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International Journal of Green Energy

ISSN: 1543-5075 (Print) 1543-5083 (Online) Journal homepage: https://www.tandfonline.com/loi/ljge20

An overview of development and challenges in


hydrogen powered vehicles

Seyed Ehsan Hosseini & Brayden Butler

To cite this article: Seyed Ehsan Hosseini & Brayden Butler (2020) An overview of development
and challenges in hydrogen powered vehicles, International Journal of Green Energy, 17:1,
13-37, DOI: 10.1080/15435075.2019.1685999

To link to this article: https://doi.org/10.1080/15435075.2019.1685999

Published online: 18 Nov 2019.

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INTERNATIONAL JOURNAL OF GREEN ENERGY
2020, VOL. 17, NO. 1, 13–37
https://doi.org/10.1080/15435075.2019.1685999

An overview of development and challenges in hydrogen powered vehicles


Seyed Ehsan Hosseini and Brayden Butler
Combustion and Sustainable Energy Laboratory (ComSEL), Department of Mechanical Engineering, Arkansas Tech University, Russellville, AR, USA

ABSTRACT ARTICLE HISTORY


Hydrogen has the potential to be the sustainable fuel of the future, decrease the global dependence on Received 30 March 2019
fossil fuel resources, and lower the pollutant emissions from the transportation industry. In this study, Accepted 24 October 2019
recent development in hydrogen-based transportation engines is reviewed to scrutinize the feasibility of KEYWORDS
using hydrogen as a major fuel of future. Using hydrogen in internal combustion engines achieves only Internal combustion engine;
20-25% efficiency and low power output compared to fossil-fueled internal combustion engines. fuel cell; transportation
Although hydrogen-based internal combustion engines have recently received considerable interests, system; hydrogen storage;
several practical barriers have prevented the fast development of this technology. Hence, at the current hydrogen safety; exhaust
stage, using hydrogen as an additive to hydrocarbon fuel systems have been taken into consideration to gas recirculation
produce higher performance than hydrogen-only internal combustion engines. Using the dual-fuel
strategy can increase the combustion stability and thermal efficiency while decreasing the CO and
unburned hydrocarbons emissions, and fuel consumption. Alternatively, hydrogen can be used in fuel
cells for vehicular applications with several automotive manufacturers producing fuel cell vehicles
currently. Fuel cells can achieve efficiencies of up to 60%, while the rest is lost as heat. Strategies that
have been investigated to increase the efficiency, performance, and lifespan of fuel cells are capillary
pumping systems, a chemisorption chiller, nanofluids and supercapacitors. All such strategies improved
the fuel cells in one or more ways. Safety, hydrogen delivery, onboard storage, and the capital and
operating costs of hydrogen powered vehicles are analyzed to approach to clean transportation utopia.

