase sustainable aviation fuel and the remainder in “high quality” climate protection offsets. The Green Fares can be booked “with just one click” via the airlines’ websites as well as the NDC platform in Economy and Business classes. The Group has also signed an MoU with VARO Energy on the production and supply SAF, deliveries of which could possibly start as early as from 2026. It also revealed more than 20 Boeing 777-300ER long-haul aircraft will be equipped with film modelled on the microscopic structure of shark skin that collectively will reduce the Group’s CO2 footprint by over 25,000 tonnes annually.

“People don’t just want to fly and discover the world – they also want to protect it at the same time,” commented Christina Foerster, responsible for brand and sustainability on Lufthansa Group’s Executive Board. “We already offer the most comprehensive portfolio for more sustainable travel and are now expanding this further with the Green Fares.”

The Green Fares offer, available on flights by Lufthansa, Austrian Airlines, Brussels Airlines, SWISS, Edelweiss, Eurowings Discover and Air Dolomiti, is also available to corporate customers, who will receive a CO2 mitigation certificate for the CO2 reduction achieved through the use of SAF.

A random midweek Lufthansa flight in March from Munich to London is quoted at €140 ($150) for a one-way Economy Classic ticket. The cost of the Economy Green fare for the same flight is €165, and has the added benefit of free rebooking, worth €35, and additional 20% status miles and 20% award miles. On the same flight, the Business Green fare in business class carries a €60 premium over Business Saver.

“The Green Fares were already successfully tested last year for flights from Denmark, Sweden and Norway. This showed that the demand for more sustainable travel offers is increasing,” said Harry Hohmeister, who has responsibility for global markets and network on the Lufthansa Group Executive Board. “We are pioneering the industry and living up to our ambition to develop innovative solutions for aviation of the future and we are making it even easier for our customers to book more sustainable offers.”

Under the MoU between Lufthansa and Swiss-based VARO Energy, which they say builds on their existing relationship, the two companies will explore SAF production and supply, and also jointly investigate the use of biogenic feedstock, such as sewage sludge, to produce green hydrogen that can potentially be used at a later stage for e-kerosene.

VARO says decarbonising the aviation industry is a core element of its strategy and is targeting production of more than 260,000 tonnes of SAF per year by 2026, with a long-term target of more than 500,000 tonnes per year.

“Our ONE VARO Transformation strategy is centred on meeting the needs of our customers to decarbonise as they progress in the energy transition while ensuring reliability of supply,” commented Dev Sanyal, CEO of VARO Energy. The company has a majority share in the Bayernoil refinery in southern Germany and a 51% stake in nature-based carbon dioxide removals company SilviCarbon.

The AeroSHARK bionic film developed by Lufthansa Technik and BASF is applied to the aircraft’s outer skin and after a testing and certification process lasting several months, EU safety agency EASA has granted Lufthansa Technik a Supplemental Type Certificate for the series application of the technology on two Boeing 777s. The first SWISS aircraft equipped with AeroSHARK has already been in scheduled service since October as part of the flight test certification programme. Over time, all 12 B777-300ER aircraft will fly with the fuel-saving surface technology, as well as Lufthansa Cargo’s fleet of 11 Boeing 777F freighters.

AeroSHARK consists of millions of ribs around 50 micrometres in size, known as riblets, that imitate the properties of sharkskin and thus optimise the aerodynamics at flow-relevant points, such as the fuselage or the engine nacelles. By covering 950 square metres of a 777-300ER’s outer skin, Lufthansa estimates annual savings of around 400 tonnes of jet fuel and more than 1,200 tonnes of CO2 can be achieved.

“Our ambitious goal is a neutral CO2 balance by 2050 and by 2030 we want to halve our net CO2 emissions compared to 2019,” said Foerster. “With the broad rollout of the AeroSHARK surface technology, we are once again underlining our innovation leadership. We are the first airline group worldwide to use this new technology.”

