Remodeling of a commercial plug-in battery electric vehicle to a hybrid configuration with a PEM fuel cell

In the present research, a commercial battery-powered pure electric vehicle was suitably modified to convert it into a hybrid one integrating a PEMFC stack. The hydrogen supply system to the stack included a passive recirculation system based on a Ventury-type ejector. Besides, in order to achieve an optimum operation of the PEMFC stack, a discrete state machine model was considered in its control system. The inclusion of a rehabilitation operating mode prevented the stack from possible failures, increasing its lifetime. It was verified that for the rated operating point when supplying power to the vehicle (2.5 kW) the hydrogen consumption decreased, and the actual efficiency (47.9%) PEMFC was increased close to 1%. Field tests performed demonstrate that the range of the hybrid electric vehicle was increased by 78% when compared to the one of the original battery electric car. Also, under the tested experimental conditions in hybrid mode, 34% of the total energy demanded by the electric machine of the vehicle was supplied by the PEMFC stack.     

Design and development of a multipurpose utility AWD electric vehicle with a hybrid powertrain based on PEM fuel cells and batteries

This paper presents the results obtained on the research project CIT-370000-2008-11, entitled “Multi-purpose remote-controlled all-wheel-drive tool-vehicle powered by fuel cells” funded by the Spanish Ministry of Science and Technology. A new concept multipurpose electric vehicle has been designed and manufactured, based on three basic features: a hybrid power system consisting in PEM fuel cells + batteries, an all-wheel-drive traction system, and the capability of being either on-site driven or remote-controlled. The vehicle is formed by two frames connected by a two-degree of freedom joint, and is powered by two 2.5 kW DC motors, one in each axle. All the electric circuits for the suitable control of the power hybrid system have been developed in our Laboratory, allowing a large flexibility. After the different tests performed, it has been verified that the vehicle presents good maneuverability, a good traction performance in off-road driving, as well as a good slope-climbing capability. Under the experimental conditions tested, the vehicle reached a maximum speed of 11 km/h on flat surface, keeping the maximum power consumption always around 3 kW.     

Disruptive innovations: The case for hydrogen fuel cells and battery electric vehicles

The investment of private money in technological innovation is driven by the expectation of successful market penetration. This decision to invest is less risky when the innovation represents gradual improvement of existing technologies. The term disruptive innovation is used to describe the opposite case, i.e. innovations that are so different that their establishment in the market causes a disruption to the pre-existing system. The existing literature on disruptive innovations provides us with historic case studies of successful market capture by new technologies, but this in itself is insufficient to clarify the chances of success for nascent technologies. This paper sets out to bring greater clarity to the characteristics of disruptive innovation in a way that informs the debate on the viability of emerging technologies. Whilst existing definitions are based on technologies that were successful, this paper proposes a three part criteria to define candidate disruptive technologies: disruption should relate to manufacturers and/or infrastructure (the two often being inter-related), whilst innovation must provide more than the equivalence of service to the end-user. A review of seven historical case studies of successful disruptive technologies reveals seven characteristics of candidate disruptive technologies at the stage of niche market penetration. Examining battery electric and hydrogen fuel cell vehicles against these seven characteristics, shows that both candidate disruptive technologies share the same challenges as those identified in the successful historic case studies and also helps to identify potential pathways to greater market penetration in the future for these technologies.     

Dynamic behaviour of Li batteries in hydrogen fuel cell power trains

A Li ion polymer battery pack for road vehicles (48 V, 20 Ah) was tested by charging/discharging tests at different current values, in order to evaluate its performance in comparison with a conventional Pb acid battery pack. The comparative analysis was also performed integrating the two storage systems in a hydrogen fuel cell power train for moped applications. The propulsion system comprised a fuel cell generator based on a 2.5 kW polymeric electrolyte membrane (PEM) stack, fuelled with compressed hydrogen, an electric drive of 1.8 kW as nominal power, of the same typology of that installed on commercial electric scooters (brushless electric machine and controlled bidirectional inverter). The power train was characterized making use of a test bench able to simulate the vehicle behaviour and road characteristics on driving cycles with different acceleration/deceleration rates and lengths. The power flows between fuel cell system, electric energy storage system and electric drive during the different cycles were analyzed, evidencing the effect of high battery currents on the vehicle driving range. The use of Li batteries in the fuel cell power train, adopting a range extender configuration, determined a hydrogen consumption lower than the correspondent Pb battery/fuel cell hybrid vehicle, with a major flexibility in the power management.     

