Sylvie Willis
Fuel cell technology in cars is an innovative and sustainable approach to powering vehicles. Also known as fuel cell electric vehicles (FCEVs), these cars use fuel cells to convert hydrogen fuel into electrical energy, powering the vehicle's electric motor. Unlike traditional internal combustion engines, FCEVs produce zero tailpipe emissions, offering a cleaner and more environmentally friendly alternative. The concept of fuel cells was first demonstrated by Humphry Davy in 1801, but it was chemist, lawyer, and physicist William Grove who invented the first working fuel cell in 1842. Since then, major automobile manufacturers have been working to develop and commercialize fuel cell technology, with companies like Toyota, Honda, and Stellantis leading the way. This technology is particularly well-suited for light commercial vehicles that require long-range, fast refueling, and zero emissions.
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What You'll Learn
How fuel cells work
Fuel cell technology in cars is an alternative to traditional gasoline-powered vehicles and electric vehicles (EVs). These fuel cells use hydrogen and oxygen in the air to produce electricity and water. This process involves a chemical reaction, where hydrogen combines with oxygen to form water.
A basic hydrogen fuel cell consists of two electrodes—an anode and a cathode—surrounded by an electrolyte. The negative side, or anode, is fed with hydrogen, while the positive side, or cathode, is fed with air. The hydrogen at the anode interacts with a catalyst, causing it to separate into protons (positive) and electrons (negative). The electrons are directed into a circuit, which can then be used to power things, while the protons move through the electrolyte to bond with the oxygen in the air, creating heat and water.
The electricity generated from this chemical reaction can then be stored or used. Typically, hydrogen fuel cell-powered vehicles use a small traction battery or a supercapacitor to store the electricity. This electricity can then be used to power the vehicle, with the waste heat from the fuel cell recovered through a heat exchanger and passed to a cabin heater, reducing the demand for electricity for heating.
The efficiency of the fuel cell depends on maintaining its operation within a specific temperature range, usually between 60°C and 80°C. As the fuel cell generates heat, it needs to be cooled to stay within this range. This is achieved through a Fuel Cell Stack Cooling Package, which transfers heat from the fuel cell stack to a coolant, which is then pumped into a radiator and cooled by ambient air.
While fuel cell technology offers certain advantages, there are also challenges. Storing and transporting hydrogen is difficult because it is the lightest element and requires high pressures or low temperatures to be compact enough for practical use. This has led to issues with hydrogen availability and infrastructure, impacting the price and reliability of this fuel source.
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Types of fuel cells
Fuel cell technology in cars, or fuel cell electric vehicles (FCEVs), use a propulsion system where energy stored as hydrogen is converted into electricity by the fuel cell. This electricity then powers the car's electric motor. One of the main benefits of this technology is that it produces no harmful tailpipe emissions—the only waste product is water vapour.
There are several types of fuel cells that can be used in FCEVs, each with its own unique characteristics and advantages. Here are some of the most common types:
Polymer Electrolyte Membrane (PEM) Fuel Cell
The PEM fuel cell is the most common type used in vehicles. It consists of an electrolyte membrane sandwiched between a positive electrode (cathode) and a negative electrode (anode). Hydrogen is introduced to the anode, while oxygen from the air is introduced to the cathode. An electrochemical reaction, aided by a catalyst, causes the hydrogen molecules to break apart into protons and electrons. The protons travel through the membrane to the cathode, while the electrons are forced through an external circuit, providing power to the electric motor. Finally, the protons, electrons, and oxygen molecules combine at the cathode to form water.
Hydrogen Fuel Cell
This type of fuel cell, as the name suggests, uses compressed hydrogen gas as fuel. The hydrogen gas is stored in reinforced tanks inside the car and fed into an onboard fuel cell stack. The fuel cell stack transforms the chemical energy of the hydrogen into electrical energy, powering the car's electric motor. This process produces zero tailpipe emissions, and the only byproduct is water vapour.
Regenerative Braking System
While not exactly a type of fuel cell, it is worth mentioning that many FCEVs use regenerative braking systems to capture the energy lost during braking and store it in a battery. This increases the overall efficiency of the vehicle and provides extra power during acceleration.
Fuel Cell Stack
The fuel cell stack is an assembly of individual membrane electrodes that use hydrogen and oxygen to produce electricity. It combines multiple fuel cells to generate electricity and power the electric motor.
The development and commercialisation of fuel cell technology for cars is an active area of innovation, with major automobile manufacturers offering an increasing number of FCEV models to the public.
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Hydrogen fuel tanks
The outer shell of the tank is designed for impact and damage resistance, providing an extra layer of protection. Additionally, these tanks are equipped with a pressure regulator and an in-tank gas temperature sensor to monitor pressure and temperature during the filling process. The pressure regulators are particularly important for safety, as hydrogen is stored at high pressures, typically ranging from 350 to 700 bar.
While liquid hydrogen offers a higher energy density than compressed gas, it requires extremely low temperatures (below -253 degrees Celsius) to maintain its liquid state, necessitating advanced freezer systems. Compressed hydrogen gas, on the other hand, is more widely adopted by car manufacturers due to its convenience and the availability of fueling infrastructure. BMW is a notable exception, with their Hydrogen 7 automobile utilising both cryogenic liquid hydrogen and gasoline.
