Analysis of fuel cell hybrid locomotives

Led by Vehicle Projects LLC, an international industry–government consortium is developing a 109 t, 1.2 MW road-switcher locomotive for commercial and military railway applications. As part of the feasibility and conceptual-design analysis, a study has been made of the potential benefits of a hybrid power plant in which fuel cells comprise the prime mover and a battery or flywheel provides auxiliary power. The potential benefits of a hybrid power plant are: (i) enhancement of transient power and hence tractive effort; (ii) regenerative braking; (iii) reduction of capital cost.Generally, the tractive effort of a locomotive at low speed is limited by wheel adhesion and not by available power. Enhanced transient power is therefore unlikely to benefit a switcher locomotive, but could assist applications that require high acceleration, e.g. subway trains with all axles powered.In most cases, the value of regeneration in locomotives is minimal. For low-speed applications such as switchers, the available kinetic energy and the effectiveness of traction motors as generators are both minimal. For high-speed heavy applications such as freight, the ability of the auxiliary power device to absorb a significant portion of the available kinetic energy is low. Moreover, the hybrid power plant suffers a double efficiency penalty, namely, losses occur in both absorbing and then releasing energy from the auxiliary device, which result in a net storage efficiency of no more than 50% for present battery technology.Capital cost in some applications may be reduced. Based on an observed locomotive duty cycle, a cost model shows that a hybrid power plant for a switcher may indeed reduce capital cost. Offsetting this potential benefit are the increased complexity, weight and volume of the power plant, as well as 20–40% increased fuel consumption that results from lower efficiency.Based on this analysis, the consortium has decided to develop a pure fuel cell road-switcher locomotive, that is, not a hybrid.     

Onboard fuel processor for PEM fuel cell vehicles

To lower vehicle greenhouse gas emissions, many automotive companies are exploring fuel cell technologies, which combine hydrogen and oxygen to produce electricity and water. While hydrogen storage and infrastructure remain issues, Renault and Nuvera Fuel Cells are developing an onboard fuel processor, which can convert a variety of fuels into hydrogen to power these fuel cell vehicles.The fuel processor is now small enough and powerful enough for use on a vehicle. The catalysts and heat exchangers occupy 80 l and can be packaged with balance of plant controls components in a 150-l volume designed to fit under the vehicle. Recent systems can operate on gasoline, ethanol, and methanol with fuel inputs up to 200 kWth and hydrogen efficiencies above 77%. The startup time is now less than 4 min to lower the CO in the hydrogen stream to the target value for the fuel cell.     

Fuel economy and life-cycle cost analysis of a fuel cell hybrid vehicle

The most promising vehicle engine that can overcome the problem of present internal combustion is the hydrogen fuel cell. Fuel cells are devices that change chemical energy directly into electrical energy without combustion. Pure fuel cell vehicles and fuel cell hybrid vehicles (i.e. a combination of fuel cell and battery) as energy sources are studied. Considerations of efficiency, fuel economy, and the characteristics of power output in hybridization of fuel cell vehicle are necessary. In the case of Federal Urban Driving Schedule (FUDS) cycle simulation, hybridization is more efficient than a pure fuel cell vehicle. The reason is that it is possible to capture regenerative braking energy and to operate the fuel cell system within a more efficient range by using battery.Life-cycle cost is largely affected by the fuel cell size, fuel cell cost, and hydrogen cost. When the cost of fuel cell is high, hybridization is profitable, but when the cost of fuel cell is less than 400 US$/kW, a pure fuel cell vehicle is more profitable.     

Performance comparison of two fuel cell hybrid buses with different powertrain and energy management strategies

In order to assess the influences of different powertrain structures and energy management strategies on the performance of hybrid fuel cell buses (FCB), two buses (FCB A and FCB B) were constructed with a “energy hybrid structure” and “power hybrid structure”, respectively. Different energy management strategies were investigated based on analysis of the two systems. And the two buses were compared with each other in a bus cycle and constant speed testing. The Polymer Electrolyte Membrane Fuel Cell (PEMFC) in FCB A showed an advantage in fuel economy for it worked usually in the high efficient range of the PEMFC engine. The hydrogen consumption rate in the cycle testing was 7.9 kg/100 km and 9.8 kg/100 km for FCB A and FCB B, and in the 40 kmph constant speed testing it was 3.3 kg/100 km and 4.0 kg/100 km, respectively. The fuel economy could be improved when the hydrogen and air supply subsystems are optimized and controlled with an advanced algorithm. It could also benefit from a braking energy regeneration system. Compared with FCB A, the PEMFC in FCB B worked under unfavorable operation conditions because its working range was comparatively wide, and the power changing rate was relatively large from a statistical point of view, which resulted in performance recession of the PEMFC in FCB B. After a mileage of 7000 km, the output power of the PEMFC in FCB B was reduced by 10%, compared with 2.4% in FCB A. An advanced energy management strategy is necessary to split the power between the PEMFC and a battery suitable for long durability of a PEMFC.     