Photo: Lufthansa Technik

Christopher Surgenor

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Rolls-Royce and European low-cost carrier easyJet have performed the first-ever operation of a prototype aircraft engine powered by green hydrogen. The ground test, conducted at a military aircraft testing site in Boscombe Down, England, was hailed by the companies as “a new aviation milestone” and a major step towards the introduction of zero emission hydrogen propulsion systems for aircraft. The test was conducted using a converted Rolls-Royce AE 2100-A engine and followed the recent establishment by Rolls-Royce and easyJet of a partnership to research hydrogen propulsion for aircraft such as the Airbus A320-family of narrowbody jets operated by the airline. The engine test also coincided with other initiatives designed to progress hydrogen-powered aviation. In Hamburg, Lufthansa Technik has just converted a decommissioned A320 to test ground processes for future hydrogen-powered aircraft, while hydrogen propulsion company ZeroAvia has partnered with the UK’s AGS Airports to investigate hydrogen fuelling infrastructure. 

The engine used for the Rolls-Royce and easyJet test was a modified version of a powerplant typically used by high-speed turboprop aircraft, including the SAAB 2000 regional airliner and the Lockheed C130J military transporter. The companies are now planning more rig tests, ahead of a full-scale ground trial using a Rolls-Royce Pearl 15 jet engine, a new powerplant designed to extend the range of Bombardier Global 5500 and 6500 corporate jets. The longer-term aim is to undertake flight tests and eventually to develop hydrogen engines for larger planes. Green hydrogen for the Boscombe Down test was provided by the European Marine Energy Centre and generated by wind and tidal power at its test facility on Eday, part of the Orkney Islands that lie north of the Scottish mainland.

Grazia Vittadini, Chief Technology Officer, Rolls-Royce, described the engine test as “an incredible start” to the new partnership with easyJet.  “The success of this hydrogen test is an exciting milestone. We are pushing the boundaries to discover the zero carbon possibilities of hydrogen, which could help reshape the future of flight,” she said.

Johan Lundgren, easyJet’s CEO, said his airline was committed to supporting the research “because hydrogen offers great possibilities for a range of aircraft, including easyJet-sized aircraft. That will be a huge step forward in meeting the challenge of net zero by 2050.”

Both organisations have signed up to the UN-backed Race to Zero campaign that commits them to achieve the net zero carbon emissions target.

In Hamburg, an Airbus A320 operated by Lufthansa for 30 years has been converted into the Hydrogen Aviation Lab (HAL), a mobile laboratory designed to test maintenance and ground handling processes for future aircraft powered by hydrogen. The initiative is a collaboration between Lufthansa Technik, which has converted the jet into a research platform, Hamburg Airport, an early adopter of low-or-no carbon practices, and two major research groups, the German Aerospace Center (DLR) and Hamburg’s ZAL Centre for Applied Aeronautical Research. It was funded by Hamburg’s Ministry of Economic Affairs and Innovation and IFB Hamburg, the city’s investment and development bank.

While this particular jet will never fly again, it will be equipped in coming months with test systems, an internal tank for liquid hydrogen and an onboard fuel cell compatible with ground-based hydrogen infrastructure, to help prepare both airlines and airports for new zero-emission aircraft. The testbed plane will be towed between the Lufthansa Technik base and locations on the airport as part of the study of future ground management processes. Research will include integration of hydrogen fuel systems into existing airport infrastructure, safe and efficient refuelling of aircraft with liquid hydrogen, cooling and insulation of the fuel, and inert storage of hydrogen.

“We’ve enabled a unique project,” said Michael Westhagemann, Hamburg’s Senator for Economic Affairs. “It will make a valuable contribution to enabling the use of hydrogen as a fuel for aviation. The focus on maintenance and refuelling procedures should provide us with insights that will be important for developing hydrogen infrastructure. This real-world lab lets us add a crucial building block to Hamburg’s strategy to make aviation more sustainable. We are following two strategic goals – the development of a hydrogen economy in Hamburg and the decarbonisation of the mobility industries. We are very pleased to make this world-first project possible through the Special Aviation Fund.”

The Hydrogen Aviation Lab jet will also be used for research into predictive maintenance methods for future generations of aircraft, with a ‘digital twin’ of the decommissioned A320 to be used to help predict failures of hydrogen components and systems, and enable timely responses. 

In another research project, aero-hydrogen propulsion pioneer ZeroAvia has partnered with AGS Airports, which owns and operates Aberdeen, Glasgow and Southampton airports in the UK, to investigate the development of hydrogen fuel infrastructure, regulatory requirements and resources needed to deliver zero-emission flights. Their focus will be on short-haul hydrogen-powered flights from Aberdeen and Glasgow.

