Rajan Wilcox
Filling up a fuel cell electric vehicle (FCEV) is just as easy as filling up a gasoline-powered car. The cost of filling up a fuel cell depends on the type of hydrogen being used and the vehicle's fuel range. The price of hydrogen fuel has increased to $36 per kilogram, with the goal of eventually reaching $5-10/kg. FCEVs can have a driving range of more than 300 miles on one tank of hydrogen, which typically holds around 5 kg of compressed hydrogen. Refueling an FCEV takes roughly five minutes and is considered extremely safe.
Characteristics and Values of Filling up a Fuel Cell
| Characteristics | Values |
|---|---|
| Refueling time | 5 minutes or less |
| Hydrogen fuel cost | $36/kg |
| Hydrogen fuel cost goal | $5-10/kg |
| Hydrogen fuel cost in the past | $15/kg |
| Fuel card value | $15,000 worth of hydrogen purchases |
| Fuel card validity | 3 years |
| Fuel card validity | 6 years |
| Number of hydrogen refueling stations in the U.S. | 60 |
| Hydrogen tank capacity | 5 kg |
| Hydrogen tank capacity | 5.6 kg |
| Driving range | 300 miles on one tank |
| Driving range | 220 miles per fill |
| Driving range | 400 miles per fill |
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What You'll Learn
- Hydrogen fuel costs: prices can vary from $5-10/kg to $25/kg or even $36/kg
- Hydrogen fueling stations: there are a limited number of stations, mostly in California
- Refueling time: it takes roughly five minutes to refuel a full tank of hydrogen
- Safety: dispensers are equipped with safety features like breakaway hoses and leak detection sensors
- Fuel efficiency: the Toyota Mirai, for example, has a range of 220 miles per fill-up
Hydrogen fuel costs: prices can vary from $5-10/kg to $25/kg or even $36/kg
The cost of filling up a fuel cell varies depending on several factors, including location, production methods, infrastructure, and local market conditions.
In the United States, for example, hydrogen fuel costs can vary from state to state. In California, retail prices for green hydrogen reached around $30/kg in 2023, significantly higher than in other states. This is due to the state's leadership in environmental initiatives and the higher costs associated with early adoption and production of green hydrogen. However, California's historic retail hydrogen prices have been lower than market conditions due to grants from the California Energy Commission (CEC). In 2021, hydrogen retailed for $8.50/kg to $10.80/kg, and in 2022, it was priced at $16.50/kg.
In other parts of the United States, prices can be lower. For instance, in some locations, hydrogen fuel costs are expected to decrease to less than $4/kg by 2020 or 2025. In certain areas, hydrogen fuel costs can be as low as $5-10/kg, with some users reporting prices of $15/kg.
Outside of the United States, hydrogen fuel costs vary even more widely. In Europe, for example, prices can range from less than €1/kg to over €10/kg, depending on the region and its infrastructure. In Spain, Germany, and France, prices were reported to be around €7-€8 per kilogram as of early 2023.
In China, the cost of hydrogen can vary depending on the production method, with electrolysis-based sources (renewable energy) costing more than traditional methods like coal gasification. Prices in China typically range from less than ¥40/kg to more than ¥70/kg (approximately $6 to $11 USD per kg).
These variations in pricing are due to the differences in production methods, infrastructure, local market conditions, and other factors, influencing the overall cost of hydrogen fuel globally.
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Hydrogen fueling stations: there are a limited number of stations, mostly in California
The adoption of fuel cell vehicles is dependent on the availability of hydrogen fuelling stations. While filling up a fuel cell electric vehicle is just as easy and safe as filling up a gasoline-powered car, the limited number of hydrogen fuelling stations, especially outside of California, is a key challenge for consumers.
As of 2024, there were 54 retail hydrogen stations in the United States, with over 20 more in various stages of planning or construction. Most of these existing and planned stations are in California, with one in Hawaii. California's focus has been on adding hydrogen fuel to existing gasoline stations, particularly in northern California near San Francisco and southern California near Los Angeles and San Diego. Retail hydrogen fuelling stations are already operational in California, with funding in place for 100 more. Stations are also in development in the Northeast, with an agreement between eight states to put 3.3 million zero-emission vehicles on the roads by 2025.
The cost of hydrogen fuel is another factor influencing the expansion of hydrogen fuelling infrastructure. The Department of Energy's Fuel Cell Technologies Office has been working to drive down the total cost of hydrogen fuel to less than $4/kg by 2020. The Inflation Reduction Act of 2022 also provides incentives for projects with low-lifecycle greenhouse gas emissions by offering a tax credit of up to $3 per kilogram of hydrogen produced. These efforts aim to stabilize and expand the market for hydrogen fuel, making it more accessible and affordable for consumers.
The rollout of hydrogen fuelling stations is expected to match the increasing demand for fuel cell electric vehicles. Manufacturers like Hyundai and Toyota are offering production FCEVs for sale or lease in markets where hydrogen fuel is available, primarily in California. 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 stations improves, and the volume of station component production will drive down costs.
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Refueling time: it takes roughly five minutes to refuel a full tank of hydrogen
Filling up a fuel cell is a straightforward process, and it takes roughly the same amount of time as fuelling a gasoline-powered car. In fact, it takes approximately five minutes or less to refuel a full tank of hydrogen. This is a significant advantage over battery electric vehicles (EVs), which can take 30-45 minutes or more to charge.