1. Introduction (Chang, Ma, and Wu 2018). Road vehicles consume approxi-


mately 50% of the world’s oil produced (Balat 2008). The
The most significant problem of the 21st century is the global
demand for crude oil has continuously increased because of
demand for enhanced energy generation and the related
economic acceleration. Energy planners of many countries are
environmental issues such as local pollution and global warm-
searching for sustainable solutions to fulfill their energy
ing. In 2016, it was internationally agreed that 2°C of global
demand, especially in the transportation sector (Hosseini
temperature increase is inevitable (Álvarez Fernández et al.
et al. 2013). In this context, research and investments in the
2018). This limit means that the design goals for the energy
utilization of renewable and sustainable alternative fuels, as
system must be widened from only concerning technology
well as the enhancement of energy efficiency of the engines
and economics to including environmental impact, sustain-
have been developed (Hosseini and Wahid 2014). Hydrogen is
ability through its life cycle, constituent materials, and the
one of the most important candidates to supply energy
waste products (Hosseini 2019). A significant amount of the
demands in future and plays a crucial role in most govern-
energy consumed globally is by transportation vehicles and
mental strategic plans (Elnashaie, Chen, and Prasad 2007;
machineries which are almost exclusively dependent on fossil
Hosseini, Wahid, and Ganjehkaviri 2015b). Hydrogen has
fuels (Chapman 2007; Mori and Hirose 2009). Due to fossil
a heating value three times larger than petroleum, on a mass
fuel resources depletion and increasing rate of anthropogenic
basis, and creates significantly less zero harmful tailpipe-
greenhouse gas (GHG) emissions, the possibility of using
emissions in internal combustion engines and fuel cells,
other prime movers and energy carriers is highlighted by
which is one of the most significant drawbacks of fossil fuels
energy strategists and environmentalists (Hosseini and
(Fayaz et al. 2012; Muradov and Vezirolu 2005).
Wahid 2012). Currently, around 65% of the worldwide energy
There are countless benefits to using hydrogen instead of
demand is supplied by fossil fuels in fluid form because they
fossil fuels. The most notable benefits are that it is considered
are easily accessible and convenient to use. In the urban
as an environmentally friendly fuel because it emits only H2
transportation (private cars, taxis, buses, and urban rail tran-
O when used in a fuel cell (Zeng and Zhang 2010). Hydrogen,
sit), the energy consumption of various options is different,
the most plentiful element, has the highest specific energy
with private cars having the highest energy consumption. The
content compared to the fossil fuels (Balat and Balat 2009).
rapid development of the private cars industry has an adverse
Hydrogen possesses an energy yield of 122 kJ/g, which is 2.75
influence on the energy scenario and environment of the cities

CONTACT Seyed Ehsan Hosseini shosseini@atu.edu Combustion and Sustainable Energy Laboratory (ComSEL), Department of Mechanical Engineering,
Arkansas Tech University, 1811 N Boulder Ave, Russellville, AR 72801, USA
Color versions of one or more of the figures in the article can be found online at www.tandfonline.com/ljge.
© 2019 Taylor & Francis Group, LLC
14 S. E. HOSSEINI AND B. BUTLER