Lithium polymer batteries and proton exchange membrane fuel cells as energy sources in hydrogen electric vehicles

This paper deals with the application of lithium ion polymer batteries as electric energy storage systems for hydrogen fuel cell power trains. The experimental study was firstly effected in steady state conditions, to evidence the basic features of these systems in view of their application in the automotive field, in particular charge-discharge experiments were carried at different rates (varying the current between 8 and 100 A). A comparison with conventional lead acid batteries evidenced the superior features of lithium systems in terms of both higher discharge rate capability and minor resistance in charge mode. Dynamic experiments were carried out on the overall power train equipped with PEM fuel cell stack (2 kW) and lithium batteries (47.5 V, 40 Ah) on the European R47 driving cycle. The usage of lithium ion polymer batteries permitted to follow the high dynamic requirement of this cycle in hard hybrid configuration, with a hydrogen consumption reduction of about 6% with respect to the same power train equipped with lead acid batteries.     

Transportation options in a carbon-constrained world: Hybrids,plug-in hybrids,biofuels, fuel cell electric vehicles,and battery electric vehicles

Multiple alternative vehicle and fuel options are being proposed to alleviate the threats of climate change, urban air pollution, and oil dependence caused by the transportation sector. We report here on the results from an extensive computer model developed over the last decade to simulate and compare the societal benefits of deploying various alternative transportation options including hybrid electric vehicles and plug-in hybrids fueled by gasoline, diesel fuel, natural gas, and ethanol, and all-electric vehicles powered by either batteries or fuel cells. These simulations compare the societal benefits over a 100-year time horizon of each vehicle/fuel combination in terms of reduced local air pollution, greenhouse gas pollution, and oil consumption compared to gasoline cars.     

The utilization of hydrogen in hydrogen/diesel dual fuel engine

A hydrogen fueled internal combustion engine has great advantages on exhaust emissions including carbon dioxide (CO₂) emission in comparison with a conventional engine fueling fossil fuel. In addition, if it is compared with a hydrogen fuel cell, the hydrogen engine has some advantages on price, power density, and required purity of hydrogen. Therefore, they expect that hydrogen will be utilized for several applications, especially for a combined heat and power (CHP) system which currently uses diesel or natural gas as a fuel.A final goal of this study is to develop combustion technologies of hydrogen in an internal combustion engine with high efficiency and clean emission. This study especially focuses on a diesel dual fuel (DDF) combustion technology. The DDF combustion technology uses two different fuels. One of them is diesel fuel, and the other one is hydrogen in this study. Because the DDF engine is not customized for hydrogen which has significant flammability, it is concerned that serious problems occur in the hydrogen DDF engine such as abnormal combustion, worse emission and thermal efficiency.In this study, a single cylinder diesel engine is used with gas injectors at an intake port to evaluate performance swung the hydrogen DDF engine with changing conditions of amount of hydrogen injected, engine speed, and engine loads. The engine experiments show that the hydrogen DDF operation could achieve higher thermal efficiency than a conventional diesel operation at relatively high engine load conditions. However, it is also shown that pre-ignition with relatively high input energy fraction of hydrogen occurred before diesel fuel injection and its ignition. Therefore, such abnormal combustion limited amount of hydrogen injected. Fire-deck temperature was measured to investigate causal relationship between fire-deck temperature and occurrence of pre-ignition with changing operative conditions of the hydrogen DDF engine.     

The feasibility of long range battery electric cars in New Zealand

New Zealand transport accounts for over 40% of the carbon emissions with private cars accounting for 25%. In the Ministry of Economic Development's recently released “New Zealand Energy Strategy to 2050”, it proposed the wide scale deployment of electric vehicles as a means of reducing carbon emissions from transport. However, New Zealand's lack of public transport infrastructure and its subsequent reliance on private car use for longer journeys could mean that many existing battery electric vehicles (BEVs) will not have the performance to replace conventionally fuelled cars.As such, this paper discusses the potential for BEVs in New Zealand, with particular reference to the development of the University of Waikato's long-range UltraCommuter BEV. It is shown that to achieve a long range at higher speeds, BEVs should be designed specifically rather than retrofitting existing vehicles to electric. Furthermore, the electrical energy supply for a mixed fleet of 2 million BEVs is discussed and conservatively calculated, along with the number of wind turbines to achieve this. The results show that approximately 1350 MW of wind turbines would be needed to supply the mixed fleet of 2 million BEVs, or 54% of the energy produced from NZ's planned and installed wind farms.     