“In recent months, we have stepped up our work with airports significantly to better understand the operational needs and requirements for hydrogen as a fuel,” said Arnab Chatterjee, ZeroAvia’s VP Infrastructure. “Working with the team at AGS allows us to plan for some of the commercial routes that we will be able to support in a little over two years’ time, and to do so in the setting of a major international airport.”

The CEO of AGS Airports, Derek Provan, said the development of hydrogen-propulsion was becoming “an increasingly viable option” for regional and short-haul aircraft. “As a regional airport group serving the highlands and islands of Scotland as well as the Channel Islands from Southampton, AGS will be the perfect testbed for hydrogen flight,” he said. “Through our partnership with ZeroAvia we’ll address some of the challenges associated with the generation, delivery and storage of hydrogen on site, and how we can prepare our infrastructure to support zero emission flights.”

Photo: Ground testing of the converted Rolls-Royce AE 2100-A regional aircraft engine

Two prominent themes emerged at the 2021 Dubai Airshow: recalibration and decarbonisation. With recovery now underway in the air transport industry, confidence was in abundance, with major orders for passenger and freighter aircraft accompanied by the ubiquitous deployment of the word ‘sustainable’, as the air transport industry zeroed in on net zero, while simultaneously increasing operations post-pandemic, reports Tony Harrington. For the first time outside the United States, Boeing displayed and demonstrated its super-efficient but delayed 777-9 widebody, ordered by major customers including all three big Gulf carriers, Emirates, Qatar Airways and Etihad. The latter announced it was renewing and expanding its Greenliner sustainability programme – currently focused on the airline’s GEnX-powered Boeing 787 aircraft – to include its Rolls-Royce XWB-powered Airbus A350 fleet. Building on its 2020 commitment to achieve net zero by 2050, UAE national airline Etihad revealed during the air show interim targets to reducing emissions intensity and volumes, and signed a number of sustainability-focused agreements.

It announced that by 2025, the carrier would reduce its fleet emissions intensity by 20% and by 2035 it would halve its 2019-equivalent emission volumes, en-route to the net zero 2050 target.

Etihad’s first of five Airbus A350-1000s, which rolled off the production line and into storage prior to the Covid outbreak as the airline restructured its operations, was unveiled at the show in a ‘UAE50’ livery in recognition of the 50th anniversary of the federation of the UAE and Etihad’s net zero by 2050 commitment. Last month, the UAE announced the UAE Net Zero by 2050 Strategic Initiative, making it the first nation in the Middle East to commit to the emissions goal.

Tony Douglas, CEO of Etihad Aviation Group, said “there was no silver bullet, no obvious, single act” that would decarbonise aviation. “It’s going to require the combination and the sum of many different organisations and governments working together for small, incremental improvements,” he said. “Governments and regulators must help the industry to drive innovation for long-term solutions to decarbonising aviation. Support is needed for development of affordable and sufficient supply of sustainable fuels. Optimising flight paths on the busiest routes in the world would prevent untold amounts of CO2 from being pumped into the atmosphere. There is a big opportunity here that doesn’t require any new technology to implement and could be implemented today if there was a will.”

The renewal of the agreement with Boeing and GE will see them exploring opportunities to test new propulsion technologies that lower emissions. The partnership with Airbus establishes a formal framework to collaborate across a number of core areas on Etihad’s A350 fleet to improve environmental performance, specifically the promotion and commercialisation of sustainable aviation fuel, waste and weight management, and the development of data driven analysis. The agreement with Rolls-Royce will look to maximise the potential of the XWB engine as well as targeting the application of electrification technologies and hybrid systems, together with the use of electric motors for commuter aircraft and the emerging urban air mobility sector.

Additionally, Etihad signed MoUs in Dubai to collaborate with UK-based Satavia, which uses data to optimise flight plans and reduce aircraft-generated contrails and CO2, with Tadweer, the Abu Dhabi Waste Management Centre, to jointly explore opportunities to convert commercial, industrial and municipal solid waste into sustainable aviation fuel, and also with The Story Group, to plant mangrove trees in Abu Dhabi’s Jubail Mangrove Park as part of the airline’s carbon offsetting strategy.

