Simulations, design, and test results for a 240 kW two-phase pumped cooling system for aviation fuel cell application

Hydrogen-powered proton exchange membrane (PEM) fuel cells are a promising energy source for electric aircraft, but their widespread adoption requires lightweight and efficient thermal management systems. Two-phase pumped cooling offers significant mass savings compared with conventional liquid cooling by exploiting the latent heat of vaporization. This paper presents the design, modelling, and experimental results for a methanol-based two-phase pumped cooling system with a cooling capacity of 240 kW, where electrical heaters are used to emulate the heat load of a fuel cell stack. Experimental results show good agreement with model predictions on fluid pressure drop (<30%) and coolant mass (12.5%) and demonstrate stable operation over a wide range of thermal loads. The system achieves the required cooling performance with a coolant mass of just 9 kg and a 2 kg pump, highlighting the potential for substantially lighter thermal management systems for future fuel cell powered aircraft.