Rajan Wilcox
A car fuel cell gas tank is a stainless, aluminium, or plastic gas tank that is generally located behind the driver and not under the vehicle. Fuel cells are designed to prevent fuel leaks and fires during high-speed racing, reducing the risk to drivers and spectators. They are also lightweight, which contributes to better acceleration and handling on the track. There are two types of fuel cells: gasoline/diesel fuel cells and hydrogen fuel cells. The latter combines hydrogen gas with atmospheric oxygen to produce water and electricity directly.
Characteristics and Values of a Car Fuel Cell Gas Tank
| Characteristics | Values |
|---|---|
| Materials | Stainless, aluminum, or plastic |
| Location | Behind the driver, not under the vehicle |
| Safety | Impact-resistant materials, internal bladder systems to prevent fuel spillage |
| Performance | Lightweight design for better acceleration and handling |
| Fuel Type | Gasoline/diesel or hydrogen |
| Cost | Basic options: $200-$300; Advanced options: $300-$800+ |
| Maintenance | Easier to service/replace the in-tank fuel pump when located behind the driver |
| Compliance | Meets racing regulations and safety standards |
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What You'll Learn
Fuel cell safety
Fuel cells are an alternative to conventional fuel tanks, offering efficient, clean, and safe transportation. They are particularly well-suited for electric vehicles (EVs) as they don't require plugs.
Safety Features of Fuel Cells
No Combustion
The biggest safety feature of hydrogen fuel-powered cars is that they do not rely on combustion. Instead, they utilise a safe chemical transfer without burning fuel. This eliminates the risk of explosions, which some people associate with hydrogen fuel due to the 1937 Hindenburg disaster. However, it is important to note that hydrogen fuel cells have little in common with the design of the airship involved in that incident.
Design Innovations
Manufacturers of hydrogen fuel cell cars incorporate various safety features and redundancies to address potential weaknesses. These innovations ensure that modern hydrogen fuel applications are designed with safety in mind, similar to the firewalls found in conventional fuel cars.
Environmental Benefits
Hydrogen fuel cells offer environmental advantages over conventional fuels, contributing to global sustainability and renewable energy resilience.
Safety Considerations
Engine Noise
One safety concern for electric vehicles, including those powered by fuel cells, is the lack of obvious engine noises, which can pose a risk to pedestrians. To mitigate this, these cars often emit simulated engine sounds by default.
Hydrogen Storage
While hydrogen fuel cells offer numerous safety advantages, the storage of hydrogen poses challenges. Hydrogen storage is extremely problematic, and this issue must be addressed before hydrogen vehicles can become mainstream.
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Fuel cell placement
Safety: In terms of safety, it is generally recommended to place the fuel cell in a protected location, such as behind the driver or in the truck, as mentioned by some car enthusiasts. This helps safeguard the fuel cell from potential damage in the event of a collision. Placing the fuel cell in a protected area also makes it easier to service and replace the in-tank fuel pump, as all the necessary components are easily accessible.
Weight Distribution and Performance: The placement of the fuel cell can also impact the weight distribution of the vehicle, which in turn affects its performance. Placing the fuel cell too high or too far back may negatively affect the car's centre of gravity and handling. Therefore, manufacturers must carefully consider the placement to optimize weight distribution and maintain the desired performance characteristics of the vehicle.
Space Constraints: Fuel cells, especially those with larger capacities, can take up significant space in a vehicle. Placing the fuel cell in an area that does not compromise passenger comfort or cargo space is essential. This may involve careful packaging considerations and ensuring that the fuel cell does not occupy valuable cabin or trunk space.
Thermal Management: Fuel cells generate heat during operation, and an efficient thermal management system is required to maintain optimal temperature levels. The placement of the fuel cell should facilitate proper ventilation and cooling to prevent overheating. Additionally, in cold environments, the thermal system may need to provide heating to ensure the fuel cell operates efficiently.
Accessibility for Refuelling: The placement of the fuel cell should also consider the accessibility for refuelling. The fuel filler receptacle, which connects to the fuel dispenser nozzle, should be easily accessible, typically on the exterior of the vehicle. This ensures convenient and quick refuelling without requiring complex manoeuvring or access to restricted areas.
In summary, fuel cell placement in a car involves a balance between safety, performance, space optimization, thermal management, and accessibility considerations. Each factor plays a crucial role in ensuring the efficient and safe operation of the fuel cell system, ultimately contributing to the overall performance and practicality of the vehicle.
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Fuel cell types
Fuel cells are classified based on the type of electrolyte they use and their start-up time. Electrolytes are usually made from substances like potassium hydroxide, salt carbonates, and phosphoric acid. The most common type of fuel used is hydrogen.