Meanwhile, Emirates and GE Aviation also signed a MoU to test fly a GE90-powered 777-300ER with 100% sustainable aviation fuel (SAF) by the end of 2022. John Slattery, CEO of GE Aviation, said the engine manufacturer was committed to developing emission reduction technologies for both in-service and new aircraft, while Emirates COO Adel Al Redha said the partnership was “an important step” towards securing certification of 100% SAF flights.

The airline received its first A380 powered by SAF in December 2020 and, with the support of Swedavia’s Biofuel Incentive Programme, also uplifted 32 tonnes of SAF for its flights from Stockholm earlier that year. Flights from Oslo have also begun operating on SAF under the Norwegian government’s SAF blending mandate policy.

New technologies to improve the sustainable performance of existing aircraft also featured at the Dubai show.

Among them, US-based Universal Hydrogen, which is developing kits to convert conventionally-powered turboprop aircraft to hydrogen-electric propulsion systems, has secured a letter of intent from Acia Aero Leasing for kits to convert 10 ATR-72 aircraft, and options for 20 additional kits for various turboprop types. Universal has developed hydrogen capsules, which can be transported via existing freight networks from hydrogen production facilities direct to airports and loaded into the aircraft they will power.

Lufthansa Technik (LHT) and BASF showcased their Aeroshark surface film, designed to reduce aircraft aerodynamic drag. The product features micro-riblets to replicate the skin of a shark, and initially will be applied to 10 Lufthansa Cargo Boeing 777s from early 2022, reducing carbon emissions by an estimated 11,700 tonnes per year. LHT also signed a MoU with Etihad that will explore digital solutions to further optimise the airline’s technical fleet and operations management, and boost fuel efficiency.

Boeing displayed the latest aircraft in its ecoDemonstrator programme, a Boeing 737-9 on loan from Alaska Airlines, which is being used to evaluate 20 safety and sustainability projects. 

As backdrops to the show, Airbus, Boeing and Embraer all released 20-year forecasts of air travel growth – globally, by region and by segment – with significant but varied predictions of requirements for new aircraft. Airbus estimates that by 2040, 39,000 new-build planes will be needed, 29,700 of them ‘small’ jets such as the narrowbody A220 and A320; 5,300 ‘medium’ A321XLR (extra-long range) narrowbodies or twin-aisle A330neos; and 4,000 large, long-range twins. Boeing goes higher with around 43,000, including 32,660 single-aisle jets, 2,390 regional jets and 7,670 widebodies. Regional specialist Embraer forecasts the need for 10,900 new sub-150 seat aircraft, 8,640 of them jets and 2,260 turboprops. In addition to opportunities to cut operating costs, all cited the need for airlines to decarbonise their operations as one of the key drivers of fleet renewal.

Photo: Dubai Airshow 2021 (© Mark Pilling)

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MRO and technical aircraft services provider Lufthansa Technik has joined with Hamburg Airport in an initiative to design and test maintenance and ground processes for handling liquid hydrogen (LH2) that is expected to be used in powering future aircraft. The two-year research project, which has received funding from the city of Hamburg, will also involve the German Aerospace Center (DLR) and the Center for Applied Aeronautical Research (ZAL). As part of the project, a decommissioned Airbus A320 aircraft will be converted into a stationary, fully functional field laboratory equipped with LH2 infrastructure at Lufthansa Technik’s base at the airport. In the first phase, due to be completed by the end of this year, the partners will identify areas for developing and elaborating the concept for subsequent testing with the aim next year to jointly implement a pioneering demonstrator to be operational by 2022. Elsewhere in Germany, start-ups Deutsche Aircraft and H2FLY have agreed to work together on developing hydrogen fuel cell technology for commercial regional aircraft.

As well as contributing to the Hamburg project operational expertise in the maintenance and modification of commercial aircraft, Lufthansa Technik says it is also able to incorporate a customer perspective through its airline customers. In parallel, DLR will be creating a virtual environment to achieve digital and highly accurate mapping of the defined fields of development and says the platform will aim to provide inspiration for the next generation of aircraft through parameterised and highly accurate virtual models. DLR adds that it has long-standing and cross-sector experience with hydrogen.

“The aircraft of the future are lighter, more efficient and fly with alternative propulsion concepts, and hydrogen will play an important role in this. We need to learn – promptly and in detail – the ground requirements for aircraft and their maintenance of real-world operation with hydrogen,” explained Dr Markus Fischer, DLR Deputy Board Member Aeronautics. “In the project, we are using this data and experience to develop digital models for ground processes that can then be used directly in the design of future-oriented and yet practical aircraft configurations.”

