Rajan Wilcox
Fuel cells are an eco-friendly alternative to traditional combustion engines, offering a green solution to global warming, air pollution, and energy crises. They can be used in a wide range of applications, including transportation, and are especially useful for vehicles that require indoor applications, such as forklifts, where clean emissions are important for maintaining air quality. The most common type of fuel cell for vehicles is the polymer electrolyte membrane (PEM) fuel cell, which combines hydrogen and oxygen to generate electricity and power electric motors. While fuel cell technology has been advancing and gaining traction in the automotive sector, electric vehicles (EVs) currently dominate the market due to factors such as cost and cultural taste. However, fuel cells still hold potential for the future, especially in heavy-duty vehicles and long-haul trucking, where their long driving ranges and refueling advantages could be beneficial.
| Characteristics | Values |
|---|---|
| Most common type of fuel cell | Polymer Electrolyte Membrane (PEM) Fuel Cell |
| Parts of a fuel cell | Electrolyte, Anode, Cathode |
| Types of fuel cells | Direct Methanol Fuel Cells, Phosphoric Acid Fuel Cells, Molten Carbonate Fuel Cells, Solid Oxide Fuel Cells, Reformed Methanol Fuel Cell, Regenerative Fuel Cells |
| Hydrogen fuel cell vehicles | Honda Clarity Fuel Cell, Hyundai Nexo SUV, Toyota Mirai |
| Hydrogen fuel cell vehicles sold in the US in 2023 | 3,143 |
| Total number of BEVs sold in the US in 2023 | 380,000 |
| Number of hydrogen-powered vehicles in the US as of mid-2022 | 17,000 or fewer |
| Lifetime cost of ownership for a fuel cell car | 40% higher than a comparable gasoline vehicle, and about 10% more than an EV |
| Fuel cell vehicles | Cars, Buses, Forklifts, Material Handling Vehicles, Boats |
| Fuel cell vehicles for all modes of transport | Yes |
| Fuel cell efficiency | Can exceed 60% |
| Fuel cell durability targets | 8,000 hours for light-duty vehicles, 30,000 hours for heavy-duty trucks, and 80,000 hours for distributed power systems |
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What You'll Learn
Hydrogen fuel cells vs. batteries
Hydrogen fuel cell vehicles (FCVs) are electric vehicles that use a fuel cell, sometimes in combination with a small battery or supercapacitor, to power their onboard electric motor. They are emission-free, with water vapour being the only exhaust emission. Hydrogen fuel cells generate power with hydrogen-rich fuel, which is stored as a gas or cryogenic liquid in pressurised tanks.
Battery electric vehicles (BEVs), on the other hand, are powered by a large, heavy battery that must be recharged at a charging station or from a mains outlet. The battery is recharged by the motor creating a magnetic field that turns a rotor shaft, which drives the car's wheels.
FCVs have a faster refuelling time than BEVs, with a similar five-minute refuelling time to that of a petrol or diesel car. However, there are very few hydrogen refuelling stations, with only 48 stations in the entire US as of 2023. BEVs, on the other hand, have 49,210 charging stations nationwide and can also be charged at home.
FCVs are also more expensive to buy than BEVs and are less efficient. However, FCVs are more efficient than internal combustion engine cars.
Both FCVs and BEVs have faced criticism from industry figures, including Tesla CEO Elon Musk and Volkswagen CEO Herbert Diess, who argue that green hydrogen should be reserved for industries such as steel, chemical, and aero, rather than cars. Despite this, companies such as Toyota, Hyundai, and BMW continue to invest in fuel cell development and vehicles.
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Pros and cons of hydrogen cars
Hydrogen fuel cell vehicles (FCVs) are related to electric cars but differ in the way they store energy. They are powered by an electric motor and classified as e-cars. However, unlike electric cars, they do not rely on a large, heavy battery. Instead, they are powered by a fuel cell stack in which pure hydrogen passes through a membrane to combine with oxygen from the air, producing electricity and water vapour.