Proton-Exchange Membrane Fuel Cells (PEMFC)
Also known as PEM fuel cells, these fuel cells have a start-up time of 1 second. They are the most common type of fuel cell and are used in most FCEVs (fuel cell electric vehicles) today. PEMFCs are susceptible to contamination by carbon monoxide.
Solid Oxide Fuel Cells (SOFC)
SOFCs are solid oxide fuel cells that take 10 minutes to start up. They are the best type of sulfur-resistant fuel cell and can endure higher magnitudes of sulfur than most other fuel cells. SOFCs can utilize carbon monoxide as fuel, allowing them to use coal-based natural gas and biogas. However, they require extensive thermal protection and are not suitable for transportation due to high operating temperatures.
Phosphoric Acid Fuel Cells (PAFC)
PAFCs are one of the first generation's fuel cells and are also one of the most developed cell types. They are used for stationary power production and to power large vehicles like city buses. PAFCs are more resistant to pollutants in hydrogen-reformed fossil fuels than PEM cells.
Alkaline Fuel Cells
Invented by Francis Thomas Bacon in 1932, these fuel cells have been used in NASA space programs. They are also used in stationary applications, such as the market-ready 6 kW generator with alkaline fuel cells mentioned by Mulder et al. in 2008.
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Fuel cell cost
Fuel cells are available in a variety of types and price ranges. The PEM Fuel Cell, for instance, is a miniature fuel cell with an output power of 0.27 W, making it ideal for educational purposes and teaching children about hydrogen. This type of fuel cell is typically priced at around $60.
For demonstration or home applications, the H-12 fuel cell stack is a good choice. It has an integrated cooling fan and a rated power of 12 W, allowing it to power basic domestic appliances. The price of this fuel cell typically starts at $450.
If you're looking for a more powerful option, the H-100 fuel cell stack is an air-cooled system that can be used for various personal and research applications. With a rated power of 100 W, it can power small motorboats and is priced at around $2,100.
For those seeking even higher power output, the Horizon H-1000 XP Fuel Cell offers 1 kilowatt (1000 watts) and is specifically designed for powering hydrogen vehicles. This system is easy to integrate and typically costs between $9,000 to over $20,000, depending on the specific model and system requirements.
It's worth noting that the cost of fuel cells can vary significantly depending on their application, power output, and cooling mechanism. Air-cooled fuel cell stacks tend to be lighter but less powerful than liquid-cooled options. Additionally, the cost of a fuel cell system for a vehicle will depend on factors such as the size of the electric motor and the vehicle's power requirements.
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Fuel cell maintenance
In the automotive sector, hydrogen fuel cell systems require personnel with specialised qualifications and technical training. This includes understanding the unique safety risks associated with hydrogen, such as its highly explosive nature, and the potential for embrittlement of materials like aluminium, titanium, and steel. As a result, maintenance involves careful material selection and regular inspections to mitigate these risks.
Maintenance procedures for hydrogen fuel cells often encompass the use of modern, computer-aided diagnostic tools for fault detection and interpretation of error messages and warning signs. Technicians must be adept at handling leaks, safely assembling and disassembling fittings, identifying faulty screw connections, and working with valves, pressure reducers, and damaged gas pipes. Rendering the gas system inert is a crucial step in ensuring safety during maintenance operations.
The aviation industry, which also employs fuel cells, has the added complexity of ensuring airworthiness and the safety of flight operations. This results in stringent safety certifications and highly standardised processes. Similar to the automotive sector, aviation fuel cell maintenance requires qualified personnel to work with high-voltage electric systems and conduct specialised tasks like detecting leaks and using mobile gas detectors.
While fuel cell maintenance can be challenging due to the complexity and unique environments of certain applications, advancements in condition monitoring systems offer the potential to streamline the numerous inspection tasks and tests typically associated with fuel cell MRO.
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Frequently asked questions
A car fuel cell gas tank is a stainless, aluminum, or plastic gas tank that is generally located behind the driver, rather than under the vehicle. They are designed with safety in mind and are often used in race cars.
Car fuel cell gas tanks are built with strong, impact-resistant materials and internal bladder systems that prevent fuel spillage in the event of a collision or rollover. They are also lightweight, which contributes to better acceleration and handling on the track.
The cheaper car fuel cell gas tanks are probably less safe than a stock tank, as they are just plastic shells with easy-to-break-off fittings on the bottom. They also usually have a difficult-to-open filler and do not have a working evaporative emissions system, which can cause fuel to go stale quickly.