Hamburg Airport CEO Michael Eggenschwiler said climate-friendly flying with hydrogen technology was only possible through a perfect fit with ground infrastructure. “Close coordination is required here and we as an airport are pleased to be able to contribute our know-how to this important project, from questions over storage and distribution to the refuelling process on the apron.

“At the airport, we also rely on hydrogen as a technology of the future for our ground transport. This project offers us the chance to identify and make the best possible use of synergy effects between gaseous hydrogen, such as that used for refuelling our baggage tractors, and liquid hydrogen for aircraft refuelling.”

ZAL, meanwhile, will provide its know-how in fuel cell technology and digital process mapping. “The development of a field laboratory and a digital twin are important components of Hamburg’s Green Aviation Technology Roadmap,” said ZAL CEO Roland Gerhards. “They were developed together with the members of the Hamburg Aviation Cluster last year to strengthen Hamburg’s competence in research and development in a European context.”

The project is the largest single initiative in a City of Hamburg’s special programme to mitigate the economic impact of the coronavirus pandemic on the aviation industry.

“Hamburg is not just one of the three largest aviation clusters in the world – last year the city also developed a clear vision of becoming a major hydrogen metropolis,” said Michael Westhagemann, the city’s Senator for Economics and Innovation. “The port, the energy sector, industry and the entire mobility sector are involved and are preparing for this groundbreaking technology.

“With this project, we are now also making an essential contribution to the transformation of aviation into a climate-neutral mobility solution of the future. The clear goal is to build up a hydrogen economy in Hamburg that will occupy a leading position internationally.”

Responded Lufthansa Technik CEO Dr Johannes Bussmann: “I am very grateful for the foresight of the city of Hamburg and its generous funding of this project.

“There is no alternative to the transformation of our industry towards climate-neutral aviation. With this project, we want to tackle this enormous technological challenge at an early stage – for the entire MRO industry as well as for us. We are building up know-how today for the maintenance and ground processes of tomorrow.”

Meanwhile, the partnership between German start-up H2FLY, which is developing hydrogen fuel cell systems for aircraft, and a new German aircraft manufacturer Deutsche Aircraft will aim to convert a Dornier 328 aircraft for a first hydrogen flight in 2025.

The programme is expected to validate climate neutral regional air travel with up to 40 seats and the teams are planning to equip the demonstrator with a 1.5MW hydrogen system which they say will make it the most powerful hydrogen-electric powered aircraft to date. The companies will work together on integrating the power system into the aircraft as well as defining the specific technical and certification requirements for fuel cell systems in EASA’s large aircraft class.

H2FLY grew out of a partnership between DLR and the University of Ulm and its four-seater hydrogen-electric powered HY4 has already undertaken over 70 take-offs in flight campaigns. With its range of up to 750km, the company believes regional markets can be developed.

“Hydrogen fuel cell technology provides an opportunity for us to completely eliminate carbon and NOx emissions from regional flights and the technology to make that happen is closer than most people think,” said Prof Dr Josef Kallo, co-founder and CEO of H2FLY.

“Over the last 16 years we have worked hard to demonstrate our technology on smaller aircraft, completing record breaking flights based on six powertrain generations. We are pleased to be taking that to the next level with Deutsche Aircraft as we scale our efforts up to regional aircraft.”

Deutsche Aircraft says it is putting climate change at the heart of its design philosophy. “We are looking forward to partner with companies that not only share our passion for the environment but also have the technical expertise to ensure climate-optimised aviation stays safe and reliable,” said Martin Nüsseler, Deutsche Aircraft’s CTO.

The company says the higher propulsive efficiency of propeller-powered aircraft will drive a change in propulsion technology that will result in further reductions in fuel consumption and emissions.

“Combining modern propeller aircraft design with zero carbon energy sources is central to achieving climate-neutral air transportation,” added Nüsseler.

Commenting on the project, Thomas Jarzombek, Member of the German Bundestag and Coordinator of the Federal Government for German Aerospace, said: “From 2035 onward, hybrid-electric flying has to be the new standard in Germany. The German government will continue to support this path to innovation with its R&D funding programme, aiming to let the vision of zero-emission aircraft become a reality.”

Top image: Airbus