Pros of Hydrogen Cars
Hydrogen cars have several advantages:
- They are zero-emission vehicles, emitting only water vapour.
- They have a shorter refuelling time, similar to that of a traditional gas station.
- They have the potential for excellent fuel economy, with a cheaper cost per mile compared to gasoline-powered cars.
- They can run on existing gasoline supplies and do not require any change in lifestyle habits.
- Hydrogen is an abundant natural resource and can be made from renewable energy.
- They are quiet when running and have instant torque from the electric motor.
- They can also recover braking energy, similar to other e-cars.
Cons of Hydrogen Cars
There are also several drawbacks to hydrogen cars:
- Hydrogen cars are expensive, with high-pressure, on-board hydrogen storage requirements.
- There are limited places to refuel, and hydrogen is very expensive to transport.
- Hydrogen is currently made from non-renewable natural gas, a process that creates high CO2 emissions.
- Hydrogen is flammable, raising safety concerns.
- Maintenance costs are unclear and could be high.
- Hydrogen cars are much rarer than electric vehicles, with only about 17,000 hydrogen-powered vehicles on US roads as of mid-2022, compared to almost three million EVs.
- They have a limited range, and the infrastructure for refuelling is still being developed.
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Hydrogen fuel cell development
Hydrogen fuel cell technology has been hailed as an exciting development in the automotive industry, offering an emission-free alternative to traditional combustion engines and electric vehicles. Unlike electric vehicles, hydrogen fuel cell cars are powered by an on-board electric motor that produces electricity from hydrogen and oxygen, eliminating the need for recharging. This technology, known as reverse electrolysis, results in zero emissions as the only by-products are electrical energy, heat, and water vapour.
The concept of the fuel cell was first demonstrated by Humphry Davy in 1801, but it has taken several centuries for the technology to be utilised in vehicles. Honda was a pioneer in this field, establishing the world's first fuel cell vehicle dealer network in 2008 and leasing the Honda FCX Clarity in Japan and Southern California. However, Honda discontinued the FCX Clarity by 2015, and by 2020, only three carmakers were still actively manufacturing hydrogen cars.
Despite the promise of hydrogen fuel cell technology, there are several challenges that have hindered its widespread adoption. One significant obstacle is the limited availability of hydrogen fuelling stations, which has led to lawsuits from vehicle owners who struggled to access hydrogen fuel for their cars. The high cost of hydrogen fuel and the specialised infrastructure required for its distribution have also contributed to the slow uptake of hydrogen fuel cell vehicles.
Another challenge is the production of pure hydrogen, which demands a substantial amount of energy to extract from compounds such as natural gas, resulting in CO2 as a byproduct. Nevertheless, hydrogen technology has the potential to benefit from increased production volumes, and manufacturers like BMW remain optimistic about its future. Additionally, hydrogen fuel cell vehicles can be categorised as zero-emissions vehicles since the pollutants are centralised at the site of hydrogen production rather than being released during vehicle operation.
In conclusion, while hydrogen fuel cell development for cars has faced setbacks and obstacles, it continues to be an area of interest and exploration for automotive manufacturers. With advancements in technology and infrastructure, hydrogen fuel cell vehicles may yet become a viable alternative to traditional combustion engines and electric vehicles.
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Hydrogen fuel cell costs
Hydrogen fuel cell vehicles (FCVs) are electric vehicles that use a fuel cell, sometimes in combination with a small battery or supercapacitor, to power their onboard electric motor. They are distinct from battery-electric vehicles (BEVs) in that they produce electricity themselves, rather than relying on a built-in battery. This electricity is generated through a process known as reverse electrolysis, in which hydrogen from the vehicle's tank combines with oxygen from the air to produce electrical energy, heat, and water vapour.