times larger than numerous hydrocarbon fuels (Kapdan and and methods; however, only a few of these methods are
Kargi 2006). Energy per unit mass stored in hydrogen is about currently commercially viable (Barbir 2009). Presently, the
2.6 times more than gasoline; however, hydrogen is disadvan- price of hydrogen is more than double that of diesel and
tageous because it requires approximately four times more petrol on a mass basis. To enable hydrogen production to be
volume for storage than gasoline when stored as a liquid, environmentally sustainable and competitively priced, sub-
and approximately 19 times more volume when stored as stantial progress must be made. To establish an operational
a gas (Petkov, Veziroǧlu, and Of n.d.). Utilizing hydrogen as hydrogen economy, the required energy for pure hydrogen
a fuel in an internal combustion engine (ICE) or fuel cell (FC) production, its storage and transport should be estimated
propelled vehicles is a promising direction for the future of (Herzog and Tatsutani 2005).
the transportation sector. Hydrogen-fueled ICEs (H2ICEs) Although very low density of hydrogen has made some
have low achievable efficiency of 20–25%, which is a cause challenges for its bulk storage, as well as its distribution and
for problems when considering the current hydrogen storage onboard vehicle storage, the advantages of hydrogen utiliza-
capabilities in both gas and liquid states. Lacking the ability to tion in the transportation system are significant enough to
achieve driving ranges comparable to those of fossil-fueled introduce hydrogen as a serious energy carrier candidate for
ICE vehicles makes H2ICEs less appealing to consumers. The modern transportation systems (Verhelst and Wallner 2009).
poor efficiency of H2ICEs and low storage capabilities com- Renewable energy can provide hydrogen locally; however,
bined with the lack of hydrogen refueling infrastructure they are not adequate sources to provide enough hydrogen
makes the engine type not feasible for consumers at this to meet the global requirement (Lindorfer et al. 2019). This is
time. Studies have investigated methods of improving the because there are currently no adequate storage solutions for
efficiency of hydrogen ICEs to make the application of hydro- hydrogen that are inexpensive. According to the US
gen in ICE vehicles feasible for light- and heavy-duty vehicles. Department of Energy (DOE), solar is most likely the only
To supplement the low storage capabilities of hydrogen, some source of renewable energy that could produce sufficient
studies have investigated the use of dual-fuel fossil fuel- hydrogen to develop the hydrogen economy (Edwards et al.
hydrogen ICEs. On the other hand, hydrogen FC vehicles 2008).
offer more potential with the current efficiency of up to Due to the several challenges in hydrogen production and
60%; however, the use of rare-earth metals in different types utilization processes, investigation about development and
of FCs increases the cost and creates a limiting factor on the various characteristics of hydrogen, especially in the transpor-
manufacturability (US Department of Energy 2017a). Certain tation engines application, has become one of the most sig-
types of membranes used in fuel cells are subject to damage nificant research directions. Hence, in this paper, recent
from using less-than-pure quality hydrogen, which shortens developments in hydrogen-based transportation engines with
the lifespan of the fuel cell stack. Studies have been conducted special focus on ICEs and fuel cell vehicles (FCVs) is reviewed
on improving the operation and increasing the efficiency in to evaluate the feasibility of a hydrogen-based transportation
order to improve the durability and lifespan of FCs. system.
A hydrogen-based transportation system would drastically
alter the fuel production industry and introduces several
2. Hydrogen transportation engines
new economic challenges and opportunities (Chen et al.
2019). Two main hydrogen-based technologies have been employed to
Several experimental methods to produce hydrogen power vehicles: hydrogen fuel cell (HFC) (Ehsani et al. 2018),
(hydrogen from wind energy (Nagasawa et al. 2019), solar and hydrogen-fueled internal combustion engine (H2ICE)
energy (Burhan et al. 2017), biomass (Hosseini et al. 2015a), (Boretti 2011). The benefits of hydrogen FCVs are the high
geothermal (Kianfard, Khalilarya, and Jafarmadar 2018), efficiency, the lack of harmful emissions (water vapor is the
nuclear energy (Sorgulu and Dincer 2018), dissociating only emission which is harmless compared to the emissions
water by electrolysis (Dos Santos et al. 2017), fossil fuels created by the fossil fuels combustion, such as nitric oxide,
(Lee, Elgowainy, and Dai 2018a), etc.) have been investigated, nitrogen dioxide, carbon dioxide, and sulfur dioxide), they
but the majority of hydrogen is generated from costly, non- operate quietly, and are modular (Dicks and Rand 2018).
renewable sources (Holladay et al. 2009). A variety of clean/ FCVs use electrochemical reactions to produce electricity
highly efficient methods have been developed to convert the from hydrogen and oxygen. Alternatively, the benefits of
chemical energy of hydrogen to a desirable energy type (fuel H2ICEs are the reliance on a mature industry with a huge
cell (Das et al. 2017), gas turbine (Ditaranto, Li, and Løvås production infrastructure, the ability to offer “flex-fuel” to aid
2015), internal combustion engine (ICE) (Yang et al. 2018), in the transitional period which could aid in the deployment of
etc.) (Hosseini and Wahid 2016). The annual hydrogen pro- the hydrogen infrastructure, lower requirements for hydrogen
duction is estimated to be about 50 million tons; where the compared to HFCs, ultra-low emissions, raised peak and part
share of natural gas (NG), oil, coal, and renewable energy load efficiencies in comparison with conventionally fueled
sources is 48%, 30%, 18% and 4%, respectively (Srinivasan ICEs, and they are not dependent on rare materials (Verhelst
2006). Electrolysis is a production method that can use renew- 2014). FCVs and battery-electric vehicles (BEVs) use rare mate-
able energy, but it is an energy extensive process, making it rials which could limit the spread of these devices. FCs require
not ideal for sustainable use at this time (Hwang 2013). platinum, which is already expensive and will increase in price
Hydrogen is a clean, versatile, and efficient fuel if it is pro- as the demand raises. BEVs use rare earth elements that would
duced from any of the variety of renewable energy sources be difficult to produce in large quantities. It is estimated that
INTERNATIONAL JOURNAL OF GREEN ENERGY 15

