Ameer Randolph
Hydrogen fuel cell cars are an increasingly popular clean energy alternative to traditional fossil fuel vehicles. Unlike electric vehicles, hydrogen fuel cell cars do not need to be charged and are fuelled similarly to traditional petrol or diesel cars. However, the process of refuelling a hydrogen fuel cell car differs in several ways. This introduction will explain the process of refuelling a hydrogen fuel cell car, the benefits of hydrogen fuel, and the challenges facing the industry.
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What You'll Learn
- Hydrogen fuel cell cars are refuelled in a similar way to traditional cars
- Hydrogen is measured in kilograms, not gallons
- Hydrogen refuelling stations are few and far between
- Hydrogen fuel is supplied at high pressure, so nozzles may frost over
- Hydrogen fuel cell cars are more efficient than gasoline-powered engines
Hydrogen fuel cell cars are refuelled in a similar way to traditional cars
There are some important differences to be aware of, however. Firstly, hydrogen fuel is measured in kilograms, not gallons, and a full tank for a car like the Toyota Mirai is approximately five kilograms. Secondly, the hydrogen dispenser must be H70 rated, offering a supply pressure of 70MPa (700 bar). If the pressure inside the car's hydrogen storage tanks is higher than the supply pressure from the hydrogen station, a full refuel will not be possible.
It is also important to note that the end of the nozzle and the vehicle's receptacle will become cold and may develop frost during refuelling due to the high-pressure liquid gas. You should not touch these metal surfaces. If the dispenser does not release easily when refuelling is complete, it may be frozen in place.
While hydrogen fuel cell cars are promising for their clean energy and long-range capabilities, the availability of refuelling stations is currently limited. There are only a few hydrogen filling stations in the UK, and they are costly to build. However, initiatives like the Tees Valley Hydrogen Transport Hub in the north-east of England aim to increase refuelling infrastructure, primarily for delivery trucks but also potentially for cars.
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Hydrogen is measured in kilograms, not gallons
Refuelling a hydrogen fuel cell car is similar to refuelling a conventional petrol or diesel car. You drive up to a pump at a fuelling station, insert the pump into the tank gasket, and wait for the tank to fill up. This process takes about the same time as refuelling a petrol or diesel car, typically between 3 to 5 minutes for a full tank.
However, there is an important distinction to note when it comes to how hydrogen fuel is measured. Unlike petrol or diesel, which are typically measured in gallons, hydrogen fuel is measured in kilograms. So, when you refuel a hydrogen fuel cell car, you are filling up the tank with a certain number of kilograms of hydrogen gas, not gallons.
This difference in measurement is due to the unique properties of hydrogen as an element. Hydrogen is always bonded to other elements, so it must be separated and purified before it can be used in a fuel cell. The amount of hydrogen that can be stored in a tank is dependent on its mass, not its volume, hence the use of kilograms as the unit of measurement.
For example, a full tank for the Toyota Mirai, a popular hydrogen fuel cell car, is approximately five kilograms, which provides about 66 miles per gallon equivalent (MPGe) of hydrogen gas. The cost of hydrogen fuel is typically around $16 per kilogram, although some manufacturers, like Toyota, offer incentives such as a hydrogen gas card with a significant value included.
As the hydrogen fuel industry is still in its early stages, there are ongoing developments in the efficient transport and storage of hydrogen gas. This will hopefully lead to reduced costs and improved accessibility for hydrogen fuel cell cars, making them a more sustainable and viable option for drivers in the future.
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Hydrogen refuelling stations are few and far between
Refuelling a hydrogen fuel cell car is a relatively straightforward process. Similar to a typical gas-powered vehicle, you drive up to a pump station, insert the pump into the tank gasket, and wait for it to fill up. The entire process takes between 3 to 5 minutes for a full tank, and hydrogen fuel cell cars can provide over 300 miles worth of hydrogen gas. However, a significant challenge arises due to the limited availability of hydrogen refuelling stations.
Despite the growing popularity of hydrogen fuel cell vehicles, the number of refuelling stations remains scarce. As of 2021, there were only 218 stations in China, and globally, the number increased from a mere 214 to 685 in the previous seven years. In 2024, the United States had 54 retail stations, mostly in California, with a handful in other states. This scarcity of infrastructure presents a hurdle for the widespread adoption of hydrogen fuel cell technology.
