A

SEMINAR REPORT

ON

HYDROGEN FUEL CELL VEHICLES

A Report Submitted in Fulfilment of The Requirement for the Award of The Degree

of
BACHELOR OF TECHNOLOGY
In

Electrical & Electronics Engineering

By

Tanishq Sharma
(01411504919)

BHARATI VIDYAPEETH’S COLLEGE OF ENGINEERING,

A-4, PaschimVihar, Main Rohtak Road, New Delhi – 110 063
List of content
Heading Page no.

Acknowledgment 1

Abstract 2

Introduction 2

Key components of a hydrogen fuel cell electric car 3

Fuel cell hybrid vehicle 4

Principal of fuel cell 5

Significance and advantages of fuel cell 6

Simscape PEM fuel cell system model 7

Hydrogen production 8

Reducing the cost of transport 12

Advantages of FCEVs 13

Disadvantages of FCEVs 14

Comparison between internal combustion engine cars and FCEVs 15

Comparison between FCEVs and battery electric vehicle 16

The future of hydrogen fuel cell technology 18

References 19
 1

Acknowledgement

I would like to express my profound gratitude to Mrs. Kusum Tharani, HOD of Electrical and
Electronics department,
I would like to express my special thanks to our mentor Dr Bharat Singh for his/her time and
efforts he/she provided throughout the year. Your useful advice and suggestions were really
helpful for completion of my seminar report “Hydrogen fuel cell vehicle”. In this aspect, I am
eternally grateful to you.
I would like to acknowledge that this project was completed entirely by me and not by
someone else.

Tanishq Sharma
01411504919
 2

Abstract
The hazardous effects of pollutants from conventional fuel vehicles have caused the
scientific world to move towards environmentally friendly energy sources. Though we
have various renewable energy sources, the perfect one to use as an energy source for
vehicles is hydrogen. Like electricity, hydrogen is an energy carrier that has the ability
to deliver incredible amounts of energy. Onboard hydrogen storage in vehicles is an
important factor that should be considered when designing fuel cell vehicles. In this
study, a recent development in hydrogen fuel cell engines is reviewed to scrutinize the
feasibility of using hydrogen as a major fuel in transportation systems. A fuel cell is
an electrochemical device that can produce electricity by allowing chemical gases and
oxidants as reactants. Fuel cells use reactants, which are not harmful to the
environment and produce water as a product of the chemical reaction. As hydrogen is
one of the most efficient energy carriers, the fuel cell can produce direct current (DC)
power to run the electric car. By integrating a hydrogen fuel cell with batteries and the
control system with strategies, one can produce a sustainable hybrid car.

Introduction

Energy is a factor determining a country’s economy, infrastructure, transportation, and

standard of life. The problem faced globally is the disparity between the consumption
and the availability of energy. All nations are presently depending upon fossil fuel for
the energy production, and these fossil fuels are not sustainable sources. To supply the
energy demands of the more rapidly increasing global population, it is essential to
upgrade to an alternative, sustainable energy source that does not negatively affect the
environment . In recent decades, the United States has been putting emphasis on the
environmental impact of the transportation sector and reducing petroleum dependence.

Why hydrogen?

Hydrogen is the simplest form of all molecules; it has the lowest energy content by
volume, but it has the highest energy content of any fuel by weight. It is available in
the atmosphere as gas and in water as liquid. Due to the high energy content of
hydrogen, it is employed as a fuel in applications such as FCs and rockets. Hydrogen
creates zero harmful emissions, which is one of the most significant drawbacks of
fossil fuels, and the heating value of hydrogen is three times higher than that of
petroleum.
Currently, around half of the world’s industrial hydrogen comes from natural gas. The
traditional method of extracting hydrogen from natural gas also creates around 10
tonnes of CO2 for every tonne of hydrogen produced. Therefore, we needed to find a
more sustainable way to produce it.
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Key Components of a Hydrogen Fuel Cell Electric Car

