Katerina Swanson
Toyota has been investing in hydrogen fuel cell technology since the early 1990s, with the creation of its Electric Vehicle Development Division in 1992. The company has been testing and developing hydrogen cars for over three decades, with its Mirai model taking centre stage in today's green revolution. As of February 2024, there were an estimated 18,025 fuel-cell cars sold or leased in the United States, mostly Toyota Mirais. Toyota has been pushing hydrogen as the clean fuel of the future, and has announced a third-generation fuel cell system to bring the technology closer to commercial viability. The company has been criticised for not investing more in battery-electric vehicles, but it remains committed to its hydrogen vision, with plans to expand production and reduce costs. While the exact amount Toyota has spent on developing fuel cells is unknown, it has been significant, with the company aiming to lead the EV market with its hydrogen fuel cell technology.
| Characteristics | Values |
|---|---|
| Years of investment in fuel-cell technology | 30+ years |
| Year of investment in hydrogen cars | Since 1992 |
| Number of fuel-cell cars sold or leased in the US as of February 2024 | 18,025 |
| Number of hydrogen refuelling stations in California | 55 |
| Number of hydrogen stations under development in California | 108 |
| Estimated cost of production of each fuel cell stack | $11,000 |
| Expected cost of production of each fuel cell stack after increased production capacity | $8,000 |
| Expected global FCV sales after 2020 | 30,000 units annually |
| Expected driving range of the next Mirai | 700-750 kilometers |
| Expected driving range of the Mirai by 2025 | 1,000 kilometers |
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What You'll Learn
Hydrogen fuel cell vehicles
Toyota has been investing in hydrogen fuel cell vehicles for over 30 years. In 1992, the company created its Electric Vehicle Development Division, setting the stage for research and development aimed at meeting stringent emission regulations. The Toyota Mirai, which combines luxury and style, is an example of the company's continued dedication to unique innovations.
Toyota has been doubling down on its investment in hydrogen fuel cell vehicles, designing lower-cost, mass-market passenger cars, SUVs, buses, and trucks to build economies of scale. The company is also working on improving performance, with plans to increase the driving range of the next Mirai to 700-750 kilometers and reach 1,000 kilometers by 2025. Driven by the belief that hydrogen will become a key source of clean energy, Toyota has made significant strides in fuel cell technology.
Toyota's fuel cells use PEM (Proton Exchange Membrane) technology, which transforms the chemical energy from the electrochemical reaction of hydrogen and oxygen into electrical energy, producing no emissions except water. The company has developed FCV prototypes of small delivery vehicles and large transport trucks, and its fuel cells have been integrated into heavy-duty hydrogen-powered trucks for the European market.
Despite the challenges and criticisms associated with hydrogen fuel cells, Toyota remains committed to its development. The company has been working to expand its production and reduce the cost of hydrogen fuel cell vehicles. Strategic Analysis Inc. estimates that it costs Toyota about $11,000 to produce each fuel cell stack, and the company is building up production capacity to lower this cost.
Toyota's North American Hydrogen Headquarters in Gardena, California, has been co-developing technology with Toyota Motor Corporation in Japan, from early fuel cells to semi-truck applications and mobile and stationary generators. The company is collaborating with traditional competitors to develop standards for hydrogen fueling connections and protocols, recognizing the benefits of industry standardization.
Toyota's efforts toward decarbonization include a focus on hybrid, plug-in hybrid, and battery-electric powertrains, but hydrogen-powered fuel cell electric vehicles remain an important part of its multi-pathway strategy. The company believes hydrogen can play a significant role in transitioning to a carbon-neutral future, especially in sectors with large carbon footprints, such as heavy-duty trucking.
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Hydrogen refueling stations
Although hydrogen has been touted as the clean fuel of the future, the reality of hydrogen-powered vehicles has not yet come to pass. However, Toyota has been pushing hard in this area and has been investing in hydrogen fuel cell vehicles for over 30 years.
As of 2024, there were 54 open retail hydrogen stations in the United States, with most of these concentrated in California. California is a key market for hydrogen fuel as manufacturers such as Toyota and Hyundai offer production fuel cell electric vehicles (FCEVs) for sale or lease to customers in markets where hydrogen fuel is available. In 2024, California had 55 hydrogen refuelling stations open to the public, with 108 more under development.
The rollout of hydrogen refuelling stations is supporting the initial deployment of FCEVs. Hydrogen fuel is being added to existing gasoline stations, particularly in northern California near San Francisco and southern California near Los Angeles and San Diego. Mobile hydrogen fuellers, which store liquefied or compressed hydrogen and dispensing equipment onboard a trailer, are also being developed to support the expansion of hydrogen infrastructure.
As demand for FCEVs grows, the business case for building more refuelling stations with higher capacities improves. The rollout of heavy-duty hydrogen trucks will require very large stations compared to light-duty needs. Private fleet fuelling stations, which are used by businesses for their fleets of vehicles, require fewer locations than public consumer stations.
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Hydrogen production costs
Hydrogen has been touted as the clean fuel of the future for the automotive industry. Toyota has been at the forefront of developing hydrogen fuel cells for vehicles for over three decades. The company has been investing in research and development aimed at meeting stringent emission regulations and bringing hydrogen fuel cell technology closer to commercial viability.
The cost of hydrogen production is a critical factor in determining the feasibility of hydrogen as a clean fuel. Currently, the cost of producing hydrogen varies depending on the source and production method. For example, the cost of producing hydrogen from fossil fuels is around $2.4/kg, while hydrogen produced from renewable electricity costs significantly more, ranging from $3 to $8/kg. The use of CCUS (carbon capture, utilisation, and storage) technologies to reduce emissions during hydrogen production further increases costs, typically by around $1/kg.
