DEVELOPMENT OF AN INTEGRATED ELECTROLYSIS SYSTEM FOR HYDROGEN PRODUCTION IN PISTON-ENGINED UNMANNED AERIAL VEHICLES

Authors

DOI:

https://doi.org/10.69609/1516-2893.2026.v32.n3.a4408

Keywords:

Onboard electrolysis, Green hydrogen, Unmanned Aerial Vehicle, Piston engine, Flight endurance, Systematic Literature Review

Abstract

ABSTRACT

This study presents a systematic literature review on the development of a conceptual onboard electrolysis system for the in situ generation of hydrogen (H₂) aboard a Remotely Piloted Aircraft (RPA), categorized as an Unmanned Aerial Vehicle (UAV), equipped with an internal combustion piston engine. The methodology was based on the Methodi Ordinatio, ranking publications by relevance in order to build a bibliographic portfolio on the use of hydrogen as an alternative fuel to extend flight endurance. The analyzed studies address the energy balance of the propulsion system, the sizing of the hydrogen generation system, material selection, weight penalty, thermal management, required modifications to the engine intake system, and regulatory aspects related to airworthiness. As a result, a conceptual equipment model is proposed to support the future development of a bench-top prototype.

 Keywords: Onboard electrolysis. Green hydrogen. Unmanned Aerial Vehicle. Piston engine. Flight endurance. Systematic Literature Review.

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Author Biographies

Carlos José Sabaini Pavan, Universidade de Taubaté

I have a Master's degree in Aeronautical Engineering from the Association of Teachers of the Department of Mechanical Engineering at UNITAU (2016). He is currently a system engineer at Akaer Engenharia. I am currently studying a Professional Master's Degree in Mechanical Engineering with a focus on Energy and Materials, seeking to develop innovative solutions to optimize energy generation and storage." (Texto informado pelo autor)

Fernando Silva de Araújo Porto, Universidade de Taubaté

He holds a Bachelor's degree in Mechanical Engineering (1988) and a Master's degree in Mechanical Engineering (1996) from São Paulo State University (UNESP), as well as a PhD in Materials Engineering from the Lorena School of Engineering (EEL-USP, 2003). He is a Senior Maintenance Engineer with experience in industrial maintenance and production statistics, focusing primarily on reliability, component service life, and mechanical maintenance. He is a two-time recipient of the Brazilian Mining and Metallurgical Industry Excellence Award (2009 and 2012). He served as a Collaborating Professor at the University of Taubaté (2015–2017) and has been an Assistant Professor II since 2015, teaching courses in Aeronautical, Mechanical, Mechatronic, and Mechanical Production Engineering, among others. He coordinates research and technological innovation projects, such as "Rompendo Barreiras" (stratospheric probes) and the Bajuta Team (Baja SAE). He worked as a Mechanical Engineer in the Physical Infrastructure Department of the Federal University of São Carlos (UFSCar) University Hospital (HU-UFSCar/EBSERH) under a temporary contract (Public Selection Process, Public Notice No. 677/2020). In this role, he was responsible for the hospital's mechanical maintenance, including elevator systems, hydraulics, heating, HVAC, and exhaust systems, as well as metalworking, joinery, carpentry, and construction oversight. He is the author of the books *Análise de Tensões em Tubulações Industriais* (LTC) and *Propriedades Termodinâmicas da Água*. He conducts applied research in aerodynamics, system reliability, discrete-event simulation, logistics, and atmospheric data analysis using LIDAR.

Miroslava Hamzagic , Universidade de Taubaté

Possui graduação em Arquitetura e Urbanismo pela Universidade de Taubaté (1984), mestrado em Mestrado Profissonal em Gestão de Desenvolvimento Regional pela Universidade de Taubaté (2004) e doutorado em Engenharia da Produção - Departamento de Engenharia de Produção da Escola Politécnica da USP (2010). Atualmente é professor visitante do Instituto Nacional de Estudos e Pesquisas Educacionais Anísio Teixeira. Consultora Autônoma, professora da Universidade de Taubaté e assessora das Pró-reitorias de Graduação e Pesquisa e Pós-graduação da Universidade de Taubaté. Possui 40 anos de experiência na área de Engenharia de Produção, atuando principalmente nas áreas de logística, inclusive a internacional, logística reversa, disposição de resíduos e ODS. 

References

REFERÊNCIAS

CENTER FOR SUSTAINABLE SYSTEMS, UNIVERSITY OF MICHIGAN. Hydrogen factsheet. Ann Arbor: University of Michigan, 2025. (Pub. No. CSS23-07).

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FARADAY, Michael. Experimental researches in electricity. Seventh series. Philosophical Transactions of the Royal Society, London, v. 124, p. 77-122, 1834.

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KHZOUZ, Martin; GKANAS, Evangelos I.; STATHEROS, Thomas; GIRELLA, A.; MILANESE, C. Sustainable hydrogen production via LiH hydrolysis for unmanned air vehicle (UAV) applications. International Journal of Hydrogen Energy, v. 45, n. 8, p. 5384-5394, 2020.

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OKTAR, Hilmi Ersin; TONYALI, Ibrahim Hakki; APAYDIN, Ahmet Hamit. A cost-effective and sustainable path to a green future: retrofitting internal combustion engines for hydrogen fuel utilization. International Journal of Hydrogen Energy, v. 50, n. 1, p. 456-470, 2025.

PAGANI, R. N.; KOVALESKI, J. L.; RESENDE, L. M. Methodi Ordinatio: a proposed method to select and order relevant scientific literature. Brazilian Journal of Management, v. 8, n. 2, p. 133-158, 2015.

SHUHAYEU, Pavel; MARTSINCHYK, Aliaksandr; MARTSINCHYK, Katsiaryna; MILEWSKI, Jaroslaw. Investigating PEM fuel cells as an alternative power source for electric UAVs: modeling, optimization, and performance analysis. Energies, v. 17, n. 17, p. 4427, 2024.

SUEWATANAKUL, Siwat; PORCARELLI, Alessandro; OLSSON, Adam; GRIMLER, Henrik; CHICHE, Ariel; MARIANI, Raffaello; LINDBERGH, Göran. Conceptual design of a hybrid hydrogen fuel cell/battery blended-wing-body unmanned aerial vehicle—an overview. Aerospace, v. 9, n. 5, p. 275, 2022.

U.S. NAVAL RESEARCH LABORATORY. NRL shatters endurance record for small electric UAV. Washington, D.C.: U.S. Naval Research Laboratory, 2013.

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Published

2026-09-30

How to Cite

Sabaini Pavan, C. J., Silva de Araújo Porto, F., & Hamzagic , M. (2026). DEVELOPMENT OF AN INTEGRATED ELECTROLYSIS SYSTEM FOR HYDROGEN PRODUCTION IN PISTON-ENGINED UNMANNED AERIAL VEHICLES. Journal of Exact Sciences, 32(3). https://doi.org/10.69609/1516-2893.2026.v32.n3.a4408

Issue

Vol. 32 No. 3 (2026)

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Articles

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Copyright (c) 2026 Carlos José Sabaini Pavan, Fernando Silva de Araújo Porto, Miroslava Hamzagic

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