Mercedes Mullins
Hydrogen fuel cells are an alternative to petrol-powered internal combustion engines and electric vehicles. Hydrogen fuel cells use hydrogen and oxygen to produce electricity, which then powers the vehicle. Hydrogen fuel cells are considered to be a clean energy source as they only emit water vapour. They are also a more convenient option than electric vehicles as they have shorter refuelling times. However, hydrogen fuel cells are not yet widely available to the public as there are few hydrogen fuelling stations. Nevertheless, hydrogen fuel cells are expected to play a significant role in the future of renewable energy, particularly in the public transport and heavy trucking sectors.
Hydrogen Car Fuel Cell Characteristics and Values Table
| Characteristics | Values |
|---|---|
| Hydrogen | The most abundant chemical substance in the universe and the lightest element on the periodic table. |
| Extraction | Can be extracted from water by electrolysis or produced in large quantities using natural gas via Methane Pyrolysis or Steam Reforming. |
| Emissions | Does not produce toxic emissions such as carbon monoxide and nitrogen oxides, only emitting water vapour. |
| Vehicle Design | The power of the vehicle is defined by the size of the electric motor(s) that receive electric power from the fuel cell and battery combination. |
| Fuel Cell Stack | An assembly of individual membrane electrodes that use hydrogen and oxygen to produce electricity. |
| Fuel Filler | A nozzle from a fuel dispenser attaches to the receptacle on the vehicle to fill the tank. |
| Fuel Tank | Stores hydrogen gas onboard the vehicle. |
| Power Electronics Controller | Manages the flow of electrical energy delivered by the fuel cell and the traction battery, controlling the speed and torque of the electric traction motor. |
| Thermal System | Maintains a proper operating temperature range for the fuel cell, electric motor, power electronics, and other components. |
| Refueling | Refueling time is similar to that of a gas station, taking around five minutes. |
| Applications | Used in cars, drones, trucks, trains, buses, ships, forklifts, bin lorries, backup power, bicycles, and more. |
| Availability | As of mid-2022, there are around 17,000 hydrogen-powered vehicles in the U.S., all located in California. |
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What You'll Learn
Hydrogen extraction methods
Steam Methane Reforming (SMR)
Steam Methane Reforming, also known as Steam Reforming, is the most common method of hydrogen production. It involves heating steam and natural gas to extremely high temperatures (around 900°C) under high pressure in the presence of a nickel-based catalyst. This process produces a mixture of carbon monoxide and hydrogen called syngas, which can be further treated to produce more hydrogen. SMR accounts for 95% of hydrogen production in the United States.
Electrolysis
Electrolysis is a sustainable method of hydrogen production that splits water molecules (H2O) into hydrogen and oxygen using an electrical current. This process occurs within equipment known as an electrolyzer. Electrolysis is particularly promising when combined with renewable energy sources like wind and solar power, resulting in carbon-free "green hydrogen".
Thermochemical Processes
Thermochemical processes, also known as thermal processes, use steam to react with hydrocarbon fuels such as natural gas, diesel, renewable liquid fuels, gasified coal, or gasified biomass to produce hydrogen. An example of this is the coal gasification method, where coal is heated to produce syngas, a mixture of hydrogen, CO, and CO2.
Solar-Driven Methods
Solar-driven hydrogen generation processes leverage light to produce hydrogen. This can be done through photobiological processes, which use the natural photosynthetic activity of bacteria and green algae to generate hydrogen, or photoelectrochemical processes, which use specialized semiconductors to separate water into hydrogen and oxygen.
Biological Methods
Biological methods, such as biomass gasification, are also being explored for hydrogen production. This process involves converting biomass materials into syngas through high temperatures and restricted oxygen access. Syngas is a versatile gas mixture that can be used for power generation, heating, biofuels, and chemical production.
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Fuel cell stack assembly
The fuel cell stack assembly process involves several steps and considerations to ensure the efficient and safe functioning of the fuel cell. Firstly, it is essential to determine the layout and design of the fuel cell stack. This includes optimizing the structure to maximize the efficiency of the fuel cell and ensuring it can support the weight of the fuel cells. Before assembly, thorough inspections are crucial to verify the integrity and condition of all components. This includes checking the anode and cathode for damage and the fuel source and oxidant for contamination.
The assembly process itself begins with connecting all the cells to create a unified unit. This is achieved through the use of special electrical connectors, which facilitate the distribution of electricity generated by the fuel cell. The fuel cell stack is then tested to ensure proper functionality and the absence of leaks or component issues. This testing encompasses measuring the voltage and current output.
The subsequent step involves packaging the fuel cell stack by sealing it within a protective casing. This packaging serves to safeguard the fuel cell during transportation and storage. Additionally, it is essential to incorporate the necessary safety features. Sensors are an integral part of the fuel cell stack, monitoring parameters such as pressure, temperature, and voltage and current levels. These sensors provide feedback to the control system, enabling the adjustment of fuel cell pump speeds and valve positions.