Battery (auxiliary): In an electric drive vehicle, the low-voltage auxiliary battery

provides electricity to start the car before the traction battery is engaged; it also
powers vehicle accessories.
Battery pack: This high-voltage battery stores energy generated from regenerative
braking and provides supplemental power to the electric traction motor.
DC/DC converter: This device converts higher-voltage DC power from the traction
battery pack to the lower-voltage DC power needed to run vehicle accessories and
recharge the auxiliary battery.
Electric traction motor (FCEV): Using power from the fuel cell and the traction
battery pack, this motor drives the vehicle's wheels. Some vehicles use motor
generators that perform both the drive and regeneration functions.
Fuel cell stack: An assembly of individual membrane electrodes that use hydrogen
and oxygen to produce electricity.
Fuel tank (hydrogen): Stores hydrogen gas in the vehicle needed by the fuel cell.
Power electronics controller (FCEV): This unit manages the flow of electrical
energy delivered by the fuel cell and the traction battery, controlling the speed of the
electric traction motor and the torque it produces.
Thermal system (cooling) - (FCEV): This system maintains a proper operating
temperature range of the fuel cell, electric motor, power electronics, and other
components.
Transmission (electric): The transmission transfers mechanical power from the
electric traction motor to drive the wheels.
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Fuel Cell Hybrid Vehicles

The development of one important aspect of the fuel cell vehicle—the electric
motor—dates to the early 19th century. Although electric vehicles were a strong
contender in the early 20th century to become a mainstream transportation method,
the ICE vehicle eventually won out due to the short range and the high cost of electric
vehicles. Additionally, the discovery of Texan oil reduced the price of gasoline, thus it
became affordable to the average consumer, which caused fuel cell and electric
vehicles to take a backseat to the ICE vehicle for most of the last 100 years.

Parallel Hybrid

One of the earlier hybrid drive train designs was the parallel hybrid architecture. In
this configuration, both the internal combustion engine and the electric motor can be
used to power the vehicle independent of one another. The ICE has a low torque
output at low speeds, therefore in stop-and-go drive cycles.
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Series Hybrid
A series hybrid drive train architecture differs from a parallel hybrid drive train in that
the two power sources are no longer independently able to power the vehicle. In this
configuration, generally the ICE will act as a charger for the batteries that supply
electricity to the electric motor—the only source to propel the vehicle . One of the
advantages of this design is that there is no need for a transmission, since the ICE is
not powering the vehicle directly. Eliminating the transmission from the engine

system reduces the weight of the vehicle, which directly correlates to increased
efficiency. In a series configuration, the ICE does not have to account for any of the
transient dynamics in the drive cycle as it would in a parallel configuration.

Principle of fuel cell

How do the redox reactions in a fuel cell generate electricity?
The chemistry of fuel cells has been understood since the 1830s. Like batteries, fuel
cells create electricity through chemical reactions that involve the transfer of
electrons. Chemists call these reactions oxidation-reduction, or redox, reactions.
Redox reactions can be split into two parts, the oxidation half and the reduction half.
Half-reactions that release electrons are called oxidation reactions; half-reactions that
accept electrons are called reduction reactions.

Inside a PEM hydrogen fuel cell, electric current is generated using the two chemical
half- reactions shown below.

Inside the fuel cell are two electrodes. Each electrode has a platinum catalyst that
speeds up the redox reaction.
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The electrode where oxidation occurs is called the anode. At the anode, hydrogen is
oxidized and electrons are delivered to an external electrical circuit. The electrons
travel through this external circuit to the cathode. Reduction occurs at the cathode,
where oxygen is reduced and the reactants combine to form water. A proton exchange
membrane separates the two electrodes. This membrane conducts protons through to
the cathode, but blocks electron transport. Electrons are forced to flow through an
external circuit and generate current. At the cathode, these protons join in the
reduction reaction to form water.

https://sepuplhs.org/high/hydrogen/fuelcell_sim5.html [Fuel cell Computer

simulation]

Significance and advantages of Hydrogen fuel cell

Hydrogen can be produced from diverse domestic resources with the potential for
near-zero greenhouse gas emissions. Once produced, hydrogen generates electrical
power in a fuel cell, emitting only water vapor and warm air. It holds promise for
growth in both the stationery and transportation energy sectors.