Market penetration analysis of fuel cell vehicles in Japan by using the energy system model MARKAL

The objective of the present work is to validate the hydrogen energy roadmap of Japan by analyzing the market penetration of fuel cell vehicles (FCVs) and the effects of a carbon tax using an energy system model of Japan based on MARKAL. The results of the analysis show that a hydrogen FCV would not be cost competitive until 2050 without a more severe carbon tax than the government's planned 2400 JPY/t-C carbon tax. However, as the carbon tax rate increases, instead of conventional vehicles including the gasoline hybrid electric vehicle, hydrogen FCVs gain market penetration earlier and more. By assuming a more severe carbon tax rate, such as 10 000 JPY/t-C, the market share of hydrogen FCVs approaches the governmental goal. This suggests that cheaper vehicle cost and hydrogen cost than those targeted in the roadmap should be attained or subsidies to hydrogen FCV and hydrogen refueling station will be necessary for achieving the goal of earlier market penetration.     

Metal membrane-type 25-kW methanol fuel processor for fuel-cell hybrid vehicle

A 25-kW on-board methanol fuel processor has been developed. It consists of a methanol steam reformer, which converts methanol to hydrogen-rich gas mixture, and two metal membrane modules, which clean-up the gas mixture to high-purity hydrogen. It produces hydrogen at rates up to 25 N m³/h and the purity of the product hydrogen is over 99.9995% with a CO content of less than 1 ppm. In this fuel processor, the operating condition of the reformer and the metal membrane modules is nearly the same, so that operation is simple and the overall system construction is compact by eliminating the extensive temperature control of the intermediate gas streams. The recovery of hydrogen in the metal membrane units is maintained at 70–75% by the control of the pressure in the system, and the remaining 25–30% hydrogen is recycled to a catalytic combustion zone to supply heat for the methanol steam-reforming reaction. The thermal efficiency of the fuel processor is about 75% and the inlet air pressure is as low as 4 psi. The fuel processor is currently being integrated with 25-kW polymer electrolyte membrane fuel-cell (PEMFC) stack developed by the Hyundai Motor Company. The stack exhibits the same performance as those with pure hydrogen, which proves that the maximum power output as well as the minimum stack degradation is possible with this fuel processor. This fuel-cell ‘engine’ is to be installed in a hybrid passenger vehicle for road testing.     

Methanol decomposition fuel processor for portable power applications

A new fuel processor approach for portable fuel cell power sources significantly improves upon microreformers by overcoming the difficulties with heat deficiencies and contaminants in the product hydrogen. Instead of reforming, the processor uses methanol decomposition to enable the byproduct, carbon monoxide (CO), to be used as the heat source. A hydrogen permselective membrane segregates the CO for combustion in an integrated burner, maximizes the decomposition conversion, and provides pure hydrogen for a fuel cell. Discharging the CO-rich retentate through an ejector to draw combustion air into the burner greatly simplifies the system. High and stable hydrogen yields are attained with optimized catalysts and fuel compositions. The resultant simple, efficient, and self-heating processor produces 85% of the hydrogen content of the fuel. A 20 W autonomous power source based on this novel fuel processor demonstrates a fuel energy density >1.5 Wh g^?1_(electrical), nearly twice as high as microreformer power sources.     

Fuel processors for fuel cell APU applications

The conversion of liquid hydrocarbons to a hydrogen rich product gas is a central process step in fuel processors for auxiliary power units (APUs) for vehicles of all kinds. The selection of the reforming process depends on the fuel and the type of the fuel cell.For vehicle power trains, liquid hydrocarbons like gasoline, kerosene, and diesel are utilized and, therefore, they will also be the fuel for the respective APU systems.The fuel cells commonly envisioned for mobile APU applications are molten carbonate fuel cells (MCFC), solid oxide fuel cells (SOFC), and proton exchange membrane fuel cells (PEMFC). Since high-temperature fuel cells, e.g. MCFCs or SOFCs, can be supplied with a feed gas that contains carbon monoxide (CO) their fuel processor does not require reactors for CO reduction and removal. For PEMFCs on the other hand, CO concentrations in the feed gas must not exceed 50 ppm, better 20 ppm, which requires additional reactors downstream of the reforming reactor.This paper gives an overview of the current state of the fuel processor development for APU applications and APU system developments. Furthermore, it will present the latest developments at Fraunhofer ISE regarding fuel processors for high-temperature fuel cell APU systems on board of ships and aircrafts.     

