Performance and cost of fuel cells for off-road heavy-duty vehicles

Replacing hydrocarbon-powered off-road vehicles with hydrogen fuel cell-powered off-road vehicles can reduce carbon dioxide and criteria pollutant emissions in the agriculture, construction, and mining industries. Off-road vehicles perform challenging work in harsh environments that complicate deployment of their fuel cell-powered counterparts. Customers and vehicle manufacturers recognize the health and environmental benefits of emissions reductions but are compelled by the total cost of ownership of their vehicles. This study provides a novel technoeconomic comparison of hydrogen fuel cell + battery hybrid powertrains to traditional diesel powertrains for three hallmark off-road vehicles: tractors, wheel loaders, and excavators. Performance metrics include fuel cell engine power, hydrogen consumption rate, hydrogen storage system volume, energy-regenerative drivetrain efficiency, cost of capital, operating and maintenance cost, fuel cost, and fuel storage cost. Results demonstrate that state-of-the-art fuel cell-powered wheel loaders and excavators are currently cost competitive with diesel platforms by total cost of ownership: compact wheel loaders are 19% less expensive, large wheel loaders are equally expensive, mini/compact excavators are 11% more expensive, and standard/full excavators are 9% less expensive. If targeted improvements to cost, performance, and durability of fuel cell stacks and storage systems are achieved, fuel cell systems would be cost competitive for tractors and significantly lower total cost of ownership options for wheel loaders and excavators. This study also elucidates the relationship between performance, cost, and vehicle duty cycle and provides guidance for optimal deployment of fuel cell off-road vehicles.