Sylvie Willis
The lifetime of a fuel cell in a car is a topic of interest as the world seeks more environmentally friendly energy solutions. Hydrogen fuel cells are already being used in some cars as an alternative to petrol or diesel, but questions remain about their longevity. While some sources suggest that the fuel cell stack in a car like the Toyota Mirai is engineered to last for the lifetime of the car, others note that automotive fuel cells are rated for only 5000 hours of use. The answer may depend on the materials used in the fuel cells, with graphene emerging as a potential solution to create more durable catalysts.
How long do fuel cells last in a car?
| Characteristics | Values |
|---|---|
| Calendar life | 20 years |
| Usage life | 1 year |
| Car usage time | 5% |
| Durability | Same as conventional petrol or diesel cars |
| Warranty | 100,000 km |
| Catalyst | Platinum |
| Catalyst support material | Graphene |
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What You'll Learn
Fuel cell durability
One of the primary methods of testing fuel cell durability is through driving cycles, which simulate the conditions a fuel cell may experience in a vehicle, such as idling and full-power conditions. These tests can be expensive and time-consuming, and so accelerated stress tests (ASTs) are often used to speed up the process. ASTs can investigate the individual and combined effects of various operational factors on component-level degradation, such as thermal, humidification, hydration–dehydration, freeze–thaw, clamping force, and vibration.
An algorithm has been developed to shorten the test duration of ASTs, which considers all relevant operation conditions of the fuel cell and its reactants. This algorithm consists of four sub-algorithms representing the most critical states in FCEVs: voltage cycling, idling, humidity cycling, and high-load operation.
The durability of a fuel cell is also dependent on its design and usage. For example, fuel cells can have a fairly short lifespan if not designed correctly or if abused (impurities in the hydrogen fuel and operation or storage under temperatures outside the design limits). Similarly, the calendar life of a fuel cell (ideally 20 years) and usage life (ideally 1 year) are important considerations, with the latter being where the real limitations might be.
Manufacturers are likely to have information about the usage life of their fuel cells, but this data is not often shared publicly. However, some car companies, such as Toyota, boast that their fuel cell stacks are engineered to last for the lifetime of the car, with the same quality, durability, and reliability as any other car they produce.
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Hydrogen fuel cells vs conventional cars
The longevity of a hydrogen fuel cell in a car is a challenging question to answer due to the relative newness of the technology and the lack of widespread adoption. However, sources suggest that hydrogen fuel cells can be expected to last for the lifetime of the car, comparable to conventional petrol or diesel engines. This is supported by warranties of up to 100,000 km provided by manufacturers like Toyota.
When discussing hydrogen fuel cells versus conventional cars, it is essential to understand their fundamental differences and similarities. Hydrogen fuel cell vehicles (HFCVs) utilize an electric motor to turn the wheels, similar to battery-electric cars. However, instead of relying on a large battery, HFCVs are powered by a fuel cell stack where hydrogen combines with oxygen from the air to produce electricity and water vapour. This makes HFCVs technically a type of hybrid vehicle.
One of the critical advantages of HFCVs over conventional cars is their zero-emission status. HFCVs emit only water vapour, making them environmentally friendly and contributing to carbon emissions reduction in the transportation sector. In contrast, conventional internal combustion engine vehicles produce carbon emissions, contributing to climate change and poor air quality.
HFCVs also offer a similar refuelling experience to conventional cars. They can be refuelled at dedicated hydrogen fuelling stations in around five minutes, comparable to the time required to fill up a petrol or diesel tank. This convenience addresses a significant drawback of battery-electric vehicles, which often require longer charging times.
However, it is important to acknowledge the challenges associated with HFCVs. Firstly, the production of pure hydrogen for HFCVs can be energy-intensive and currently relies largely on fossil fuels, which may impact their carbon neutrality. Additionally, the development of refuelling infrastructure for HFCVs requires significant investment, which could hinder their widespread adoption.
In summary, hydrogen fuel cell vehicles offer a promising alternative to conventional cars, particularly in terms of environmental sustainability and refuelling convenience. However, they also present certain challenges, such as the energy intensity of hydrogen production and the need for specialised refuelling infrastructure. As the world transitions towards sustainable transportation, HFCVs and conventional cars will compete to provide viable solutions for reducing our carbon footprint.
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Calendar life vs usage life
The calendar life and usage life of a fuel cell in a car are two important factors that determine its longevity. Calendar life refers to the expected lifespan of a fuel cell in years, while usage life refers to the amount of time a fuel cell is actively in use.
Calendar life is ideally expected to be around 20 years for a fuel cell in a car. However, it is important to note that automotive fuel cells are a relatively new technology, and the actual calendar life may vary. The calendar life of a fuel cell is influenced by various factors, including the quality of materials used, the design, and the operating environment.
On the other hand, usage life is more dependent on how the car is used. The usage life of a fuel cell is typically expected to be around 1 year, considering that a car is estimated to have only about 5% usage time, with the rest of the time spent idle. However, this can vary depending on factors such as driving conditions, frequency of use, and proper maintenance.
The durability of a fuel cell is a critical aspect of its usage life. Automotive fuel cells have been reported to have durability issues, with some rated for only 5,000 hours of use. This is significantly lower than the expected lifespan of a vehicle, which poses challenges for their practical application. Additionally, factors such as impurities in the hydrogen fuel, extreme operating temperatures, and improper storage conditions can further reduce the usage life of a fuel cell.
While there have been improvements in fuel cell technology, the high manufacturing costs, marginal performance, and short service life have hindered their widespread adoption. The service life of a fuel cell in a car driven under normal traffic conditions has increased from 1,000 hours to 2,000 hours, and there are targets to further extend this duration. However, the lack of a widespread fuelling infrastructure and high production costs remain challenges for the popularization of fuel cell vehicles.