While hydrogen fuel cell vehicles have the advantage of being emission-free, they are much rarer than BEVs. As of mid-2022, there were 17,000 or fewer hydrogen-powered vehicles on US roads, all of them in California, the only state with a network of retail hydrogen fuelling stations. By contrast, almost three million BEVs had been sold in the US by that time. The higher cost of FCVs compared to BEVs has also been a barrier to their widespread adoption.
The cost of fuel cells varies depending on their power output and intended application. Fuel cells designed for domestic or educational use can range in price from $450 to $2,100. More powerful fuel cells designed for telecommunications or backup power applications can cost between $10,000 and $15,000. The most powerful fuel cells, capable of generating 120kW of power output, can cost upwards of $100,000.
While the high cost of fuel cells is currently a barrier to their widespread adoption in vehicles, there are efforts to address this issue. For example, vehicle manufacturers such as BMW have partnered with hydrogen producers and filling station operators to expand the infrastructure for hydrogen fuelling stations. It is hoped that this will help to reduce costs for both fuel cell and battery technologies in the long term.
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Hydrogen refuelling infrastructure
In Australia, for example, there are currently only five hydrogen refuelling stations in operation, with 20 planned or under construction. The country's transport sector accounts for a significant portion of its greenhouse gas emissions, and hydrogen-powered vehicles are seen as a crucial solution to meet its Net Zero commitments. The 'Hydrogen Vehicle Refuelling Infrastructure' report by CSIRO and GHD outlines the opportunities and challenges for building the necessary infrastructure to support hydrogen-powered road vehicles in Australia. It highlights the need for centralised off-site hydrogen production and distribution to refuel vehicles at scale.
Similarly, in the United States, California is the only state with a network of retail hydrogen fuelling stations, accommodating the 17,000 or fewer hydrogen-powered vehicles on US roads as of mid-2022. The lack of hydrogen refuelling infrastructure in other states has led to lawsuits, such as the class-action lawsuit filed by Mirai owners in 2024, alleging fraudulent concealment and misrepresentation due to the limited availability of hydrogen fuel.
To address the challenges with hydrogen refuelling infrastructure, partnerships between businesses and government organisations have been successful in some countries. For instance, in Germany, BMW has collaborated with hydrogen producers and filling station operators through the Clean Energy Partnership initiative to expand the hydrogen refuelling infrastructure. H2 MOBILITY is responsible for planning and operating hydrogen filling stations in the country.
As the demand for hydrogen-powered vehicles grows, the development of a robust hydrogen refuelling infrastructure will become increasingly important. Centralised off-site production and distribution of hydrogen, along with collaborations between stakeholders, will be key to achieving a sustainable hydrogen-powered transport future.
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Frequently asked questions
The likelihood of fuel cells for cars is uncertain. Fuel cell vehicles (FCVs) are a promising green solution to global warming, air pollution, and energy crises. However, as of 2023, only 3,143 hydrogen cars were sold in the US compared to 380,000 battery-electric vehicles (BEVs). The high cost of hydrogen fuel and the limited availability of hydrogen fuelling stations are significant factors contributing to the dominance of BEVs.
Fuel cell vehicles have several advantages over conventional combustion engines:
- Lower or zero emissions: Fuel cells emit only water vapour and have no air pollutants that contribute to smog or health issues.
- Higher efficiency: Fuel cells can operate at higher efficiencies than combustion engines, converting chemical energy directly into electrical energy with efficiencies exceeding 60%.
- Hydrogen abundance: Hydrogen is the most abundant chemical substance in the universe.
Some challenges and disadvantages of fuel cell vehicles include:
- High cost: The cost of hydrogen fuel is high, making the lifetime cost of ownership for a fuel cell car higher than comparable gasoline vehicles and BEVs.
- Limited fuelling infrastructure: As of 2024, a significant number of public hydrogen fuelling stations in California were unable to dispense hydrogen, leading to a class-action lawsuit from Mirai owners.
- Performance: Hydrogen fuel cells are most suitable for steady power output, while cars require varying power demands.