The process of refuelling a hydrogen car is similar to that of a petrol or diesel car. First, you open the filler cap and connect the nozzle to the car's fuel port. The nozzle locks on to the fuel receptacle, creating a secure pressure seal. Within just 3-5 minutes, the tank is filled, and you can be on your way.
The hydrogen fuel stations offer two types of pressures: 350 bar, which is typically used for larger vehicles like buses and trucks, and 700 bar, the latest standard for passenger cars. The amount of hydrogen dispensed can range from about 5-7 kg, depending on the vehicle type and size of the tank.
The cost of hydrogen fuel can vary, and there have been efforts to drive down the total cost of production and delivery. For example, the Fuel Cell Technologies Office aimed to reduce the cost to less than $4/kg by 2020. However, the price of hydrogen fuel can be significantly higher, with some users reporting costs of $15/kg or even $25/kg for dirty hydrogen.
As more hydrogen fuelling stations are built and technology advances, hydrogen cars are expected to become more mainstream. Retail hydrogen fuelling stations are already available in California, with funding in place for 100 more. Stations are also in development in the Northeast of the United States, with an agreement to put 3.3 million zero-emission vehicles on the roads by 2025.
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Safety: dispensers are equipped with safety features like breakaway hoses and leak detection sensors
Filling up a fuel cell electric vehicle is as easy and safe as filling up a gasoline-powered car. Dispensers are equipped with safety features like breakaway hoses, leak detection sensors, and grounding mechanisms to protect from human error. For instance, if a motorist forgets to remove the nozzle after filling up their tank and drives away, the breakaway hose will pull apart, preventing the motorist from pulling the dispenser off the pump island. A valve installed between the nozzle and dispenser will close instantly in both parted sections of the hose, stopping fuel from flowing out.
Leak detection sensors are also an important safety feature of fuel dispensers. These sensors can quickly detect leaks, enabling a swift response that prevents serious damage to facilities and equipment. For example, the Pressure Line Leak Detector (PLLD) sensor monitors pressure decay or drops during site operation. If the pressure readings differ from the norm, an alarm will sound, indicating a potential leak. Other sensors can detect the presence of liquids, including water, fuel, and oil, in various parts of the dispenser.
The use of these safety features in fuel dispensers helps to protect the investment and environment of the fuel station, while also ensuring the safety of customers and their vehicles. These features provide peace of mind and contribute to a more positive refuelling experience, knowing that potential hazards are being actively monitored and addressed.
Overall, the inclusion of breakaway hoses and leak detection sensors in fuel dispensers demonstrates the importance of safety in the design of refuelling infrastructure. These features help to prevent accidents, mitigate environmental risks, and ensure the well-being of customers interacting with the dispensers. With these safety mechanisms in place, customers can refuel their vehicles with added confidence and security.
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Fuel efficiency: the Toyota Mirai, for example, has a range of 220 miles per fill-up
Filling up a fuel cell electric vehicle is as easy as filling up a gasoline-powered car. It takes roughly five minutes or less to refuel a full tank of hydrogen, which is similar to the time taken to fill a gasoline tank. The process is also extremely safe, with safety features such as breakaway hoses, leak detection sensors, and grounding mechanisms in place to protect from human error.
The Toyota Mirai is currently the only production hydrogen fuel cell vehicle available on the market. It offers impressive fuel efficiency, with a range of 220 miles per fill-up, and even up to 400 miles per fill according to some estimates. However, it is important to note that the mileage may vary depending on driving habits and conditions. For example, one owner of a 2021 Mirai in Southern California reported getting closer to 370 miles on a full tank due to their driving conditions, which included a mix of freeway and local driving with minimal hills.
The Mirai's fuel efficiency is a significant advantage, but the cost of hydrogen fuel can be a drawback. The price of hydrogen fuel has increased to $36 per kilogram, and the Mirai's tank holds 5.6 kilograms, resulting in a total cost of over $200 to fill up an empty tank. To offset this, Toyota provides Mirai buyers with a fuel card worth $15,000 in hydrogen purchases, valid for six years. However, even with this incentive, the high cost of hydrogen fuel may still be a burden for some owners, especially considering the limited number of hydrogen refueling stations in the United States, which are mostly concentrated in Southern California.
Despite the challenges posed by the current hydrogen fuel infrastructure and costs, the Mirai's fuel efficiency of 220 miles per fill-up or more contributes to its appeal as a zero-emission vehicle. With ongoing developments in fuel cell and hydrogen technologies, it is hoped that the cost of hydrogen fuel will decrease, making fuel cell electric vehicles like the Mirai a more accessible and sustainable option for consumers in the future.
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Frequently asked questions
The cost to fill up a fuel cell varies depending on location and the type of hydrogen being used. The price of hydrogen fuel per kilogram ranges from $15 to $36.
It takes roughly five minutes or less to refuel a full tank of hydrogen, which is similar to the time taken to fill up a gasoline tank.
The frequency of refuelling depends on the vehicle's fuel range and your usage. Some vehicles can travel over 300 miles on one tank of hydrogen, while others have a range of around 220 miles.
Yes, refuelling fuel cells is extremely safe, similar to refuelling gasoline tanks. Dispensers are equipped with safety features such as breakaway hoses, leak detection sensors, and grounding mechanisms to prevent accidents.
Hydrogen refuelling stations are available in select locations, primarily in California, with a concentration in Southern California from Los Angeles to San Diego. Stations are also being developed in the Northeast, with a commitment to introducing more zero-emission vehicles by 2025. You can use online tools like alternative fuel station locators or apps to find the nearest hydrogen refuelling station.