Energy Security
Hydrogen can be produced domestically from resources like natural gas, coal, solar
energy, wind, and biomass. When used to power highly efficient fuel cell electric
vehicles, hydrogen holds the promise of helping strengthen national energy security,
conserve fuel, and diversify our transportation energy options for a more resilient
system.
 7

Public Health and Environment

The environmental and health benefits are also seen at the source of hydrogen
production if derived from low- or zero-emission sources, such as solar, wind, and
nuclear energy and fossil fuels with advanced emission controls and carbon
sequestration. Because the transportation sector accounts for about one-third of U.S.
carbon dioxide emissions, using these sources to produce hydrogen for transportation
can cut greenhouse gas emissions. Learn more about hydrogen emissions.

Fuel Storage
Hydrogen's energy content by volume is low. This makes storing hydrogen a
challenge because it requires high pressures, low temperatures, or chemical processes
to be stored compactly. Overcoming this challenge is important for light-duty vehicles
because they often have limited size and weight capacity for fuel storage. Typically,
the storage capacity for hydrogen in light-duty vehicles should enable a driving range
of more than 300 miles to meet consumer needs.

Production Costs
To be competitive in the marketplace, the cost of fuel cells will have to decrease
substantially without compromising performance. From at least one original
equipment manufacturer, the predicted cost of mass-produced fuel cell electric
vehicles could be similar to the cost of their hybrid counterparts by 2025.

Simscape PEM fuel cell system model

With Simscape, engineers can customize a complete PEM fuel cell model. This
includes the fuel cell stack and balance-of-plant components such as air compressors,
humidifiers, hydrogen recirculation paths, cooling systems, and water management.
This first-principles–based fuel cell model using electrochemistry enables
development of a PEM fuel cell at both the component and system levels. This level
 8

of fuel cell model detail lets engineers model functionalities like current, voltage, and
power monitoring and thermal management.

A fuel cell model as part of an electrical system provides a framework for performing
trade studies to economize fuel cell stack efficiency, hydrogen and oxygen utilization,
and fuel and air consumption.

Hydrogen production

Hydrogen is an energy carrier that can be used to store, move, and deliver energy
produced from other sources.

Today, hydrogen fuel can be produced through several methods. The most common
methods today are natural gas reforming (a thermal process), and electrolysis. Other
methods include solar-driven and biological processes.

NATURAL GAS REFORMING

This is an advanced and mature production process that builds upon the existing
natural gas pipeline delivery infrastructure. Today, 95% of the hydrogen produced in
the United States is made by natural gas reforming in large central plants. This is an
important technology pathway for near-term hydrogen production.

Most hydrogen produced today in the United States is made via steam-methane
reforming, a mature production process in which high-temperature steam (700°C–
1,000°C) is used to produce hydrogen from a methane source, such as natural gas. In
steam-methane reforming, methane reacts with steam under 3–25 bar pressure (1 bar =
14.5 psi) in the presence of a catalyst to produce hydrogen, carbon monoxide, and a
relatively small amount of carbon dioxide. Steam reforming is endothermic—that is,
heat must be supplied to the process for the reaction to proceed.

Subsequently, in what is called the "water-gas shift reaction," the carbon monoxide
and steam are reacted using a catalyst to produce carbon dioxide and more hydrogen.
 9

Why Is This Pathway Being Considered?

Reforming low-cost natural gas can provide hydrogen today for fuel cell electric
vehicles (FCEVs) as well as other applications. Over the long term, DOE expects that
hydrogen production from natural gas will be augmented with production from
renewable, nuclear, coal (with carbon capture and storage), and other low-carbon,
domestic energy resources.

Petroleum use and emissions are lower than for gasoline-powered internal combustion
engine vehicles. The only product from an FCEV tailpipe is water vapor but even with
the upstream process of producing hydrogen from natural gas as well as delivering
and storing it for use in FCEVs, the total greenhouse gas emissions are cut in half and
petroleum is reduced over 90% compared to today's gasoline vehicles.

ELECTROLYTIC PROCESSES

Water can be separated into oxygen and hydrogen through a process called
electrolysis. Electrolytic processes take place in an electrolyser, which functions much
like a fuel cell in reverse—instead of using the energy of a hydrogen molecule, like a
fuel cell does, an electrolyser creates hydrogen from water molecules.
Like fuel cells, electrolysers consist of an anode and a cathode separated by an
electrolyte. Different electrolysers function in different ways, mainly due to the
different type of electrolyte material involved and the ionic species it conducts.