The development of hydrogen fuel tanks has progressed alongside the growth of the hydrogen-powered car industry. These tanks are designed to be safe and efficient, addressing concerns about hydrogen's explosive potential. The tanks are constructed to withstand high pressures and impacts, ensuring that the stored hydrogen remains secure even in high-speed crashes.
In conclusion, hydrogen fuel tanks are a critical and specialised component of fuel cell cars, employing advanced materials and technologies to safely store and manage hydrogen fuel. The ongoing evolution of these tanks plays a pivotal role in the broader advancement and adoption of hydrogen-powered vehicles.
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Electric motors
Fuel cell technology in cars is an innovative and environmentally friendly alternative to traditional internal combustion engines. These vehicles, known as Fuel Cell Electric Vehicles (FCEVs) or fuel cell cars, use hydrogen fuel and oxygen to generate electricity and power their electric motors.
The electric motor in a fuel cell car is typically powered by a combination of the fuel cell and a battery. The battery used in fuel cell cars is smaller and lighter than those in all-electric vehicles. It serves as a "`buffer,", storing excess electrical energy from the fuel cell and providing additional power during acceleration or when the fuel cell is idling or turned off. This battery also captures energy from regenerative braking, further enhancing the efficiency of the system.
The power of a fuel cell vehicle is defined by the size and capabilities of its electric motor(s). This design process allows manufacturers to customize the vehicle's performance characteristics. The electric motor in an FCEV can provide dynamic and virtually silent acceleration due to its ability to deliver full torque even at low speeds. This results in a smooth and responsive driving experience.
Overall, the electric motor in a fuel cell car is a key component that enables the vehicle to operate efficiently and cleanly. By utilizing electrical energy generated by the fuel cell, the electric motor powers the car, providing a driving experience similar to that of conventional electric vehicles but with the added benefit of shorter refuelling times.
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Benefits and drawbacks
Fuel cell technology in cars, also known as hydrogen fuel cell vehicles (HFCV), uses an electric motor powered by a fuel cell stack. Pure hydrogen passes through a membrane in the fuel cell stack to combine with oxygen from the air, producing electricity and water vapour. This technology offers several benefits over traditional internal combustion engine vehicles.
One of the main advantages of fuel cell technology in cars is that it produces zero harmful tailpipe emissions, resulting in reduced carbon emissions and improved environmental performance. The only byproduct of the chemical reaction in the fuel cell is water vapour, making HFCVs a zero-emission vehicle option. Additionally, HFCVs have a similar refuelling process to traditional gas-powered cars, with a refuelling time of around five minutes. This convenience is a significant advantage over battery-electric vehicles (BEVs), which typically require longer charging times.
Another benefit of fuel cell technology in cars is the efficient use of energy. Similar to BEVs, HFCVs can capture and reuse energy lost during braking through regenerative braking systems. However, unlike BEVs, the amount of energy stored in an HFCV is determined by the size of the hydrogen fuel tank rather than the battery size. This allows for a more flexible design and potentially longer driving ranges.
Furthermore, fuel cell technology in cars has the potential to reduce costs in the long term. The development and expansion of hydrogen refuelling infrastructure will drive down costs for both fuel cell and battery technologies. This expansion is already underway, with initiatives like the Clean Energy Partnership working to increase the number of hydrogen refuelling stations.
Despite these advantages, fuel cell technology in cars also has some drawbacks. One of the main challenges is the limited availability of hydrogen-powered vehicles and the lack of widespread refuelling infrastructure. As of mid-2022, hydrogen-powered vehicles are primarily found in California, the only state in the US with a comprehensive network of retail hydrogen refuelling stations. The low production volumes of hydrogen-powered cars also contribute to their higher cost compared to BEVs or internal combustion engine vehicles.
Another drawback is the energy-intensive process of creating pure hydrogen for vehicles. Producing hydrogen often involves "cracking" compounds like natural gas, which is derived from fossil fuels and results in CO2 as a byproduct. This process goes against the goal of reducing carbon emissions and can be seen as a step backward in terms of environmental sustainability.
Additionally, while HFCVs offer similar performance to BEVs, they may not be as fast or dynamic in terms of acceleration. The lack of transmission and the use of a fuel cell stack instead of a large battery can result in different driving characteristics compared to BEVs.
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Frequently asked questions
Fuel cell technology in cars uses a fuel cell, sometimes in combination with a small battery or supercapacitor, to power its onboard electric motor. The most common type of fuel cell for vehicle applications is the polymer electrolyte membrane (PEM) fuel cell.
Fuel cells generate electricity using oxygen from the air and compressed hydrogen. Hydrogen molecules break apart into protons and electrons due to an electrochemical reaction aided by a catalyst. The electrons are forced to travel through an external circuit to perform work (providing power to the electric motor) and then recombine with the protons. The protons, electrons, and oxygen molecules then combine to form water.
Fuel cell cars are quiet, very energy efficient, produce no tailpipe emissions, and have a similar range and performance to gasoline cars. They can be fuelled in about 5 minutes and have a driving range of more than 300 miles.
Fuel cell cars are currently more expensive than traditional cars. Industrialization in production is not yet fully developed, and there is a high demand for platinum, which acts as a catalyst in electricity generation. Additionally, there may be pollutants created during the transportation and storage of hydrogen.
