Ameer Randolph
Fuel cells are used to safely increase a vehicle's fuel supply and driving range. They are generally made from stainless steel, aluminium or plastic, and are located behind the driver. There are two main types of fuel cells: gasoline/diesel fuel cells and hydrogen fuel cells. Gasoline fuel cells are reinforced tanks with baffles and a bladder, while hydrogen fuel cells combine hydrogen gas with atmospheric oxygen to produce water and electricity. Fuel cells can be purchased with either a fuel bladder or hard plastic, with foam inside to prevent fuel sloshing and potential explosions.
| Characteristics | Values |
|---|---|
| Types | Gasoline/diesel fuel cell, Hydrogen fuel cell, Fuel bladder, Hard-plastic fuel cell |
| Material | Stainless, Aluminum, Plastic |
| Placement | Behind the driver/passenger seat, Under the vehicle |
| Capacity | 3, 5, 10, 15, 20 gallons |
| Accessories | Ground strap, Roll-over valve, Fuel pump (in-tank or external), Fuel filler |
| Maintenance | Annual inspection and servicing, Replacement of pick-up screens and gaskets, Inspection of check valves |
| Safety | Reduced risk of damage, Absorption of explosion energy by foam, Prevention of fuel leakage |
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What You'll Learn
Fuel cell types: gasoline/diesel or hydrogen
Fuel cells are classified based on the kind of electrolyte they employ, and there are two main types: gasoline/diesel fuel cells and hydrogen fuel cells.
Gasoline/Diesel Fuel Cells
Gasoline fuel cells are reinforced tanks with baffles and sometimes a bladder. Diesel fuel cells, on the other hand, can use a variety of hydrocarbon fuels, including methanol and chemical hydrides. The waste products from these types of fuel cells are carbon dioxide and water. Diesel fuel cells are also used in hybrid systems, along with batteries, photovoltaics, and wind power.
Hydrogen Fuel Cells
Hydrogen fuel cells combine hydrogen gas with atmospheric oxygen to produce water and electricity directly. They are very lightweight and efficient, but hydrogen storage is a significant challenge. Hydrogen fuel cells operate at relatively low temperatures, around 80°C (176°F), which allows for a quick start and less wear on system components. However, they require a noble-metal catalyst, typically platinum, to separate the hydrogen's electrons and protons, adding to the system's cost.
Comparison
Both gasoline/diesel and hydrogen fuel cells have their advantages and disadvantages. Gasoline/diesel fuel cells have higher energy density than hydrogen fuel cells, making methanol easier to transport and supply using existing infrastructure. In contrast, hydrogen fuel cells offer higher fuel economy, with up to 141% higher fuel economy than diesel buses and natural gas buses. Additionally, hydrogen fuel cells produce zero emissions, making them ideal for enclosed spaces.
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Fuel cell vs gas tank
For liquid fuels, a fuel cell is a gas tank that is usually boxy and mounted inside a vehicle. It is typically made of stainless steel, aluminium, or plastic. Fuel cells are also usually reinforced and stronger than fuel tanks. They are often used in trucks and off-road vehicles, where they are mounted in the bed, making them safer and less likely to be damaged in a crash.
Fuel cells are also commonly used in racing cars due to their impact resistance. They have a higher burst strength than fuel tanks and are equipped with a non-vented cap and tip-over valve to prevent spilling in a rollover. Additionally, fuel cells may have a bladder or fuel cell foam as extra safety measures.
In contrast, fuel tanks can be located inside the driver's compartment, which is required by some sanctioning bodies. While fuel tanks may be more convenient and cost-effective, older tanks can clog pumps and injectors with contaminants and may not be rated for use with modern fuels, including ethanol.
Another type of fuel cell is the hydrogen fuel cell, which takes hydrogen gas and combines it with atmospheric oxygen to produce water and electricity. Hydrogen fuel cells are lightweight and efficient, but they face practical challenges, such as the difficulty of storing hydrogen and the corrosion it can cause to materials other than special alloys.
Overall, fuel cells offer enhanced safety features compared to fuel tanks, particularly in the event of a crash. They are also more adaptable to modern fuels and can be customised to fit various vehicles. However, fuel tanks may be more convenient and cost-effective for those with older vehicles that are not used for racing or off-road purposes.
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Fuel bladder vs hard-plastic fuel cell
Fuel cells are designed to prevent automotive fires and safely increase a vehicle's fuel supply and driving range. They consist of three main components: an aluminium or steel outer container, an internal soft-resin bladder, and explosion-suppressant foam.