Numerical analysis of an energy storage system based on a metal hydride hydrogen tank and a lithium-ion battery pack for a plug-in fuel cell electric scooter

This work investigates on the performance of a hybrid energy storage system made of a metal hydride tank for hydrogen storage and a lithium-ion battery pack, specifically conceived to replace the conventional battery pack in a plug-in fuel cell electric scooter. The concept behind this solution is to take advantage of the endothermic hydrogen desorption in metal hydrides to provide cooling to the battery pack during operation.The analysis is conducted numerically by means of a finite element model developed in order to assess the thermal management capabilities of the proposed solution under realistic operating conditions.The results show that the hybrid energy storage system is effectively capable of passively controlling the temperature of the battery pack, while enhancing at the same time the on-board storage energy density. The maximum temperature rise experienced by the battery pack is around 12 °C when the thermal management is provided by the hydrogen desorption in metal hydrides, against a value above 30 °C obtained for the same case without thermal management. Moreover, the hybrid energy storage system provides the 16% of the total mass of hydrogen requested by the fuel cell stack during operation, which corresponds to a significant enhancement of the hydrogen storage capability on-board of the vehicle.     

Dynamic simulation and lifecycle assessment of hydrogen fuel cell electric vehicles considering various hydrogen production methods

In this research study, a real model of a hydrogen fuel cell vehicle is simulated using Simcenter Amesim software. The software used for vehicle simulation enabled dynamic simulation, resulting in more precise simulation. Furthermore, considering that fuel cell degradation is one of the significant challenges confronting fuel cell vehicle manufacturers, we examined the impact of fuel cell degradation on the performance of hydrogen vehicles. According to the findings, a hydrogen vehicle with a degraded fuel cell consumes 14.3% more fuel than a fresh fuel cell hydrogen vehicle. A comprehensive life cycle assessment (LCA) is also performed for the designed hydrogen vehicle. The results of the hydrogen vehicle life cycle assessment are compared with a gasoline vehicle to fully understand the effect of hydrogen vehicles in reducing air emissions. The methods considered for hydrogen production included natural gas reforming, electrolysis, and thermochemical water splitting method. Furthermore, because the source of electricity used for electrolysis has a significant impact on the life cycle emission of a hydrogen vehicle, three different power sources were considered in this assessment. Finally, while a hydrogen vehicle with a degraded fuel cell emits lower carbon dioxide (CO₂) than a gasoline vehicle, the emitted CO₂ from this vehicle using hydrogen from electrolysis is approximately 25% higher than that of a new hydrogen vehicle.     

Willingness to pay for hydrogen fuel cell electric vehicles in China: A choice experiment analysis

The hydrogen energy is considered to be main power source of transport sector in the future, and a huge amount of funds have been invested into developing hydrogen fuel cell electric vehicles (FCEVs). Since FCEVs are in initial development stage and there're few FCEVs on the road, before their expansion this paper intends to conduct an economic analysis for FCEVs by using the choice experiment method. In the choice experiment, 1072 participants were required to select among two FCEVs and one conventional fuel vehicle. Logit models were estimated and then the results were used to calculate the willingness to pay for FCEVs. Results showed that purchase price, driving range, refueling time, fuel cost, emissions reduction, refueling accessibility are significant influences, and the marginal values for every 200 km improvement in driving range, 5 min reduction in refueling time, RMB 0.5/kilometer reduction in fuel cost, 20% reduction in emissions, and 20% improvement of refueling accessibility were estimated to be RMB 49,091, 12,727, 3818, 47,818, and 12,909, respectively. A range of FCEV configurations were calculated, and compared to a gasoline-powered counterpart the extra value that customers were likely to pay for a FCEV ranged from RMB 20,810 to 95,310. These results have significant implications for promoting FCEVs and contribute to better sustainability in transport sector.     