FCVs are capable of reducing greenhouse gas (GHG) emissions 3.2. Hydrogen storage tank
by 80% in the US in 2100 compared with that of 1990, and the
There are several levels of hydrogen storage that are required to
country will become independent of gasoline fuel in the trans-
develop a successful hydrogen economy: at production centers,
portation system by the 2100s (Dougherty et al. 2009). An
at filling stations, onboard vehicles, and nationally as a strategic
extensive amount of progress has been made in hydrogen
reserve. The storage of hydrogen is the most difficult challenge
ICE vehicles and hydrogen FCVs in the past century. The
associated with the hydrogen economy (Chang et al. 2016).
current hydrogen-fueled vehicles available on the market and
Before a hydrogen transportation economy can be built, an
some of the most innovative test engines have been compared
appropriate storage system must be developed for hydrogen
to the most environmentally friendly fossil-fueled vehicles
powered vehicles. Due to hydrogen’s extremely low density,
available today in Table 1.
a huge onboard storage tank would be needed to transport the
fuel. To mimic the 400 km range of a standard car, only 8 kg of
hydrogen is required for an ICE or 4 kg of hydrogen for an FC
3. Challenges in hydrogen powered vehicles (Schlapbach and Züttel 2010). The challenge at hand is finding
3.1. Safety of hydrogen vehicles a material for the storage container that fulfills three require-
ments: high hydrogen density, fast release/charge kinetics with
Fuels with low density, high diffusion coefficient, and higher minimum energy barriers to hydrogen release and charge, and
specific heat are safer. The higher specific heat alleviates the reversibility of the release/charge cycle at moderate temperatures
temperature mitigations for a given heat input (Singh et al. (70–100°C) must be compatible with the FCs. The tank material
2015). For a specific fuel, some characteristics like wider must have strong chemical bonds and close atomic packing. The
ignition limits and lower ignition temperature cause the fuel material also needs loose enough atomic packing to assist fast
to become less safe by increasing the limits in which a fire diffusion of gaseous hydrogen between the surface and the bulk.
could occur. Higher emissivity/temperature of the flame and An adequate thermal conductivity of the material is required to
high explosive energy make the fuel less safe because the fire hamper decomposition by the heat released upon hydrating
will be more damaging [8]. Table 2 summarizes the fire (Sharma and Ghoshal 2015). Investigations show that several
hazard properties of gasoline, methane, and hydrogen materials can meet two of the requirements, but none have been
(Veziroğlu and Şahi˙n 2008). found that fulfill all the necessary requirements. Whichever
Hydrogen is very light (~6.9% density of air), 4 times as material is selected must also be cost effective, a practical weight,
diffusive as NG, and 12 times as diffusive as gasoline; hence, have an adequate lifetime, and meet safety requirements
a risk of combustion or explosion is minimal (Sharma and (Hydrogen Fuel: Production, Transport, and Storage, 2008;
Ghoshal 2015). Due to the non-toxicity characteristic of Satyapal et al. 2007). The gravimetric and volumetric density in
hydrogen, its leakage would not damage the environment. a storage tank material is very important in both mobile and
An explosion of hydrogen is very difficult to create, so it is stationary applications of gaseous hydrogen (Atkinson et al.
much more likely that a quick burning fire would result if 2001). Carbon nanotubes have been discovered to be a source
a hydrogen/air mixture experienced a spark (Hawkins and of hydrogen storage, which spurred a massive influx of research
Hughes 2006). A safety advantage of hydrogen is that it blazes devoted to nanostructures (Hirscher et al. 2001). By physio-
with little heat radiation, therefore only things immediately chemical or chemical treatments, the state of hydrogen can be
next to the flame would burn (Alazemi and Andrews 2015). changed and it can be stored in solid or liquid phases (Dalai et al.
The clear flame can also not sear skin at a distance due to its 2014). Various materials such as boron compounds (Fakioğlu,
low thermal radiation. Hydrogen can burn in lower concen- Yürüm, and Nejat Veziroğlu 2004), chemical hydrides (Biniwale
trations which causes safety concerns (Midilli et al. 2005). et al. 2008), carbon-based materials (Xu et al. 2007), Mg-based
The US DOE has set parameters for storage and system alloys (Jurczyk et al. 2008), and metal hydrides (Muthukumar,
safety. For permeation and leakage, the system must fulfill Prakash Maiya, and Murthy 2005; Sakintuna, Lamari-Darkrim,
SAE J2579 for system safety; for toxicity, the system must and Hirscher 2007; Xiao et al. 2008) have been employed in
meet applicable standards; and failure analysis must be con- hydrogen storage systems to achieve the best performance.
ducted and evaluated for the system. The permeation and There are six different methods for storing hydrogen
leakage tests are for the entire storage system, rather than (Züttel 2004):
each component or storage material. The toxicity criteria are
regulated by government standards such as the EPA’s Toxic
Substances Control Act Chemical Substance Inventory (TSCA ● Liquid hydrogen in cryogenic tanks (at 21 K)
Inventory) and the US Department of Labor Occupational ● Absorbed on interstitial sites in a host metal (at ambient
Safety and Health Administration (OHSHA). The safety temperature/pressure)
instructions cover the transport system, manufacture, certifi- ● Chemically bonded in covalent and ionic compounds (at
cation and operation of vehicles, fuel dispensing, and end of ambient pressure)
life issues, which each must comply with applicable federal, ● High-pressure gas cylinders (up to 800 bar)
state, and local standards. The onboard storage systems ● Adsorbed hydrogen on materials with a large specific
should comply with SAE J2579 and the United Nations surface area (at T < 100 K)
Global Technical Regulation No. 13 and the applicable stan- ● Oxidation of reactive metals (i.e. Li, Na, Mg, Al, Zn) in
dards for the country that the vehicle is deployed. water.
16