Several factors influence the cost of hydrogen production. These include the cost of electricity, the production technology's advancement level, the availability of infrastructure, and feedstock prices. According to some sources, the most financially advantageous methods for hydrogen production are steam methane reforming, coal, and biomass gasification. Nuclear thermochemical cycles also offer competitive costs compared to fossil fuels and biomass.
To address the high costs of hydrogen production, particularly from renewable sources, various strategies are being explored. These include enhancing technological infrastructure, increasing production capacity, and pursuing government incentives and initiatives. For instance, the US Department of Energy has allocated funding to reduce the cost of clean hydrogen technologies, and companies like Toyota are working on designing lower-cost, mass-market hydrogen fuel cell vehicles to build economies of scale.
While hydrogen production costs are currently a barrier to the widespread adoption of hydrogen fuel cell technology, ongoing advancements and investments in this area are expected to drive down costs over time.
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Fuel cell stack costs
Toyota has been investing in hydrogen fuel cell technology for over 30 years. In 1992, the company created its Electric Vehicle Development Division, setting the stage for research and development aimed at meeting stringent emission regulations.
Toyota has been doubling down on its investment in hydrogen fuel cell vehicles, designing lower-cost, mass-market passenger cars and SUVs, and pushing the technology into buses and trucks to build economies of scale. The company is also betting on improved performance, with plans to push the driving range of the next Mirai to 700-750 kilometers and to hit 1,000 kilometers by 2025.
The cost of fuel cell stacks varies depending on the model and its capabilities. The PEM Reversable Fuel Cell, one of the smallest fuel cell units on the market, measures 54mm x 17mm and has a power output of 0.6V. It is used by teachers to teach students about hydrogen's potential to generate clean electricity and costs around $79. In comparison, the H-500 fuel cell stack, a 500W system composed of 24 individual fuel cells, weighs 7.5lbs (3.4 kg) and has an efficiency of 50-63%. The price of one unit ranges from $2,500 to $2,900.
The 2.5kW T series fuel cell stack, intended for stationary applications like remote commercial cell phone towers, has a power rating of up to 47A @54V and a 42% efficiency rating. The price of this system starts at $10,700 and goes up to $13,700. The 120kW Liquid Cooled VL-Series, with a power output of 120kW, is often used to power Class 8 trucks and has an efficiency of at least 47.8%. The current price range for this system is $180,000 to $220,000.
The cost of producing fuel cell stacks is also a significant factor. According to Strategic Analysis Inc., it costs Toyota about $11,000 to produce each of its fuel cell stacks, the vehicles' most expensive part. However, by increasing production capacity, Toyota expects to reduce costs to about $8,000 per stack.
When considering the cost of fuel cell stacks, it is essential to look at the 'true' cost, which includes maintenance, the price of hydrogen fuel, operating conditions, long-term savings, and resale value. While the initial purchase price of fuel cell stacks can be high, ranging from $500 to the tens of thousands, fuel cells have a long lifespan and can last up to 10 to 20 years with proper maintenance. Additionally, fuel cells have a higher efficiency rate compared to fossil fuel-based systems, with hydrogen fuel cell stacks achieving efficiencies of up to 61% or higher.
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Hydrogen as a clean energy source
Hydrogen has been touted as the clean fuel for our automotive future. Hydrogen is light, storable, energy-dense, and produces no direct emissions of pollutants or greenhouse gases. Hydrogen can be used to store, move, and deliver energy produced from other sources.
Today, hydrogen is mostly used in oil refining and for the production of fertilisers. However, for it to make a significant contribution to clean energy transitions, it needs to be adopted in sectors where it is currently absent, such as transport, buildings, and power generation.
Hydrogen can be produced from a variety of sources, including natural gas, nuclear power, biomass, and renewable power like solar and wind. Electrolysis, for example, involves using renewable electricity to split water molecules, producing hydrogen and oxygen. This can be a carbon-free system if powered by zero-emissions electricity sources. Another method is biomass gasification with carbon capture and storage, which involves heating biomass without combustion to produce hydrogen, carbon monoxide, and carbon dioxide. The resulting carbon dioxide is then sequestered underground.
While hydrogen has the potential to be a clean energy source, its production and distribution face several challenges. Currently, most hydrogen is supplied from fossil fuels, and the development of hydrogen infrastructure has been slow. Additionally, producing hydrogen from low-carbon energy is costly. However, with the right policies and innovations, hydrogen could play a significant role in achieving a clean, secure, and affordable energy future.
Toyota has been at the forefront of hydrogen fuel cell development for over three decades. The company has been investing in and developing hydrogen fuel cell vehicles since the early 1990s, with its Electric Vehicle Development Division created in 1992. Toyota has continued to push hydrogen as a fuel source, announcing a third-generation fuel cell system with improved performance and lower costs. The company expects hydrogen to become a key source of clean energy in the next 100 years and is working to expand production and reduce the costs of its hydrogen fuel cell vehicles.
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Frequently asked questions
Toyota has been investing in fuel-cell vehicles for over 30 years, since the early 1990s. While there is no exact figure on how much the company has spent on developing fuel cells, it is estimated that it costs Toyota about $11,000 to produce each of its fuel cell stacks, the most expensive part of the vehicle.
The Toyota Mirai is a hydrogen fuel cell vehicle (FCV) that combines luxury and style with sustainability. It is mainly sold in California, where there are 55 hydrogen refuelling stations open to the public.
Toyota is committed to expanding its hydrogen fuel cell technology, with the goal of making FCVs more affordable and accessible to the mass market. The company is also working on improving the performance of the Mirai, with the aim of increasing its driving range to 700-750 kilometres.
