Rajan Wilcox
Fuel cell vehicles (FCVs) are electric vehicles that use a fuel cell, sometimes in combination with a small battery, to power their onboard electric motor. The most common type of fuel cell for vehicle applications is the polymer electrolyte membrane (PEM) fuel cell. In a PEM fuel cell, an electrolyte membrane is sandwiched between a positive electrode (anode) and a negative electrode (cathode). Hydrogen is introduced to the anode, and oxygen from the air is introduced to the cathode. This process, known as reverse electrolysis, produces electrical energy, heat, and water vapour. Hydrogen fuel cell vehicles are generally classified as zero-emissions vehicles. However, hydrogen storage is extremely problematic, and this has prevented hydrogen vehicles from breaking into the mainstream.
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Hydrogen fuel cells
At the heart of a hydrogen fuel cell vehicle is the fuel cell stack, which is an assembly of individual membrane electrodes. This stack uses hydrogen from the fuel tank and oxygen from the air to generate electricity through a process known as reverse electrolysis. This electricity is then directed to the electric motor, powering the vehicle's movement.
One of the key advantages of hydrogen fuel cell cars is their ability to produce electricity onboard. Unlike traditional electric vehicles that rely solely on batteries, hydrogen cars have their own miniature power plants, generating electricity as needed. This eliminates the need for recharging stations, as the fuel cell can be conveniently refilled with hydrogen.
While hydrogen fuel cell technology offers significant benefits, there are also some challenges to its widespread adoption. One of the primary obstacles is the problematic nature of hydrogen storage. Additionally, the industrialization of hydrogen fuel cell production is still in its early stages, contributing to higher costs for these vehicles compared to traditional e-cars or internal combustion engines. However, advancements in technology and increasing production volumes are expected to drive down costs over time.
Despite these challenges, hydrogen fuel cell vehicles have the potential to revolutionize the automotive industry. They offer a more efficient and environmentally friendly alternative to traditional gasoline-powered cars. With their low emissions, quiet operation, and ability to utilize renewable energy, hydrogen fuel cell cars are poised to play a significant role in the future of sustainable transportation.
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Fuel cell vehicles
A fuel cell vehicle (FCV) or fuel cell electric vehicle (FCEV) is an electric vehicle that 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. In a PEM fuel cell, an electrolyte membrane is sandwiched between a positive electrode (anode) and a negative electrode (cathode). Hydrogen is introduced to the anode, and oxygen (from the air) is introduced to the cathode. The 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 on the cathode side. The protons, electrons, and oxygen molecules combine to form water.
While hydrogen fuel cell vehicles have many benefits, there are some drawbacks. Hydrogen storage is extremely problematic, and the demand for platinum, which acts as a catalyst in electricity generation, is high. This makes hydrogen vehicles more expensive than comparable e-cars with batteries or internal combustion engines. In addition, the infrastructure for hydrogen refuelling stations is still being developed and may not be as readily available as electric charging stations.
Despite these challenges, some car manufacturers have developed hydrogen fuel cell vehicles, such as the Honda Clarity Fuel Cell (produced from 2016 to 2021) and the Toyota Mirai (available in 2025). These vehicles have high fuel economy ratings and can help reduce carbon emissions. However, by 2020, only three car makers were still manufacturing or had active manufacturing programs for hydrogen cars.
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Fuel cell stacks
A fuel cell stack is the core of a fuel cell system. It is made up of a stack of fuel cells, which can number in the hundreds. The power output of a fuel cell stack depends on its size, with the number of cells in a stack increasing the voltage and the surface area of the cells increasing the current.
The stack generates the electrical energy used to power the fuel cell electric vehicle. Each cell in the stack undergoes a cold combustion process, which converts the energy from the chemical reaction between hydrogen and oxygen into electricity. This process is an electrochemical reaction, aided by a catalyst, which breaks down the hydrogen molecules into protons and electrons. The protons travel through a polymer membrane to the cathode, while the electrons are forced to travel through an external circuit, providing power to the electric motor. At the cathode, the protons, electrons, and oxygen combine to form water. This reaction does not create any pollutants, such as particulate matter or nitrogen oxides.
The design of a fuel cell stack is determined by the desired power output, voltage, efficiency, and volume and weight limitations. Water is used for cooling and humidification, and the heat generated in each of the active cells is used for humidification.
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Fuel filler
The fuel filler is the receptacle on the vehicle where the nozzle from a fuel dispenser is attached to fill the tank with hydrogen fuel. This process of refuelling through special pumps is similar to that of conventional cars, making it convenient for users. Hydrogen fuel is stored in carbon-fibre-reinforced fuel tanks, which are rigorously tested to ensure safety.
In a fuel cell vehicle, the hydrogen fuel and oxygen from the air combine in the fuel cell stack to produce electricity through a process known as reverse electrolysis. This electricity powers the electric motor and, in some cases, charges the battery. The only by-products of this reaction are electrical energy, heat, and water vapour, making fuel cell vehicles a zero-emissions mode of transportation.
While fuel cell technology has been applied in various vehicles, including forklifts, boats, and aircraft, its use in cars has been limited due to several factors. The cost of hydrogen fuel cell cars is currently higher than that of comparable electric or internal combustion engine vehicles. This is partly due to the demand for platinum, a precious metal used as a catalyst in electricity generation. Additionally, the infrastructure for hydrogen refuelling stations is still being expanded, and the availability of hydrogen fuel has been a challenge, as evidenced by a class-action lawsuit filed by Mirai owners in California.
Despite these challenges, fuel cell vehicles offer several advantages. Hydrogen vehicles produce electricity themselves, eliminating the need for recharging as in battery-powered electric cars. They also have a longer range than battery-electric vehicles and can be refuelled much faster. Furthermore, hydrogen is one of the most efficient ways to store and transport renewable energy, making it crucial for the future energy supply.
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Fuel tank
The fuel tank is a crucial component of a car's fuel cell, and its design and capacity play a significant role in the vehicle's performance and range.
In hydrogen fuel cell vehicles, the fuel tank stores hydrogen gas onboard until it is needed by the fuel cell. These tanks are typically made of carbon-fiber-reinforced materials and are rigorously tested to ensure their safety. The size of the hydrogen fuel tank determines the amount of energy stored onboard, which is a key differentiator from all-electric vehicles, where power and energy depend on battery size.
The placement of the fuel tank in a car is also important. In race cars, for example, the fuel cell is often mounted in the truck, providing protection during high-speed races. However, this setup has the disadvantage of reducing storage space.
The process of refuelling a hydrogen fuel cell vehicle involves using a pump and nozzle at a hydrogen refuelling station. Hydrogen is pumped into the tank, where it is safely stored until used by the fuel cell.
While hydrogen fuel cell technology offers high efficiency and zero emissions, the availability of hydrogen refuelling infrastructure and the cost of hydrogen fuel remain challenges for broader adoption.
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Frequently asked questions
A fuel cell in a car is an assembly of individual membrane electrodes that use hydrogen and oxygen to produce electricity to run the car's electric motor.
A fuel cell works by combining hydrogen and oxygen to produce electricity, heat, and water. The electricity generated then flows to the electric motor to drive the vehicle.
FCEVs produce their own electricity using a fuel cell, whereas BEVs are powered by a built-in battery that can be charged from an external power source.
FCEVs are zero-emissions vehicles, producing only water vapour as exhaust. They are also more efficient than BEVs in terms of energy storage and can be refuelled through special pumps, which are becoming more widely available.
Some examples of FCEVs include the Toyota Mirai, the Honda Clarity Fuel Cell, and the BMW iX5 Hydrogen.