• Water reacts at the anode to form oxygen and positively charged hydrogen ions
(protons).
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• The electrons flow through an external circuit and the hydrogen ions
selectively moves across the PEM to the cathode.
• At the cathode, hydrogen ions combine with electrons from the external circuit
to form hydrogen gas.

Today's grid electricity is not the ideal source of electricity for electrolysis because
most of the electricity is generated using technologies that result in greenhouse gas
emissions and are energy intensive. Electricity generation using renewable or nuclear
energy technologies, is a possible option to overcome these limitations for hydrogen
production via electrolysis.

SOLAR-DRIVEN PROCESSES

Solar-driven processes use light as the agent for hydrogen production. There are a few
solar-driven processes, including photoelectrochemical, photobiological, and solar
thermochemical. Photobiological processes use the natural photosynthetic activity of
bacteria and green algae to produce hydrogen. Photoelectrochemical processes use
specialized semiconductors to separate water into hydrogen and oxygen. Solar
thermochemical hydrogen production uses concentrated solar power to drive water
splitting reactions often along with other species such as metal oxides.

Thermochemical water splitting uses high temperatures—from concentrated solar

power or from the waste heat of nuclear power reactions—and chemical reactions to
produce hydrogen and oxygen from water. This is a long-term technology pathway,
with potentially low or no greenhouse gas emissions.

Thermochemical water splitting processes use high-temperature heat (500°–2,000°C)

to drive a series of chemical reactions that produce hydrogen. The chemicals used in
the process are reused within each cycle, creating a closed loop that consumes only
water and produces hydrogen and oxygen. The necessary high temperatures can be
generated in the following ways:

• Concentrating sunlight onto a reactor tower using a field of mirror "heliostats".

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• Using waste heat from advanced nuclear reactors.

Why Is This Pathway Being Considered?

Solar- and nuclear-driven high-temperature thermochemical water-splitting cycles
produce hydrogen with near-zero greenhouse gas emissions using water and either
sunlight or nuclear energy.

BIOLOGICAL PROCESSES

Biological processes use microbes such as bacteria and microalgae and can produce
hydrogen through biological reactions. In microbial biomass conversion, the microbes
break down organic matter like biomass or wastewater to produce hydrogen, while in
photobiological processes the microbes use sunlight as the energy source.

Why Is This Pathway Being Considered?

In the long term, photobiological production technologies may provide economical
hydrogen production from sunlight with low- to net-zero carbon emissions. The algae
and bacteria could be grown in water that cannot be used for drinking or for
agriculture and could potentially even use wastewater.

Drawback of biological processes:

The major problem with bio-photolysis of water and photo fermentation is that they
are light dependent and their hydrogen yield and rate of hydrogen production are too
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low for practical applications. Amongst the carious other processes, dark fermentation
appears most promising.

Reducing the cost of transportation

Creating hydrogen was only half of the solution. The next problem we had to
overcome was how to affordably store and deliver this revolutionary fuel to where it
was needed.

Hydrogen is a very light molecule. It can be liquified, but that requires keeping it at a
temperature of -254°C, which makes it very difficult and expensive to transport –
particularly over long distances. The solution lay in converting the hydrogen into a
chemical compound which is already widely traded around the world: ammonia.

Compared to hydrogen, liquified ammonia is far more convenient, practical, and cost-
effective to transport, in terms of both the required temperature and pressure
conditions.
Once the blue ammonia reaches its destination, it can be converted back into blue
hydrogen, or used directly as a fuel for gas turbines for cleaner power generation.
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Advantages of FCEVs
Hydrogen fuel cell technology presents several advantages over other power sources ,
including:

1. Renewable and Readily Available

Hydrogen is the most abundant element in the Universe and despite the challenges associated
with its extraction from water, is a uniquely abundant and renewable source of energy,
perfect for our future zero-carbon needs for combined heat and power supplies.

