Fuel Cell Buses: More Efficient, But At What Cost?

how much more fuel cell bus

Hydrogen fuel cell buses have been touted as a possible solution to the problem of diesel emissions from buses. While hydrogen fuel cell buses have been experimented with and trialled since the late 1990s, they have yet to see widespread adoption. Hydrogen fuel cell buses offer certain advantages over battery electric buses, such as greater range and consistent power and range in extreme temperatures. However, they are also more expensive to operate, with higher upfront costs and higher fuelling costs. Despite this, some regions, such as California, have announced plans to deploy over 1,000 fuel cell buses, and it is expected that fuel cell buses will play a significant role in transit over the next 10 to 20 years.

Characteristics Values
Cost of hydrogen fuel $9 to $13 per gallon
Cost of diesel fuel around $6 per gallon
Mileage More than twice as much mileage from a gallon of hydrogen compared to a gallon of diesel
Hydrogen production cost projection $1.4 to $2.3 per kilogram
Purchase price of a hydrogen fuel cell bus in 2007 $2–3 million
Purchase price of a standard diesel bus in 2007 $330,000
Hydrogen fuel cell bus price in 2010 1.8 million euros
H2Bus Consortium's goal for hydrogen bus price 650,000 euros
Number of fuel cell buses in operation in Europe (2012-2020) 150
Plans for fuel cell buses in Europe 1,200
Number of Van Hool fuel cell buses sold by the end of 2020 141
Number of hydrogen fuel cell buses in the US in 2023 327
US Department of Energy funding for clean hydrogen projects in California $1.2 billion
Total funding for clean hydrogen projects in California $12.6 billion
Number of fuel cell buses to be deployed in California 1,000
Fuel cost comparison with battery-powered models 70% more expensive
Overall lifetime cost comparison with battery-electric models 41% more expensive

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Hydrogen fuel cell buses are more expensive to operate than battery-electric buses

A study by Eurac Research in September 2023 found that, for the same mileage, hydrogen fuel cell buses had operating costs that were 2.3 times higher than those of battery-electric buses. Additionally, a French transport advisory body warned that hydrogen fuel buses could incur 70% extra fuel costs compared to battery-powered models. The higher fuel costs of hydrogen fuel cell buses are due to the higher cost of hydrogen fuel, which can range from $9 to $13 per gallon, while diesel fuel costs around $6 per gallon.

The higher upfront cost of hydrogen fuel cell buses is due to the higher cost of the vehicles themselves. The purchase price of a hydrogen fuel cell bus can be up to three times that of a standard diesel bus. In 2007, the National Renewable Energy Laboratory stated that the purchase price of a hydrogen fuel cell bus was around $2–3 million, while a standard diesel bus cost around $330,000. However, it is important to note that the costs of hydrogen fuel cell buses have been decreasing as the technology becomes more commercially viable and widespread.

Despite the higher upfront and operational costs of hydrogen fuel cell buses, there are some advantages to this technology. Hydrogen fuel cell buses have a longer range than battery-electric buses, especially in extreme temperatures. Hydrogen fuel cells can also be used as a range extender for battery-electric buses, increasing their range. For example, the Mercedes-Benz eCitaro fuel cell bus has a range of 400 kilometres, compared to the 280 kilometres of the battery-electric model.

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Hydrogen fuel cell buses have consistent power and range in extreme temperatures

Hydrogen fuel cell buses are more expensive to operate than battery electric buses. The higher cost of hydrogen fuel and the vehicles themselves, as well as the inefficiency of hydrogen fuel cells compared to batteries, contribute to this. However, hydrogen fuel cell buses have consistent power and range in extreme temperatures, which is a significant advantage over battery electric buses, which have reported shorter ranges in low temperatures.

In 2023, Santa Cruz, California, noted that while hydrogen cost around $9 to $13 per gallon, compared to around $6 per gallon for diesel fuel, fuel cell buses got "more than twice as much mileage out of a gallon-equivalent of hydrogen as a gallon of diesel". This makes direct comparisons between the two fuels challenging. The cost of hydrogen fuel has been a substantial issue for transit operators, but some have used hydrogen by-products from industrial processes, such as Polyvinyl chloride production, to lower costs. Others have built small-scale plants to produce hydrogen from natural gas (brown hydrogen) or purchased it directly from industrial producers. However, brown hydrogen has been criticised due to the carbon footprint of the industrial process used to produce it. Green hydrogen, produced using renewable energy, is generally considered too expensive.

Projections from the Hydrogen Council suggest that hydrogen produced from renewable energy at scale could cost between $1.4 and $2.3 per kilogram, making it more affordable. As of 2025, the cost of hydrogen fuel in London was reported to be around £6 per kilogram, roughly comparable to the cost of diesel fuel. The costs of both battery electric and hydrogen fuel cell buses have fallen over time as the technology has become more widespread and commercially viable.

Since the early 2000s, transport operators have been moving towards greener and cleaner buses due to concerns about greenhouse gas emissions and particulate pollution produced by diesel buses. While battery electric buses are simpler and more cost-effective for small-scale deployments, fuel cells and hydrogen become more competitive when deploying larger numbers of buses from the same bus yard. Hydrogen fuel cell buses have been praised for their long range, quick refuelling times, and consistent performance in varied climates and topographies. Ballard's fuel cell systems, for example, operate from -40°C to +50°C and freeze start from -25°C.