The main fuel cell stack structure consists of alternating layers of MEA (Membrane Electrode Assembly) and BPP (Bi Polar Plate), held together by two end plates. The MEA comprises a catalyst-coated membrane sandwiched between gas diffusion layers with a microporous layer, while the BPP provides dimensional stability and ease of handling. The end plates facilitate the connection and distribution of media, and the entire assembly is typically maintained under compression to minimize electrical contact resistances and potential gas leaks.
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Hydrogen fuel tank design
There are several types of hydrogen tanks, including Type I, II, III, and IV. Type IV vessels are commonly used in automotive applications, operating at pressures of 350 or 700 bar. A typical fuel cell electric vehicle (FCEV) hydrogen car tank capacity is around 4-6 kg of hydrogen, with a tank weight of about 100 kg. For example, the Toyota Mirai has a hydrogen tank capacity of 5.6 kg, while the Hyundai Nexo offers a capacity of 6.33 kg.
To increase the driving range of FCEVs, onboard storage of hydrogen in gaseous form is typically required. This can be achieved through compressed gas storage using advanced pressure vessels made of fibre-reinforced composites. These vessels are designed to handle high pressures of up to 700 bar, with a focus on reducing system costs. Hydrogen can also be stored in liquid form (LH2), but this requires very low temperatures of around -251.15 °C. Tanks for liquid hydrogen storage, known as cryogenic hydrogen tanks, must be able to withstand extremely low temperatures and provide sufficient thermal insulation to ensure operational safety and minimise boil-off.
The design of hydrogen fuel tanks involves meeting various physical requirements depending on the pressure and temperature of storage. Hydrogen tanks can be used in a range of applications, from fuel cell systems in construction compactors or forklifts to rockets and space flight. The weight of the tank can be advantageous in certain applications, such as when used in fuel cell systems where a higher overall system weight improves vehicle function.
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Power electronics controller
The power electronics controller, or fuel cell control unit (FCCU), is a critical component of a hydrogen car fuel cell system, acting as the central control unit for the operation of the fuel cell. It plays a key role in managing the various subsystems that make up the fuel cell system, ensuring optimal performance and safety.
One of the primary functions of the FCCU is to control the hydrogen supply to the fuel cell. It monitors and regulates the flow of hydrogen gas to ensure a consistent and efficient supply to the fuel cell stack. This includes managing the pressure and temperature of the hydrogen gas, as well as the overall hydrogen storage system.
Another important aspect of the FCCU is its role in thermal management. The FCCU monitors and controls the temperature of the fuel cell system to maintain optimal operating conditions. This includes regulating the cooling system and ensuring that the fuel cell operates within a safe temperature range to prevent overheating or damage.
The FCCU also integrates a water-management system to control the humidity within the fuel cell. This is crucial for maintaining the proton conductivity of the polymer electrolyte membrane in the fuel cell stack. The FCCU may also control other subsystems, such as the air supply system, to ensure a steady supply of oxygen to the fuel cell.
To ensure the safe and efficient operation of the fuel cell system, the FCCU employs a monitoring concept that utilizes both hardware and software components. This includes the use of sensors and closed-loop control algorithms to gather data and make real-time adjustments to the fuel cell's operation. The FCCU may also incorporate cybersecurity features, such as a hardware security module, to protect the system from unauthorized access or tampering.
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Thermal system for cooling
The thermal system for cooling is a critical component of a hydrogen car fuel cell, as hydrogen fuel cells produce heat as a byproduct of electricity generation. If this heat is not effectively managed, the fuel cell's efficiency decreases, especially at temperatures above 80°C. Therefore, a cooling system is necessary to maintain optimal performance.
The cooling process typically involves transferring heat away from the fuel cell stack into a coolant, which is then pumped into a radiator to be cooled by ambient air. Fans are used to control the airflow through the radiator, optimising the cooling process. This basic process is known as a Fuel Cell Stack Cooling Package.
However, a more advanced thermal management system, known as an integrated thermal management system (ITMS), can be employed to improve temperature control and energy efficiency. This system couples the cabin, fuel cell, power battery, and motor through a waste-heat source heat pump (WSHP), allowing for more efficient energy utilisation and a broader range of operational modes, such as cooling, heating, preheating, defrosting, and energy recovery.
When designing a thermal system for cooling, careful consideration must be given to the materials used in the cooling package. Any material in contact with the cooling fluid must meet specific conductivity requirements. Additionally, the cooling capacity and size of the cooling package should be determined based on the power output and energy demands of the fuel cell to ensure optimal performance and longevity.
Furthermore, the waste heat generated by the fuel cell can be recycled and utilised for cabin heating, reducing the demand for electricity produced by the fuel cell. This integration of the cooling system with the cabin heating circuit improves overall system efficiency.
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Frequently asked questions
Hydrogen car fuel cells are an alternative to electric vehicles. They are powered by a fuel-cell stack in which pure hydrogen passes through a membrane to combine with oxygen from the air, producing electricity to turn the wheels and water vapour as a by-product.
You can convert a gasoline-powered car to a hydrogen car fuel cell by purchasing a HydroCell Kit from Amazon.com. This kit is added to your gasoline-powered car.
Hydrogen car fuel cells are a zero-emission vehicle option, only emitting water vapour. Hydrogen is also the most abundant chemical substance in the universe and the lightest element on the periodic table.