2. Hydrogen is a Clean and Flexible Energy Source to support Zero-Carbon

Energy Strategies

Hydrogen fuel cells provide an inherently clean source of energy, with no adverse
environmental impact during operation as the by-products are simply heat and water. Unlike
biofuel or hydropower, hydrogen doesn’t require large areas of land to produce. In fact,
NASA have even been working on using hydrogen as a resource with the water produced as a
by-product being used as drinking water for astronauts. This shows that hydrogen fuel cells
are a non-toxic fuel source and therefore superior in this way to coal, natural gas and nuclear
power which are all either potentially dangerous or hard to obtain.

3. More Powerful and Energy Efficient than Fossil Fuels

Hydrogen fuel cell technology provides a high-density source of energy with good energy
efficiency. Hydrogen has the highest energy content of any common fuel by weight. High
pressure gaseous and liquid hydrogen have around three times the gravimetric energy density
(around 120MJ/kg) of diesel and LNG and a similar volumetric energy density to natural gas.
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5. Almost Zero Emissions

Hydrogen fuel cells do not generate greenhouse gas emissions as for fossil fuel sources, thus
reducing pollution and improving air quality as a result.

6. Reduces Carbon Footprints

With almost no emissions, hydrogen fuel cells do not release greenhouse gases, which means
they do not have a carbon footprint while in use.

7. Fast Charging Times

The charge time for hydrogen fuel cell power units is extremely rapid, similar to that for
conventional internal combustion engine (ICE) vehicles and markedly quicker in comparison
to battery-powered electric vehicles. Where electric vehicles require between 30 minutes and
several hours to charge, hydrogen fuel cells can be recharged in under five minutes. This fast-
charging time means that hydrogen powered vehicles provide the same flexibility as
conventional cars.

8. Long Usage Times

Hydrogen fuel cells offer greater efficiencies with regard to usage times. A hydrogen vehicle
has the same range as those that use fossil fuels (around 300 miles). This is superior to that
currently offered by electric vehicles (EVs), which are increasingly being developed with fuel
cell power units as ‘range-extenders’. Hydrogen fuel cells are also not significantly impacted
by the outside temperature and do not deteriorate in cold weather, unlike EVs. This advantage
is increased further when coupled with the short charging times.

Disadvantages of FCEVs

1. Hydrogen Extraction

Despite being the most abundant element in the Universe, hydrogen does not exist on its own
so needs to be extracted from water via electrolysis or separated from carbon fossil fuels.
Both of these processes require a significant amount of energy to achieve. This energy can be
more than that gained from the hydrogen itself as well as being expensive. In addition, this
extraction typically requires the use of fossil fuels, which in the absence of CCS undermines
the green credentials of hydrogen.

2. Investment is Required

Hydrogen fuel cells need investment to be developed to the point where they become a
genuinely viable energy source. This will also require the political will to invest the time and
money into development in order to improve and mature the technology. Put simply, the
global challenge for development of widespread and sustainable hydrogen energy is how best
to incrementally build the ‘supply and demand’ chain in the most cost-effective manner.
 15

3. Overall Cost

The cost for a unit of power from hydrogen fuel cells is currently greater than other energy
sources, including solar panels. This may change as technology advances, but currently this
cost is a barrier to widespread use of hydrogen even though it is more efficient once
produced. This expense also impacts costs further down the line, such as with the price of
hydrogen operated vehicles, making widespread adoption unlikely at the moment.

6. Hydrogen Storage

Storage and transportation of hydrogen is more complex than that required for fossil fuels.
This implies additional costs to consider for hydrogen fuel cells as a source of energy.

7. Infrastructure

Because fossil fuels have been used for decades, the infrastructure for this power supply
already exists. Large scale adoption of hydrogen fuel cell technology for automotive
applications will require new refuelling infrastructure to support it, although for long-range
applications such as those for HGVs and delivery truck is it likely the start-to-end refuelling
will be used.

8. Highly Flammable

Hydrogen is a highly flammable fuel source, which brings understandable safety concerns.
Hydrogen gas burns in air at concentrations ranging from 4 to 75%.

Comparison between internal combustion engine cars and fuel cell electric
vehicles
In order to achieve gradual but timely decarbonisation of the transport sector, it is essential to
evaluate which types of vehicles provide a suitable environmental performance while
allowing the use of hydrogen as a fuel. This work compares the environmental life-cycle
performance of three different passenger cars fuelled by hydrogen: a fuel cell electric vehicle,
an internal combustion engine car, and a hybrid electric vehicle. Besides, two vehicles that
use hydrogen in a mixture with natural gas or gasoline were considered. In all cases,
hydrogen produced by wind power electrolysis was assumed. The resultant life-cycle profiles
were benchmarked against those of a compressed natural gas car and a hybrid electric vehicle
fed with natural gas. Vehicle infrastructure was identified as the main source of
environmental burdens.