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Fuel cell buses are twice as efficient as diesel buses per gallon of fuel

The first hydrogen fuel cell buses were trialled in Chicago and Vancouver in 1998, and since then, many cities have experimented with this technology. As of 2023, research shows that hydrogen fuel cell buses are more expensive to operate than battery-electric buses due to higher vehicle and fuel costs. However, fuel cell buses have advantages in terms of performance and range. For example, they are less affected by temperature, with consistent power and range in extreme hot or cold weather.

The upfront cost of fuel cell buses is also a significant factor. In 2010, the first hydrogen bus cost 1.8 million euros, but efforts are being made to reduce this figure to 650,000 euros. Fuel cell buses are projected to become more cost-effective at a larger scale, and governments are investing in this technology to reduce emissions. For example, the U.S. Department of Energy (DOE) has announced a plan to deploy over 1,000 fuel cell buses in California, with a funding commitment of $1.2 billion.

Despite the higher upfront costs and operational expenses, fuel cell buses offer significant environmental benefits. Each fuel cell bus put into service can reduce carbon emissions by 100 tons annually and eliminate the need for 9,000 gallons of fuel over its lifetime. This results in a savings of more than $37,000 per vehicle per year. With the transition to zero-emission technology, fuel cell buses play a crucial role in reducing the environmental impact of transportation, especially in congested areas.

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Fuel cell buses have been trialled in cities since the late 1990s

The National Renewable Energy Laboratory (NERL) in the United States has been researching hydrogen fuel cell buses since 2000, in collaboration with the Federal Transit Administration. In 2007, the National Renewable Energy Laboratory stated that the purchase price of a hydrogen fuel cell bus was around $2–3 million, compared to around $330,000 for a standard diesel bus.

In 2012, the world's first hydrogen fuel cell bus fleet, consisting of 47 buses, was launched in 10 cities on three continents as part of the HyFLEET:CUTE project. As of 2020, 64 buses were in service in California, Hawaii and Ohio, with AC Transit having the largest fleet of hydrogen fuel cell buses in the United States, with 22 buses in service from Van Hool and New Flyer.

In 2020, the city of Nanning in China announced plans to replace its 7,000 battery-electric bus fleet with hydrogen fuel cell/battery hybrid buses. In 2022, New York City's MTA announced that they would trial hydrogen fuel cell buses, with the first two buses to be launched in The Bronx by late 2024. As of 2023, research shows that hydrogen fuel cell buses are more expensive to operate than battery-electric buses due to higher vehicle and fuel costs and the inefficiency of hydrogen fuel cells compared to batteries. However, fuel cell buses are less affected by temperature and have a longer range than battery-electric buses.

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Fuel cell buses can reduce carbon emissions by 100 tons annually

Fuel cell buses are powered by hydrogen fuel cells, which generate electricity through an electrochemical reaction. This electricity is then used to power the electric motor that drives the wheels of the bus. The only by-products of this process are water and heat, meaning that fuel cell buses produce zero local emissions.

The use of fuel cell buses can significantly reduce carbon emissions, with projections indicating a potential reduction of 100 tons annually. This is because the electricity generated by the fuel cell is produced without any carbon emissions, as long as the hydrogen used is sourced from low or zero-carbon methods. Hydrogen can be produced through various ultra-low carbon routes, including renewable electricity, biomass, and carbon capture and storage.

While fuel cell buses have higher upfront costs compared to diesel or electric buses, their operating costs have decreased over time as the technology has become more widespread and commercially viable. In addition, fuel cell buses have advantages over battery electric buses, such as longer ranges and better performance in extreme temperatures.

Several cities and companies have already adopted fuel cell buses, with around 150 fuel cell buses in operation in Europe between 2012 and 2020, and plans to increase this number to over 1,200. For example, Cologne and Wuppertal in Germany have ordered a total of 25 hydrogen-fuelled Solaris vehicles, and RVK Cologne has added 35 fuel cell buses to its existing fleet.

The transition to fuel cell buses is a step towards achieving net-zero carbon mobility and transport, with the potential to significantly reduce carbon emissions and provide a more environmentally friendly mode of transportation.

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Frequently asked questions

The cost of fuel cell buses has been falling as the technology becomes more widespread and commercially viable. In 2007, a hydrogen fuel cell bus cost around $2-3 million, while a standard diesel bus was around $330,000. In 2010, the first hydrogen bus cost €1.8 million. The H2Bus Consortium has set a goal of reducing that figure to €650,000.

Hydrogen fuel cell buses are more expensive to operate than battery-electric buses due to higher vehicle costs, higher fuel costs, and the inefficiency of hydrogen fuel cells compared to batteries. A French transport advisory body warns that H2 fuel cell buses rack up 70% extra in fuel costs compared to battery-powered models. Government advisors also estimate that hydrogen buses cost 41% more over their lifetime than battery-electric equivalents.

Around 150 fuel cell buses were put into operation in Europe between 2012 and 2020, but there are plans to increase this number to over 1,200. In the US, fuel cell bus figures grew by 76% in 2023, with California leading the way in the nationwide adoption of Zero Emission Buses (ZEBs). The US Department of Energy (DOE) has announced a $12.6 billion agreement to accelerate clean hydrogen projects in California, including an initiative to deploy over 1,000 fuel cell buses.

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