Hydrogen Engine and Fuel Cell: Exploring Both Options

The development of hydrogen powertrains is gaining momentum, particularly in the heavy-duty trucking sector. As manufacturers explore diverse technologies, the question arises: why develop both hydrogen fuel cells and hydrogen internal combustion engines (ICE)? Insights from industry leaders shed light on this pivotal question.

According to Mehdi Ferhan, senior vice president of powertrain engineering at Volvo Trucks, the answer lies in the complexity and diversity of global markets. “There is no silver bullet, one-size-fits-all solution for the entire world markets,” he states. This recognition leads to a careful balancing act in offering solutions that cater to the distinct needs of different applications while ensuring affordability for customers.

HPDI hydrogen ICE development

Volvo's collaboration with Westport through Cespira Technologies is a significant step in hydrogen ICE development, focusing on High Pressure Direct Injection (HPDI) technology. This innovative approach leverages HPDI technology previously validated in liquefied natural gas (LNG) applications, providing fleets with a viable path to lower emissions without completely shifting away from combustion platforms. Presently, over 8,000 LNG trucks are operational in Europe, demonstrating the feasibility of this technology.

HPDI technology has been in use in Volvo trucks for over five years, proving its effectiveness in significantly reducing CO2 emissions in Liquified Biogas (LBG) applications. This technology also presents an avenue for the integration of hydrogen, marking a crucial step towards cleaner heavy-duty transportation.

Fuel cell development with cellcentric

In parallel, Volvo is advancing fuel cell technology through its joint venture with Daimler, known as cellcentric. The engineers have developed a NextGen fuel cell system designed as a compact unit that fits seamlessly into a conventional 13-liter diesel engine bay. This system weighs approximately 400 kg (around 882 lbs) and integrates with existing platforms, delivering up to 375 kW (over 500 horsepower) of continuous net power.

Key features of this fuel cell system include:

• 20% reduction in fuel consumption
• 40% reduction in waste heat at 300 kW
• 40% increase in power density compared to the previous model

Experts anticipate that a 40-ton truck utilizing this technology will consume about 9.7 kg of hydrogen per 100 miles, translating to approximately 10.2 miles per kilogram. Enhanced efficiency results from a larger active stack area, improved membrane electrode assembly (MEA) catalyst formulations, and optimized operating conditions. Notably, cellcentric NextGen fuel cell trucks can achieve ranges exceeding 650 miles on a single charge.

Why both hydrogen powertrains matter

The distinction between hydrogen ICE trucks and fuel cell electric vehicles (FCEVs) is essential for understanding their respective roles in the market. Hydrogen ICE trucks operate similarly to traditional diesel trucks but use hydrogen as fuel, while FCEVs generate power through electrochemical reactions, emitting only water vapor and offering higher efficiency.

However, the higher system cost of fuel cells presents a barrier for some applications. Ferhan emphasizes the importance of recognizing the varied regulations and customer expectations across different regions. He notes, “Different regions of the world mean different customer expectations will leave room for different types of technologies.”

For example, in Europe, stringent CO2 emission standards may classify hydrogen combustion engines as zero-emission vehicles, accelerating their market introduction. In contrast, North America faces uncertainties regarding zero-emission regulations. Nevertheless, Ferhan highlights that these two hydrogen powertrain options are not in competition but rather serve to complement each other.

Key points regarding the roles of hydrogen powertrains include:

• Fuel cells provide zero emissions and high efficiency at a premium cost.
• Hydrogen ICE offers a more straightforward, economical solution with minimal NOx emissions and a low CO2 footprint.
• Both technologies can coexist, catering to different market segments and customer needs.

Ferhan further posits that “hydrogen can be a game changer for the decarbonization of carbon-emitting industries,” particularly within the commercial vehicle sector. While progress is currently slow, the expectation is that advancements will pave the way for competitive and affordable solutions harnessing either hydrogen ICE or fuel cell technologies.

Comparing hydrogen combustion engines and fuel cells

Understanding the differences between hydrogen combustion engines and fuel cells enhances clarity regarding their potential applications. In essence, hydrogen combustion engines utilize combustion processes similar to traditional engines but replace fossil fuels with hydrogen, resulting in lower emissions. Conversely, fuel cells convert hydrogen directly into electricity through an electrochemical reaction.

Both technologies present unique advantages and drawbacks:

• Hydrogen ICE: Simplicity and lower costs, but may produce some emissions.
• Fuel Cells: Higher efficiency and lower emissions, but higher upfront costs.

In specific applications, such as long-haul trucking, the choice between these technologies may depend on factors such as range, payload capacity, and infrastructure availability.

Current challenges and future prospects

Despite their promise, hydrogen powertrains face several challenges that need addressing before widespread adoption:

• Infrastructure: The development of refueling stations and distribution networks is crucial.
• Cost: Both hydrogen production and fuel cells need to become more cost-competitive.
• Public perception: Educating consumers and industries about the benefits of hydrogen technologies is essential.

However, industry leaders remain optimistic. As research progresses and technologies evolve, the potential for hydrogen to play a pivotal role in decarbonizing transport becomes increasingly feasible. The investment in both hydrogen ICE and fuel cell technologies could lead to breakthroughs that accelerate the transition to greener transportation.

For a deeper understanding of the differences between hydrogen combustion engines and fuel cells, you can watch this informative video:

For more insights into truck powertrain solutions, visit the Volvo Trucks North America website.

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