Increasing the operation temperature of polymer electrolyte membranes for fuel cells: From nanocomposites to hybrids

Among the possible systems investigated for energy production with low environmental impact, polymeric electrolyte membrane fuel cells (PEMFCs) are very promising as electrochemical power sources for application in portable technology and electric vehicles. For practical applications, operating FCs at temperatures above 100 °C is desired, both for hydrogen and methanol fuelled cells. When hydrogen is used as fuel, an increase of the cell temperature produces enhanced CO tolerance, faster reaction kinetics, easier water management and reduced heat exchanger requirement. The use of methanol instead of hydrogen as a fuel for vehicles has several practical benefits such as easy transport and storage, but the slow oxidation kinetics of methanol needs operating direct methanol fuel cells (DMFCs) at intermediate temperatures. For this reason, new membranes are required. Our strategy to achieve the goal of operating at temperatures above 120 °C is to develop organic/inorganic hybrid membranes. The first approach was the use of nanocomposite class I hybrids where nanocrystalline ceramic oxides were added to Nafion. Nanocomposite membranes showed enhanced characteristics, hence allowing their operation up to 130 °C when the cell was fuelled with hydrogen and up to 145 °C in DMFCs, reaching power densities of 350 mW cm⁻². The second approach was to prepare Class II hybrids via the formation of covalent bonds between totally aromatic polymers and inorganic clusters. The properties of such covalent hybrids can be modulated by modifying the ratio between organic and inorganic groups and the nature of the chemical components allowing to reach high and stable conductivity values up to 6.4 × 10⁻² S cm⁻¹ at 120 °C.     

Dynamic behaviour of hydrogen fuel cells for automotive application

An experimental analysis was conducted on a 30 kW fuel cell power train with the aim to elucidate specific concerns of dynamic behaviour of hydrogen fuel cells in automotive applications. The study was conducted on a dynamic test bench able to simulate the behaviour of the reference vehicle, a minibus for historical centres collective service, on predefined driving cycle. The transient performance of the fuel cell system was firstly investigated without electric drive, using as load electric resistances electronically controlled. Experimental data were collected during warmup phases characterized by two acceleration slopes (150 W/s and 1500 W/s) and during a sequence of dynamic test cycles characterized by a very high acceleration slope of about 6 kW/s. The role of reactant feeding, humidification and cooling systems was investigated during all tests evaluating the performance during the transient steps in terms of cell voltage uniformity, expressed by the coefficient of variation C_v, used as statistical indicator. A driving cycle characterized by stop-and-go pattern and acceleration slopes compatible with a real utilization of the reference vehicle was finally adopted for tests on the overall power train. The results demonstrated a very good dynamic performance of the fuel cell stack as evidenced by the analysis of C_v, which resulted lower than 2.5% in all investigated working conditions, and by the overall power train efficiency which resulted about 30% with fuel cell system efficiency close to 50%.     

Development of portable fuel cell arrays with printed-circuit technology

Portable hydrogen/oxygen fuel cell power sources were constructed using printed-circuit board (PCB) technology. Multiple iterations of miniature planar fuel cell devices were prototyped, demonstrating fast cycle innovation and dramatic power density improvements in <1 year of development. Several novel flow structure and gas routing designs were explored. Electrical interconnections for configurable voltage were wired on board by printed-circuit traces and vias. Fuel cell device voltages ranging from 1 V single cells to 16 V planar arrays were demonstrated, with power output ranging from <1 to >200 W. The lightweight laminate PCB technology allows the best prototypes to achieve >700 mW/cm² area power density and >400 mW/cm³ volumetric power density. PCB technology offers an intriguing platform for portable fuel cell development below 1 kW. Possibilities for on board diagnostics/control and further power density improvements are envisioned.     

A 28-W portable direct borohydride–hydrogen peroxide fuel-cell stack

A 28-W direct borohydride–hydrogen peroxide fuel-cell stack operating at 25 °C is reported for contemporary portable applications. The fuel cell operates with the peak power-density of ca. 50 mW cm⁻² at 1 V. This performance is superior to the anticipated power-density of 9 mW cm⁻² for a methanol–hydrogen peroxide fuel cell. Taking the fuel efficiency of the sodium borohydride–hydrogen peroxide fuel cell as 24.5%, its specific energy is ca. 2 kWh kg⁻¹. High power-densities can be achieved in the sodium borohydride system because of its ability to provide a high concentration of reactants to the fuel cell.     