The expansion of hydrogen refuelling stations is crucial to support the increasing demand for hydrogen fuel cell electric vehicles (FCEVs). Initiatives like the Bipartisan Infrastructure Law, which allocated funding for Regional Clean Hydrogen Hubs, aim to address this issue by promoting the deployment of hydrogen vehicle infrastructure. Additionally, the Inflation Reduction Act of 2022 provides tax incentives for projects with low-lifecycle greenhouse gas emissions, encouraging the development of clean hydrogen production and distribution networks.
While the number of hydrogen refuelling stations is slowly growing, their limited presence can impact the driving experience. Drivers need to plan their routes carefully to ensure they have access to refuelling stations, especially for long-distance travel. This scarcity of stations can also lead to longer wait times at pumps, as some drivers may be unfamiliar with the refuelling process, causing delays for others.
The lack of widespread hydrogen refuelling stations can hinder the adoption of hydrogen fuel cell cars. However, with ongoing initiatives and increasing consumer demand, the availability of refuelling stations is expected to improve over time, making hydrogen fuel cell technology more accessible and convenient for drivers.
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Hydrogen fuel is supplied at high pressure, so nozzles may frost over
Hydrogen fuel cell vehicles are powered by hydrogen gas, which is pumped into the car in a similar way to how you would fill up a conventional petrol or diesel car. The process is almost identical: you drive up to a station with a pump, insert the pump into the tank gasket, and wait for it to fill up. However, hydrogen fuel is supplied at high pressure and extremely low temperatures, which can lead to an issue where the nozzles frost over.
This issue is more common in warm and humid regions, where condensation forms during the fueling process. If the nozzle is used again before it has a chance to warm up, frost forms due to the cold hydrogen. The formation of ice can make it difficult or even impossible to remove the nozzle from the receptacle after fueling, requiring drivers to wait until the nozzle warms up and the ice melts before they can continue on their way. This can cause delays for other drivers waiting to use the pump, as well as frustration for those who are unable to remove the nozzle.
To address this problem, companies like WEH have developed anti-freeze technology (AFT) for fueling nozzles. The WEH TK17 H2 ENR nozzle is designed with special anti-freeze technology to prevent freezing during self-service fueling. It is equipped with a purging line that allows the hose to be flushed out with nitrogen or dry air during or after the fueling process, preventing the formation of ice crystals and moisture buildup. This not only improves the fueling experience for customers but also contributes to increasing social acceptance of hydrogen fueling among consumers.
It is important to note that while these new nozzles are available, they are not always utilized by fueling station operators. Customers who are aware of the anti-freeze technology may need to inform the operator at their nearest fueling station and request the use of this feature to prevent nozzle freezing. This proactive approach can enhance the fueling experience and reduce potential disruptions caused by frozen nozzles.
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Hydrogen fuel cell cars are more efficient than gasoline-powered engines
Refuelling a hydrogen fuel cell car is a similar process to fuelling a conventional car. Hydrogen fuel cell cars are refuelled with hydrogen gas, which is pumped in the same way as a typical gas-powered vehicle. The process takes around 3-5 minutes for a full tank, which will power the car for over 300 miles.
The hydrogen fuel cell vehicle is almost twice as efficient as internal combustion engines, resulting in much lower greenhouse gas emissions. Hydrogen fuel is a promising power source for vehicles, especially for long-haul trucks or ships, which are harder to electrify. However, there is still work to be done to produce hydrogen fuel sustainably and efficiently.
There are other benefits to hydrogen fuel cell cars. For example, in California, hydrogen fuel cell cars come with three years of free fuel. Hydrogen fuel cell cars also qualify for the Clean Air Vehicle decal, allowing solo access to carpool lanes. Additionally, new vehicles purchased in 2023 or later may be eligible for a federal income tax credit of up to $7,500.
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Frequently asked questions
Refuelling a hydrogen fuel cell car is similar to refuelling a traditional petrol or diesel car. First, bring the vehicle to a complete stop with the hydrogen dispenser facing the nearside of the vehicle. Then, remove the dust cap from the vehicle's hydrogen receptacle and store it in the holder built into the fuel filler door. Push the dispenser onto the receptacle and pull up on the handle to lock it in place. Follow the instructions on the supply station to fill the tank. Once complete, release the catch on the handle to unlock the dispenser.
Refuelling a hydrogen fuel cell car takes about 3-5 minutes for a full tank, which is similar to the time it takes to refuel a petrol or diesel car.
Hydrogen fuel is currently not as common as petrol or diesel, so the cost of the fuel is relatively high. It costs about $16 for one kilogram of hydrogen gas. However, some manufacturers, like Toyota, offer incentives such as a hydrogen gas card with a value loaded onto it.