Pollutants from cars can cause both immediate as well as long-term problems. The above-
mentioned pollutants can harm both our health and environment in various ways. Some of the
ill-effects are being listed below:

• Global warming: Although there are innumerable factors affecting global warming,
the pollutants expelled from cars are one of the major reasons. Combustion of fossil
fuels leads to release of gases like carbon monoxide and carbon dioxide. It also
releases other greenhouse gases including hydrocarbons (which are indirect
 16

greenhouse gases). These gases leads to global warming and in turn affects the
environment.
• Air, water, and soil pollution: Air, water, and soil are heavily affected by the effects
of vehicular pollution. The ozone layer is depleting which puts the earth at risk of
being exposed to harmful ultraviolet radiation of the sun. Oxides of sulphur and
nitrogen mixes with rainwater to create acid rain.
• Health hazards: Right from respiratory ailments to cancer, car pollutants are
responsible for a lot of health hazards. It is also responsible for making the immunity
weak. Thus, the the risk of being exposed to different diseases and complications also
increases.

Comparison between fuel cell electric vehicles and battery electric vehicles

Hydrogen fuel cells have a far greater energy storage density than lithium-ion batteries,
offering a significant range advantage for electric vehicles while also being lighter and
occupying less space. Hydrogen-powered vehicles can also be refuelled in just a few minutes,
while those that are battery-powered require a wait while the battery charges.

Despite the environmental and efficiency advantages of battery electric vehicles, lithium-ion
batteries — considered the best currently available — only have around 1% of the energy
density of petrol or diesel. For this reason, smaller and lighter vehicles appear to be the best
candidates for battery electric powertrains. As vehicles increase in size, the size and weight of
the battery pack required to power the vehicle, as well as the available range, begins to make
battery power a less attractive option.

As with battery electric vehicles, hydrogen fuel cell electric vehicles use electricity to power
an electric motor. This is generated by a fuel cell powered by hydrogen, rather than drawing
electricity directly from a battery. The fuel cell generates electricity through an
electrochemical reaction in which hydrogen and oxygen are combined to generate electricity,
heat, and water.

The fuel cell is composed of an anode, cathode, and an electrolyte membrane. In general
terms, hydrogen enters the fuel cell through the anode, where it’s spilt into electrons and
protons. Hydrogen ions pass through the electrolyte which forces the electrons through a
 17

circuit, generating an electric current and excess heat. Oxygen entering at the cathode
combines with electrons from the electrical circuit and the hydrogen ions that have passed
through the electrolyte from the anode, creating a harmless emission — water.
 18

The future of hydrogen fuel cell technology

Nevertheless, hydrogen still has niches where its main strengths — lightness and quick
refuelling — provide a clear advantage. While it's possible to fit personal driving lifestyles
around strategic battery charging stops, this isn’t ideal for commercial or long-distance public
transport vehicles like trains or coaches, which rely on fast refuelling to reduce wait times
across long distances.
A review of current innovation around hydrogen fuel cell vehicles reveals the application of
hydrogen fuel cell technology in areas including:

• Marine technology
Daewoo is currently developing hydrogen propulsion systems for marine applications.
Korean patent KR20190054206A describes a liquid hydrogen powered fuel cell-based
propulsion system for submarines. Korean patent KR20190073050 describes a hybrid
hydrogen fuel cell-based power system for a ship using liquified hydrogen gas as the fuel to
generate electricity to power the rotation of the propeller shaft.

• Aviation
Hydrogen fuel cells are also being explored as a power source for aviation. Chinese patents
CN211543883 and CN 211253048 describe an unmanned aerial vehicle powered by a
hydrogen fuel cell.
Meanwhile, Airbus is pursuing hydrogen-fuelled airliners and has indicated that it will decide
by 2025 whether this technology is commercially viable. The company has projected that its
first hydrogen airliners may enter service in 2035.
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