The Future Of Fuel Cell Cars: Why They're Not Viable

why no fuel cell cars

Hydrogen fuel cell vehicles (FCVs) have not taken off in the same way as battery-powered electric vehicles (BEVs) despite their convenience and the promise of being the green car fuel of the future. The main reasons for this include the inefficiency of hydrogen fuel cells, the lack of fueling infrastructure, and the cost of hydrogen fuel. Hydrogen fuel cells are less energy efficient than BEVs due to the energy vector transition, resulting in higher energy losses. The production of hydrogen can also cause greenhouse emissions if not made from renewable energy sources, leading to higher carbon emissions per mile driven compared to electric vehicles. Additionally, building and maintaining a network of hydrogen fueling stations is complex and expensive, and the cost of hydrogen fuel is significantly higher than gasoline. Safety concerns, such as the explosive nature of hydrogen, have also contributed to the slower adoption of hydrogen fuel cell cars.

Characteristics Values
Safety concerns Hydrogen is a dangerously explosive gas
Energy efficiency BEVs are more energy-efficient than FCVs
Cost Hydrogen fuel costs more than gasoline
Production cost Hydrogen fuel cells are expensive to produce
Sales Hydrogen fuel cell vehicles have low sales
Environmental impact Hydrogen fuel cells have a higher carbon footprint than electric vehicles
Infrastructure Hydrogen fuel cells require a specialized infrastructure that is expensive to build and maintain
Government support Some governments are not prioritizing hydrogen fuel cell technology
Automaker interest Some automakers are not interested in hydrogen fuel cells

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Hydrogen fuel cells are inefficient

In contrast, with electric vehicles, the energy runs on wires directly from the source to the car, resulting in only a 5% loss of efficiency in the journey through the grid. There is a further loss of 10% of energy from charging and discharging the battery, and another 5% from using the electricity to power the vehicle, resulting in a total loss of 20%. Thus, an electric vehicle loses half the amount of energy that a hydrogen fuel cell vehicle loses.

The inefficiency of hydrogen fuel cells is a major reason why hydrogen fuel cell vehicles (FCVs) have not become popular, despite their convenience. FCVs have to compete with battery electric vehicles (BEVs), which are more energy-efficient and have superior infrastructure support. BEVs are also safer, as hydrogen is a dangerously explosive gas, as demonstrated by the explosion of a chemical plant producing hydrogen in Santa Clara in 2019.

However, hydrogen fuel cells may still be useful for heavier vehicles such as vans or trucks, which require very large batteries. Hydrogen fuel cells are also useful in energy-intensive industries such as steel manufacturing and fertilizer production, where hydrogen is used in chemical reactions and to achieve very high temperatures.

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Hydrogen is expensive

Hydrogen fuel is currently more expensive than traditional fuels. However, experts predict that prices will drop dramatically in the coming years as production scales up. The cost of producing hydrogen varies depending on the source. For instance, the cost of producing hydrogen is $2.40/kg from fossil fuels, $2/kg from CCS, $4/kg from electrolyzed water, $3.60/kg from solar thermochemical methods, and $3.70/kg from wind. The US Department of Energy (DOE) has announced funding of $750 million to reduce the cost of clean hydrogen technologies.

The high cost of hydrogen fuel is due in part to the low volumetric energy density of hydrogen, which makes its distribution energy use and investment and pumping-power requirements greater than for natural gas. Large-scale hydrogen distribution by pipeline adds $1–2/GJ to production costs, while the distribution of liquid hydrogen is even more costly at $7–10/GJ due to the energy needed for liquefaction. Refuelling stations may add a further $3–9/GJ.

The process of converting electricity to hydrogen via electrolysis is only 75% efficient, and the gas must then be compressed, chilled, and transported, which incurs further costs. The fuel cell process of converting hydrogen back to electricity is only 60% efficient, and there is an additional 5% loss from driving the vehicle. This means that the hydrogen fuel cell requires double the amount of energy of an electric vehicle.

Despite the higher costs, some companies remain committed to hydrogen fuel. Honda, for example, has nearly 1,100 Honda Clarity Fuel Cell vehicles on US roads, and has teamed up with Toyota and a subsidiary of Shell Oil to build new hydrogen fuelling stations in California. However, other car manufacturers such as GM and Ford have not released fuel cell vehicles for the consumer market, instead focusing on electrification.

In summary, while hydrogen fuel is currently more expensive than traditional fuels, prices are expected to drop in the coming years. The high costs are due to a variety of factors, including the energy density of hydrogen, the inefficiencies of the fuel cell process, and the distribution and infrastructure requirements.