Comparative requirements for electric energy for production of hydrogen fuel and/or recharging of battery electric automobile fleets in New Zealand and the United States

Within the current outlook for sustainable electric energy supply with concomitant reduction in emission of greenhouse gases, accelerated attention is focusing on the long-term development of hydrogen fuel cell and all-electric battery vehicles to provide alternative fuels to replace petroleum-derived fuels for automotive national fleets. The potential varies significantly between large industrially developed nations and smaller industrially developing nations. The requirement for additional electric energy supply from low-specific energy renewable resources and high-specific energy nuclear resources depends strongly on individual national economic, environmental, and political factors. Analysis of the additional electric energy supply required for the two potential large-scale technologies for fueling future national transportation sectors is compared for a large Organization for Economic Co-operation and Development (OECD) nation (USA) with a small OECD nation (New Zealand), normalized on a per-capita basis.     

An innovative optimal power allocation strategy for fuel cell, battery and supercapacitor hybrid electric vehicle

An optimal design of a three-component hybrid fuel cell electric vehicle comprised of fuel cells, battery, and supercapacitors is presented. First, the benefits of using this hybrid combination are analyzed, and then the article describes an active power-flow control strategy from each energy source based on optimal control theory to meet the demand of different vehicle loads while optimizing total energy cost, battery life and other possible objectives at the same time. A cost function that minimizes the square error between the desired variable settings and the current sensed values is developed. A gain sequence developed compels the choice of power drawn from all devices to follow an optimal path, which makes trade-offs among different targets and minimizes the total energy spent. A new method is introduced to make the global optimization into a real-time based control. A model is also presented to simulate the individual energy storage systems and compare this invention to existing control strategies, the simulation results show that the total energy spent is well saved over the long driving cycles, also the fuel cell and batteries are kept operating in a healthy way.     

Multi-mode control strategy for fuel cell electric vehicles regarding fuel economy and durability

A proton electrolyte membrane (PEM) fuel cell system and a Li-ion battery (LIB) are two power sources in a fuel cell electric vehicle (FCEV). The fuel cell system is composed of a fuel cell stack and subsystems for air/hydrogen supply and cooling water. The operation procedure of the fuel cell system can be generally separated into several processes, e.g. starting up, normal/abnormal working and shutting down. In this paper, a multi-mode real-time control strategy for a FCEV is proposed. The strategy is established based on three typical processes (starting up, normal working, shutting down) of the fuel cell system, taking the fuel economy and system durability into consideration. The strategy is applied into a platform vehicle for the 12th 5-year project of “the next generation technologies of fuel cell city buses”. Experiments of the “China city bus typical cycle” on a test bench for the bus were carried out. Results show that, the fuel economy is 7.6 kg (100 km)⁻¹ in the battery charge-sustaining status. In a practical situation, a total driving mileage of more than 270 km can be achieved. Cycle testing also showed that, the degradation rate of the fuel cell was reduced to half of the original level. No performance degradation of the LIB system was observed in the cycling test.     

Prospects for hydrogen as a transport fuel

Early forecasts for hydrogen's role in transport usually proved over-optimistic, with several seeing hydrogen as an important transport fuel by year 2010 or even much earlier. Over the past century, vehicular passenger transport has experienced hypergrowth in terms of task, energy use and greenhouse gas emissions. For a variety of reasons, future decades may well see a significantly reduced global passenger transport task, as well as a widespread phasing-out of internal combustion engine vehicles, especially in cities. In contrast, the global freight transport task is unlikely to decline much, and could even grow, so that freight transport will dominate total transport energy use. Even if the world does finally respond seriously to climate change, likely policies will not favour hydrogen for private passenger vehicles for many decades. Nevertheless, hydrogen has clear superiority over electric vehicles for heavy freight transport. Given this advantage, it may be desirable to promote hydrogen for freight well before large amounts of renewable hydrogen are available from surplus intermittent renewable energy electricity.     

In situ hydrogen utilization in an internal reforming methanol fuel cell

In this work, we report on the catalytic properties of a novel ultrathin methanol reformer incorporated into the anode compartment of a High Temperature PEM Fuel Cell (HT-PEMFC). A highly active Cu-based methanol reforming catalyst (HiFuel R120, Johnson Matthey) was deposited on the gas diffusion layer of a carbon paper and the influence of anode flow distribution through the catalytic bed was studied in the temperature range of 160–220 °C. Inhibition by produced H₂ is higher in the case of through plane flow, especially in more concentrated methanol feeds. Higher methanol conversions were achieved with the in-plane flow distribution along the catalytic bed (>98% at 210 °C and without any deactivation for at least 100 h test), with a 50 cm² reformer (total thickness = 600 μm). The corresponding Internal Reforming Methanol Fuel Cell (IRMFC) operated efficiently for more than 72 h at 210 °C with a cell voltage of 642 mV at 0.2 A cm⁻², when 30% CH₃OH/45% H₂O/He (anode feed) and pure O₂ (cathode feed) were supplied.     