Direct formic acid fuel cell portable power system for the operation of a laptop computer

A direct formic acid fuel cell (DFAFC) hybrid power system for a laptop computer has been developed at the Korea Institute of Science and Technology, Fuel Cell Research Center. At the heart of the system is a 15 MEA DFAFC stack capable of 30 W at 60 mW cm⁻². Stack characteristics relevant to integration into the power system such as concentration and orientation dependence, dynamic response, and long-term performance are elucidated and the resulting hybrid power system's performance is detailed. The stack's fast dynamic response eliminated the need for significant power buffering in the power conditioning equipment. The MEAs were found to give reduced but stable performance after 3 months of operation. The system is capable of an overall system efficiency of 0.23 (delivered power compared to theoretical power), and can operate under a substantial computing load for 2.5 h using a 280 mL tank of 50 wt.% fuel.     

Ammonia fuel cell using doped barium cerate proton conducting solid electrolytes

Proton-conducting solid electrolytes composed of gadolinium-doped barium cerate (BCG) or gadolinium and praseodymium-doped barium cerate (BCGP) were tested in an intermediate-temperature fuel cell in which hydrogen or ammonia was directly fed. At 700 °C, BCG electrolytes with porous platinum electrodes showed essentially no loss in performance in pure hydrogen. Under direct ammonia at 700 °C, power densities were only slightly lower compared to pure hydrogen feed, yielding an optimal value of 25 mW cm⁻² at a current density of 50 mA cm⁻². This marginal difference can be attributed to a lower partial pressure of hydrogen caused by the production of nitrogen when ammonia is decomposed at the anode.A comparative test using BCGP electrolyte showed that the doubly doped barium cerate electrolyte performed better than BCG electrolyte. Overall fuel cell performance characteristics were enhanced by approximately 40% under either hydrogen or ammonia fuels using BCGP electrolyte. At 700 °C using direct ammonia feed, power density reached 35 mW cm⁻² at a current density of approximately 75 mA cm⁻². Minimal loss of performance was noted over approximately 100 h on-stream in alternating hydrogen/ammonia fuels.     

Development of a miniaturized polymer electrolyte membrane fuel cell with silicon separators

The fabrication process and electrochemical characterization of a miniaturized PEM fuel cell with silicon separators were investigated. Silicon separators were fabricated with silicon fabrication technologies such as by photolithography, anisotropic wet etching, anodic bonding and physical vapor deposition (PVD). A 400 μm × 230 μm flow channel was made with KOH wet etching on the front side of a silicon separator, and then a 550 nm gold current collector and 350 nm TiN_x thin film heater were respectively formed on the front side and the opposite side by PVD. Two separators were assembled with the membrane electrode assembly (MEA) having a 4 cm² active area for the single cell. With pure hydrogen and oxygen under atmospheric pressure without humidification, the performance of the single fuel cell was measured. A single cell operation led to generation of 203 mW cm⁻² at 0.6 V at room temperature, which corresponded to 360 mW cm⁻³ in terms of volumetric fuel cell power density, with 20 ccm of gas flow rate of hydrogen and oxygen at the inlet.     

A 75-kW methanol reforming fuel cell system

A 75-kW methanol reforming fuel cell system, which consists of a fuel cell system and a methanol auto-thermal reforming fuel processor has been developed at Dalian Institute of Chemical Physics, Chinese Academy of Sciences (CAS). The core of the fuel cell system is a group of CO tolerant PEMFC stacks with a double layer composite structured anode. The fuel cell stacks show good CO tolerance even though 140 ppm CO was present in the reformate stream during transients. The auto-thermal reforming (ATR) fuel cell processor could adiabatically produce a suitable reformate without external energy consumption. The output of hydrogen-rich reformate was approximately 120 N m³ h⁻¹ with a H₂ content near 53% and the CO concentrations generally were under 30 ppm. The fuel cell system was integrated with the methanol reforming fuel processor and the peak power output of the fuel cell system exceeded 75 kW in testing. The hydrogen utilization approached 70% in the fuel cell system.     