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Hydrogen is difficult to source

The production of hydrogen often involves converting it from other sources, such as fossil fuels, biomass, water, or natural gas. For example, microbial biomass conversion uses microbes like bacteria and microalgae to break down organic matter and produce hydrogen. Another method is thermochemical water splitting, which uses high temperatures generated by solar concentrators or nuclear reactors to split water molecules and produce hydrogen. These production methods can be expensive and energy-intensive, with hydrogen production technologies requiring further development to reduce costs and environmental impacts.

The distribution of hydrogen also presents challenges. Hydrogen can be transported through existing gas pipelines, but the capacity is limited due to the short pipeline network dedicated to hydrogen delivery. Developing a nationwide network of fueling stations for hydrogen-powered vehicles requires significant infrastructure investments.

Additionally, safety concerns have been raised about the use of hydrogen, particularly in transportation, due to its highly explosive nature. While fuel tanks have been improved with Kevlar lining to mitigate explosion risks, incidents involving hydrogen explosions at a chemical plant and a refueling station have impacted public confidence.

The high cost of hydrogen fuel is another factor contributing to its limited adoption. In California, the average price of hydrogen fuel is approximately $16/kg, making it significantly more expensive than gasoline on a per-gallon energy basis. These factors collectively highlight the difficulties in sourcing and utilizing hydrogen as an alternative fuel source, especially for personal transportation.

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Hydrogen is dangerous

Hydrogen is an extremely flammable gas with a wide range of flammable concentrations in air. It has a lower ignition energy than gasoline or natural gas, which means it can ignite more easily. In enclosed spaces, hydrogen can also act as an asphyxiant gas.

Liquid hydrogen has a different chemistry compared to other cryogenic chemicals, as trace accumulated air can easily contaminate it and form an unstable mixture with detonative capabilities similar to TNT and other highly explosive materials. Because of this, liquid hydrogen requires complex storage technology, such as special thermally insulated containers, and special handling common to all cryogenic substances.

The diffusivity of hydrogen is very different from ordinary gases, and therefore gasketing materials must be chosen carefully. In addition, some metals can become brittle when exposed to hydrogen, so selecting appropriate materials is important to the design of safe hydrogen systems.

However, hydrogen generally has properties that make it safer to handle than conventional fuels. For example, hydrogen is non-toxic, and because it is lighter than air, it dissipates rapidly when released, allowing for the relatively rapid dispersal of fuel in the case of a leak.

There are many codes and standards regarding hydrogen safety in storage, transport, and use. These include federal regulations, ANSI/AIAA, NFPA, and ISO standards. Hydrogen fuel systems are designed with appropriate engineering controls and guidelines to ensure the safe handling and use of hydrogen.

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Hydrogen vehicles are unpopular

Another factor contributing to the unpopularity of hydrogen vehicles is the cost. The process of producing hydrogen fuel is expensive, and the cost of hydrogen fuel itself is high, with the average price for hydrogen fuel in California being about $16/kg. In contrast, gasoline is sold by volume, and 1 gallon of gasoline has a similar energy content to 1 kg of hydrogen. This makes hydrogen fuel less economical for consumers.

Safety concerns have also played a role in the lack of popularity of hydrogen vehicles. Hydrogen is a highly explosive gas, as demonstrated by incidents such as the explosion of a chemical plant producing hydrogen in Santa Clara, California. While hydrogen fuel tanks in cars are now Kevlar-lined to mitigate explosion risks, these incidents have nonetheless impacted public perception and confidence in hydrogen fuel technology.

Additionally, the lack of infrastructure for hydrogen refueling stations poses a significant challenge to the widespread adoption of hydrogen vehicles. Building a new hydrogen economy, including the necessary production and distribution networks, is a much larger undertaking than expanding the existing electrical infrastructure to accommodate electric vehicles.

Finally, cultural tastes and the popularity of companies like Tesla have also influenced the dominance of electric vehicles over hydrogen vehicles. Tesla's CEO, Elon Musk, has publicly dismissed hydrogen fuel cells as "mind-bogglingly stupid," influencing public opinion and steering the market towards electric vehicles.

Frequently asked questions

Hydrogen fuel cell cars are expensive to produce and require a specialised fuelling infrastructure. Hydrogen is also inefficient as a fuel because the energy must move from wire to gas to wire in order to power a car. This process is only 75% energy efficient, losing around a quarter of the electricity.

Hydrogen is a highly explosive gas, and there have been incidents involving hydrogen fuel cell vehicles and refuelling stations. However, hydrogen fuel cell vehicles are not considered more hazardous than traditional internal combustion engines.

No, fuel cells are not more efficient than battery-powered cars. With electric vehicles, the energy is transferred directly from the source to the car, losing only about 5% of efficiency. With fuel cells, the process of converting electricity to hydrogen and back loses 20% of energy.

No, most automakers are betting on battery-electric vehicles. Hydrogen fuel cells are seen as less profitable and more challenging to manufacture and support. However, some companies like Honda, Toyota, and BMW are still investing in the technology.

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