Review on health-conscious energy management strategies for fuel cell hybrid electric vehicles: Degradation models and strategies

Considering the overwhelming pressure on worldwide demand of fossil fuels and the climate change caused by air pollution, hybrid electric vehicles have seen a promising future thanks to the development of renewable energy sources. Among various kinds of energy sources that have been used in hybrid electric vehicles, lithium-ion battery and proton exchange membrane (PEM) fuel cell exist to be the most favorable ones owing to their high energy density and power density. However, the degradation issues of the energy sources tend to be neglected when designing the energy management strategies for the hybrid electric vehicles. Concerning existing literature, degradation modelling methods of lithium-ion batteries and PEM fuel cells are reviewed and the possibility of integrating them into health-conscious energy management is discussed. Besides, a variety of energy management strategies that have taken the influence of degradations into consideration are reviewed and classified. The contribution of this paper is to investigate the possibility of developing a health-conscious energy management strategy based on accurate estimation of degradation to improve the durability of the system.     

Portable direct hydrogen fed PEM fuel cell model and experimental verification

This paper focuses on the experimental verification of an electrochemical model of 100 W portable direct hydrogen fed proton exchange membrane (PEM) fuel cell (FC). The model is built based on the relationship between the FC terminal voltage and the partial pressures of hydrogen and oxygen. The model is then used to predict the output voltage and study the transient response of a PEMFC when subjected to rapid changes in the load. To validate the model, the measurements obtained from a commercially available 100 W FC are compared against the model results. Three different scenarios are considered for testing the model and the actual FC. In the first two scenarios, a step change in the load is used. In the third scenario, the load is replaced by a laptop computer. Results show a close agreement between the voltage and the power responses of the proposed model and the actual PEM FC. Copyright © 2009 John Wiley & Sons, Ltd.     

Comparative analysis of battery electric,hydrogen fuel cell and hybrid vehicles in a future sustainable road transport system

This paper compares battery electric vehicles (BEV) to hydrogen fuel cell electric vehicles (FCEV) and hydrogen fuel cell plug-in hybrid vehicles (FCHEV). Qualitative comparisons of technologies and infrastructural requirements, and quantitative comparisons of the lifecycle cost of the powertrain over 100,000 mile are undertaken, accounting for capital and fuel costs. A common vehicle platform is assumed. The 2030 scenario is discussed and compared to a conventional gasoline-fuelled internal combustion engine (ICE) powertrain. A comprehensive sensitivity analysis shows that in 2030 FCEVs could achieve lifecycle cost parity with conventional gasoline vehicles. However, both the BEV and FCHEV have significantly lower lifecycle costs. In the 2030 scenario, powertrain lifecycle costs of FCEVs range from $7360 to $22,580, whereas those for BEVs range from $6460 to $11,420 and FCHEVs, from $4310 to $12,540. All vehicle platforms exhibit significant cost sensitivity to powertrain capital cost. The BEV and FCHEV are relatively insensitive to electricity costs but the FCHEV and FCV are sensitive to hydrogen cost. The BEV and FCHEV are reasonably similar in lifecycle cost and one may offer an advantage over the other depending on driving patterns. A key conclusion is that the best path for future development of FCEVs is the FCHEV.     

Market penetration analysis of electric vehicles in the German passenger car market towards 2030

There is currently intensive public discussion of fuel cell electric vehicles (FCEV) and other electric powertrains, such as battery electric vehicles (BEV), plug-in hybrid electric vehicles (PHEV) and hybridized combustion engine vehicles (HEV). In this context, the German government has set the target of one million electric vehicles on the road by 2020, and six million by 2030 [1]. The goal of this paper is to identify the possible market share of electric vehicles in the German new car fleet in three scenarios in the timeframe from 2010 to 2030. The VECTOR21 vehicle technology scenario model is used to model the fleet in three scenarios. In the reference scenario with business-as-usual parameters, 189,000 electric vehicles will be sold in Germany by 2020. Scenario two with purchase price incentives from 5000 EUR, high oil prices, and low prices for hydrogen and electricity will result in 727,000 vehicles. In the last scenario with substantial OEM mark-up reductions and external conditions as in the business-as-usual scenario, 3.28 million vehicles will be sold.