Table 1. Comparisons of the most important engine characteristics for current experimental and developed engine technologies.
Engine 1 Engine 2 Engine 3 Engine 4
Gasoline only Diesel only Fuel Cell Gasoline-H2 dual-fuel Engine 5 Engine 6 Engine 7
Characteristic [43–45] [43,44] [46–48] [49] Diesel-H2 dual-fuel [50] Hydrogen only [29] Fuel Cell [1,51]
Engine Make/Model GM 1.4 L Ecotec Ford 3.0L Power Stroke 113 kW AC Synchronous MeM3-245 (modified) Kirloskar, Model TV1 Jaling JH600 (modified) Hyundai ix35
DOHC F-150 (PEMFC) (modified) (modified)
S. E. HOSSEINI AND B. BUTLER

Fuel Type Gasoline multi-PFI Diesel DI CH2 gas Gasoline DI; HHO Diesel DI, CH2 H2 gas Spaced dual CH2 gas
gasd gas (max 20%) PFI injection
(5.9% H2) DI
Fuel Storage: HPDEa HPDEa Type-IV CFc – CH2 at 130 bar- CH2- CH2 at 700 bar
• Method 34.1 98 122.4 142
• Tank volume (dm3)
Classification DE DE DE EX EX EX EX
• Experimental (EX) or Developed
(DE)
Orientation; Number of Cylinders/ In-line; 4-cylinder- V-6, 60 - -370 In-line; – Single cylinder- Single cylinder- -440
Number of cells per stack
Displacement Volume (dm3) 1.399 2.99 – 1.091 0.661 – –
Compression Ratio 10.6:1 16.0:1 – 9.5:1 17.5:1 9.7:1 –
Bore  Stroke (mm) 74  81.3 84  90 – 72  67 87.5  110 94  85 –
Power output (kW) 73 186 114 37.5 5.2 30 100
Torque (N-m) 127 596 335 78.5 30 51 300
Cost: 14,170 41,687 58,500 – – – –
• Average vehicle cost ($) 1,050 1,800 3,150
• Annual fuel cost ($/year for 15,000
miles)
Availability 114,555 189,290 4,644 – – – –
• # of vehicles sold the US from (approx.)
2015–2018
Efficiency: 33 mpg– 25 mpg– 66 mi/kg– -33.3- –27 –35–41 (at 49 mi/kg–
• Fuel economy 1000–6000 rpm)
• Brake Thermal Efficiency (%)
• Indicated Thermal Efficiency (%)
Driving Range (miles/1 full tank) 297 650 312 – – – 66–398
Environmental 8 4 10 – –; 35 –; 0 10
• GHG Ratingb 273; - 412; - 0; 0 0; 0
• CO2 Emissions (gram/mi; ppm)
a
HDPE is high-density polyethylene.
b
The US DOE Fuel Economy Guide ranks vehicles on a scale of 1–10, 1 being the worst and 10 being the best in terms of GHG emissions.
c
CF is carbon fiber reinforced.
d
Oxyhydrogen (HHO) is a hydrogen-containing gas.
INTERNATIONAL JOURNAL OF GREEN ENERGY 17