Fuel bladders are made from a variety of fabrics, usually coated in an elastic polymer. This coating allows the bladder to maintain its shape when filled, prevent leakage, and provide waterproofing. Fuel bladders are flexible, making them suitable for various deployments and applications. They are also lightweight, easy to store, and can be swapped out for different-sized bladders. The number one reason to use fuel bladders is their portability.
Hard-plastic fuel cells, on the other hand, are commonly used for drag racing. They are typically made from polyethylene and are compatible with several types of fuel. However, bladder fuel cells fitted with foam should only be filled with regular gasoline, as fuel additives can harm the bladder over time. Hard-plastic fuel cells are also more durable and suitable for specific purposes, such as tanker trucks, boats, or aircraft.
When choosing between a fuel bladder and a hard-plastic fuel cell, it is important to consider the application and specific requirements. For example, fuel bladders might be preferred for applications that require flexibility and portability, while hard-plastic fuel cells might be better suited for drag racing or applications that require durability and compatibility with various fuels.
Additionally, cost and maintenance considerations may come into play. Fuel bladders tend to have a shorter lifespan of around three years and may require more maintenance to prevent leakage. Fuel cells, on the other hand, can be more expensive, especially those designed for racing cars, but may offer a longer lifespan and better protection against fuel sloshing.
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In-tank vs external fuel pump
Fuel cells are generally made of stainless steel, aluminium, or plastic and are located behind the driver's seat. They can be categorised into gasoline/diesel fuel cells and hydrogen fuel cells.
In-tank fuel pumps are mounted inside the fuel tank, whereas external fuel pumps are mounted outside the tank, usually underneath the car on the passenger side. External pumps should be positioned as low as possible and close to the container to help in pump-priming and resist vapour lock.
In-tank fuel pumps are a great option for changing a carbureted car to an EFI (electronic fuel injection) system. They are also easier to service and replace than external pumps. Additionally, in-tank pumps are more cost-effective than external pumps, as they do not require the entire fuel system to be removed during installation.
On the other hand, external fuel pumps have wider applications and better real-world performance. They are more reliable and serviceable than in-tank pumps and are suitable for vehicles that require higher horsepower, such as turbocharged engines.
The decision between choosing an in-tank or external fuel pump depends on the specific needs and budget of the customer, as well as the intended use of the pump. Both options have their advantages and can be suitable for different types of vehicles.
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Roll-over valve
A rollover valve is a safety mechanism that prevents fuel leaks in the event of a vehicle accident. In the case of a mishap, the internal stainless steel ball seals, stopping fuel from leaking out of the fuel tank and into the ventilation line. This is particularly important if a vehicle ends up on its roof, as fuel can spill out and cause a fire.
The rollover valve is part of the fuel tank and is located on top of it. It is connected to the vent line, which needs to be fully looped around the tank and up the roll cage. The vent line is also where you will find the vent check ball. If the vehicle ends up on its side, the ball in the rollover valve blocks fuel from escaping the tank.
The AN8 rollover safety valve, for example, is designed to maintain the status of the fuel tank without pressure build-up or unwanted vacuum during use. It comes in three different sizes, all safe for petrol, ethanol, and methanol. It is easy to clean, inspect, and maintain, with its simple two-piece design.
You can also install an in-line vent rollover valve if needed. This is an aftermarket solution for those who do not have a rollover valve installed in their fuel tank.
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Frequently asked questions
A fuel cell tank is a deformable cell or bag tank that is designed to be safer than a regular gas tank. They are generally made from stainless steel, aluminium or plastic and are located behind the driver.
Fuel cells are designed to be safer than gas tanks, with the ability to deform in a crash and not leak. They also won't rust away and are lightweight. Gas tanks are heavier and more rigid.
There are two main types of fuel cell tanks: gasoline/diesel fuel cells and hydrogen fuel cells. Gasoline cells are reinforced tanks with baffles and sometimes a bladder. Hydrogen fuel cells combine hydrogen gas with oxygen to produce water and electricity.
Fuel cell tanks increase the fuel supply and driving range of a vehicle. They are also safer and more lightweight than traditional gas tanks.
When choosing a fuel cell tank, consider the size of the tank and the intended use of the vehicle. You will also need to decide between an in-tank fuel pump or an external one. In-tank pumps reduce noise and run cooler, while external pumps are gravity-fed and must be mounted below the tank.