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Fuel cell catalysts
The longevity of a fuel cell in a car is dependent on a variety of factors, including design, usage, and maintenance. While the technology is still relatively new, manufacturers aim for a calendar life of 20 years and a usage life of 1 year for automotive fuel cells.
Now, let's delve into the specifics of fuel cell catalysts and their role in the performance and longevity of fuel cells.
The high cost of PGMs, such as platinum, has driven research and development to explore alternative materials and optimize catalyst structures. One approach is to increase the catalytic activity of the metals, thereby reducing the volume of expensive PGMs needed. This can be achieved by investigating other metals like the Pt3Ni alloy or gold nanoparticles, or by modifying the form factor of the catalyst to maximize the number of active catalytic sites.
Another challenge in fuel cell catalyst design is addressing catalytic poisoning, which occurs when carbon monoxide bonds to the platinum catalyst, resulting in decreased performance. Strategies to mitigate poisoning can further enhance the longevity and efficiency of the fuel cell.
The development of hydrogen-oxygen fuel cell catalysts is a key area of focus, with researchers exploring the use of single atoms, nanoclusters, and nanoparticles as catalysts. Each option presents a unique set of advantages and complexities in terms of metal synergies and surface area.
In summary, fuel cell catalysts are critical to the performance and longevity of PEM fuel cells, and ongoing advancements in catalyst materials and structures contribute to the improvement of fuel cell technology, making it a dynamic and evolving field.
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Fuel cell design and lifespan
The design of a fuel cell is such that it converts the chemical energy of a fuel (often hydrogen) and an oxidizing agent (often oxygen) into electricity through a pair of redox reactions. Fuel cells are made up of three adjacent segments: the anode, the electrolyte, and the cathode. Two chemical reactions occur at the interfaces of these three segments. The first reaction involves the anode catalyst, usually fine platinum powder, breaking down the fuel into electrons and positively charged ions. The second reaction occurs at the cathode, where the ions are reunited with the electrons and the two react with a third chemical, usually oxygen, to create water or carbon dioxide.
The electrolyte substance, which usually defines the type of fuel cell, can be made from a number of substances like potassium hydroxide, salt carbonates, and phosphoric acid. The most common fuel used is hydrogen, but fuel cells can also use a wide range of other fuels and feedstocks.
The first references to hydrogen fuel cells appeared in 1838 by Welsh physicist and barrister Sir William Grove, who wrote about his development of a crude fuel cell using a combination of sheet iron, copper, and porcelain plates, and a solution of sulphate of copper and dilute acid. In 1955, W. Thomas Grubb, a chemist working for the General Electric Company (GE), modified the original fuel cell design by using a sulphonated polystyrene ion-exchange membrane as the electrolyte. This became known as the "Grubb-Niedrach fuel cell" after GE chemist Leonard Niedrach deposited platinum onto the membrane, serving as a catalyst for the necessary hydrogen oxidation and oxygen reduction reactions.
Fuel cells have several benefits over conventional combustion-based technologies currently used in many power plants and vehicles. They can operate at higher efficiencies than combustion engines and can convert the chemical energy in the fuel directly to electrical energy with efficiencies capable of exceeding 60%. They also emit only water, with no carbon dioxide emissions or air pollutants that create smog and cause health problems at the point of operation.
The lifespan of a fuel cell depends on its calendar life and usage life. Calendar life refers to the amount of time a fuel cell is expected to last, which is ideally 20 years. Usage life refers to the amount of time a fuel cell is actually in use, which is ideally 1 year for a car with about 5% usage time. However, it is difficult to obtain information about the exact usage life of automotive fuel cells as this information is often not made public by manufacturers.
The durability of fuel cells is also important to consider when discussing lifespan. The U.S. Department of Energy (DOE) has set targets for fuel cell system lifetime under realistic operating conditions at 8,000 hours for light-duty vehicles, 30,000 hours for heavy-duty trucks, and 80,000 hours for distributed power systems. Improvements in the efficiency, cost, and durability of fuel cells can be made by changing the current choice of raw materials. For example, silicone rubbers are commonly used for gaskets due to their flexibility at low temperatures and decent electrical properties, but other materials may be more suitable for certain applications.
In terms of the lifespan of fuel cells in cars, the fuel cell stack in the Toyota Mirai is engineered to last for the lifetime of the car, with a 100,000 km warranty. However, some sources suggest that automotive fuel cells may only be rated for 5000 hours of use, and that they can have a fairly short lifespan if not designed correctly or if abused, such as through impurities in the hydrogen fuel or operation outside of design limits.
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Frequently asked questions
The lifetime of a fuel cell depends on its calendar life and usage life. While the calendar life of a fuel cell is expected to be 20 years, the usage life is expected to be 1 year.
Calendar life refers to the lifespan of the fuel cell, while usage life refers to the amount of time it is actively in use. A car is estimated to have about 5% usage time, with the rest of the time spent idle.
The lifespan of a fuel cell can be affected by impurities in the hydrogen fuel and operation or storage under temperatures outside the design limits. Additionally, the choice of materials used in the fuel cell, such as platinum or graphene, can impact its durability and overall lifespan.
The Toyota Mirai, a hydrogen-powered Fuel Cell Electric car, is engineered to last for the lifetime of the car. It comes with a 100,000 km warranty and a take-back scheme for responsible end-of-life management.
Researchers from University College London (UCL) have found that using graphene instead of amorphous carbon as a support material can create ultra-durable catalysts for hydrogen fuel cells, potentially extending their lifespan.