Li-ion batteries and portable power source prospects for the next 5–10 years

This paper describes the possible evolution of Li-ion technology, and evaluates the expected improvements, arising from new materials to cell technology. New active materials under investigation and electrode process improvements may allow an ultimate final energy density of more than 500 Wh/l and 200 Wh/kg, in the next 5–10 years, while maintaining sufficient power densities. A new rechargeable battery technology cannot be foreseen today that surpasses this. The possible use of small fuel cells is also discussed. The only solution would be direct methanol fuel cell (DMFC) technology, providing that the remaining important technological issues are solved. The association with a rechargeable battery could provide an optimised energy + power, hybrid power source. Several simulated comparisons for small- to medium-sized power sources are described, between fuel cells and batteries. Hybrid Li-ion/DMFC is a good option for systems larger than 1 kWh. The hybrid concept of high-energy–low-power primary lithium (as the fuel) with high-power Li-ion (as the cell stack) is an already available, cost effective solution where long run times are required.     

Hydrogen as an energy carrier: Prospects and challenges

This paper provides an insight to the feasibility of adopting hydrogen as a key energy carrier and fuel source in the near future. It is shown that hydrogen has several advantages, as well as few drawbacks in using for the above purposes. The research shows that hydrogen will be a key player in storing energy that is wasted at generation stage in large-scale power grids by off-peak diversion to dummy loads. The estimations show that by the year of 2050 there will be a hydrogen demand of over 42 million metric tons or 45 billion gallon gasoline equivalent (GGE) in the United States of America alone which can fuel up 342 million light-duty vehicles for 51 × 10¹¹ miles (82 × 10¹¹ km) travel per year. The production at distributed level has also been discussed. The paper also presents the levels of risk in production, storage and distribution stages and proposes possible techniques to address safety issues. It is shown that the storage in small to medium scale containers is much economical compared to doing the same at large-scale containers. The study concludes that hydrogen has a promising future to be a highly feasible energy carrier and energy source itself at consumer level.     

Studies of a granular aluminum anode in an alkaline fuel cell

A granular aluminum anode was investigated for use in an alkaline aluminum/hydrogen peroxide fuel cell. The fuel cell utilizes granules of aluminum (8–12 mm in diameter) as an anode, potassium hydroxide (KOH) as an anolyte and hydrogen peroxide as a catholyte. Granular anodes have a significantly higher surface area than planar surfaces, thereby resulting in higher utilization of the anode material. Polarization experiments were performed as well as closed circuit power production experiments. KOH concentrations were varied in the experiments. Polarization experiments achieved a current density of 10.02 mA/cm² using 2 M KOH and granular aluminum with a surface area of 205.6 cm². Power production experiments sustained a current density of 0.05 mA/cm² using 1.5 M KOH and granular aluminum with a surface area of 59.8 cm². Results indicate that granular metal anodes have potential for use in high energy density fuel cells.     

Technical and economic assessment of grid-independent hybrid photovoltaic–diesel–battery power systems for commercial loads in desert environments

Solar photovoltaic (PV) hybrid system technology is a hot topic for R&D since it promises lot of challenges and opportunities for developed and developing countries. The Kingdom of Saudi Arabia (KSA) being endowed with fairly high degree of solar radiation is a potential candidate for deployment of PV systems for power generation. Literature indicates that commercial/residential buildings in KSA consume an estimated 10–45% of the total electric energy generated. In the present study, solar radiation data of Dhahran (East-Coast, KSA) have been analyzed to assess the techno-economic viability of utilizing hybrid PV–diesel–battery power systems to meet the load requirements of a typical commercial building (with annual electrical energy demand of 620,000 kW h). The monthly average daily solar global radiation ranges from 3.61 to 7.96 kW h/m². NREL's HOMER software has been used to carry out the techno-economic viability. The simulation results indicate that for a hybrid system comprising of 80 kWp PV system together with 175 kW diesel system and a battery storage of 3 h of autonomy (equivalent to 3 h of average load), the PV penetration is 26%. The cost of generating energy (COE, US$/kW h) from the above hybrid system has been found to be 0.149 $/kW h (assuming diesel fuel price of 0.1 $/L). The study exhibits that for a given hybrid configuration, the operational hours of diesel generators decrease with increase in PV capacity. The investigation also examines the effect of PV/battery penetration on COE, operational hours of diesel gensets for a given hybrid system. Emphasis has also been placed on unmet load, excess electricity generation, percentage fuel savings and reduction in carbon emissions (for different scenarios such as PV–diesel without storage, PV–diesel with storage, as compared to diesel-only situation), cost of PV–diesel–battery systems, COE of different hybrid systems, etc.