Table 2. Fire hazard of various transportation fuels (Veziroğlu and Şahi˙n 2008). for well-to-tank efficiency, well-to-engine efficiency, emis-
Property Gasoline Methane Hydrogen sions on a per kilogram of hydrogen basis and on a per mile
Densitya (kg/m3) 4.4 0.65 0.084 basis, refueling cost, and ownership cost, but not initial cost
Diffusion coefficient in air (cm2/s) 0.05 0.16 0.61
Specific heat at constant pressurea (J/gK) 1.2 2.22 14.89
and onboard efficiency.
Ignition limits in air (vol %) 1.0–7.6 5.3–15.0 4.0–75.0 Paster et al. (Paster et al. 2011) studied GHG emission, energy
Ignition energy in air (mJ) 0.24 0.29 0.02 efficiency, the well-to-wheel costs and performance of five hydro-
Ignition temperature (°C) 228–471 540 585
Flame temperature in air (°C) 2197 1875 2045 gen storage techniques. The five systems were cold, compressed
Explosion energyb (gTNT/kJ) 0.25 0.19 0.17 gaseous hydrogen at 500 bar and 200 K; cryo-compressed liquid
Flame emissivity (%) 34–43 25–33 17–25
a
hydrogen (CcH2) at 275 bar and 30 K; compressed gas hydrogen
At normal temperature and pressure.
b
Theoretical maximum; actual 10% of theoretical.
at 350 bar; compressed gas hydrogen at 700 bar; and metal
hydride sorbent metal-organic frame work (MOF 177) at 250
bar and 100 K. From this study, the most attractive storage system
In the gaseous state, hydrogen has extremely low density was determined to be the CcH2 system due to its low price since it
(0.09 kg/NA m3), and very low boiling point (20.2 K); how- runs at lower pressures than the compressed gas systems, used
ever, in liquid phase, the density of hydrogen is exceptionally a smaller tank, and can fulfill the DOE’s volumetric efficiency goal
high (70.9 kg/NA m3) (Balat 2008). These properties make even though this system had the highest GHG emissions, hydro-
storing hydrogen very complicated in mobile application. The gen cost, and energy use. For all five storage methods, the GHG
current method for storing hydrogen in transportation emissions are largely dictated by the method used to produce the
engines is as a liquid in cryogenic reservoirs (at 20 K) or as hydrogen. The systems that utilized liquid hydrogen required
a gas in high-pressure cylinders (at up to 700 bar). Neither of significantly more energy to convert the gaseous hydrogen into
these two methods are exceptionally efficient. Compressing a liquid state, thus these systems also have higher GHG emissions.
the gaseous hydrogen uses up to 20% and liquefying hydrogen Refueling compressed gaseous hydrogen tanks takes no
requires up to 40% of the energy content. Solid-phase hydro- more than 5 min, which is comparable to gasoline. DOE
gen storage is compatible with electrolyzers and FCs. Fuel Cell Technologies Office (FCTO) is currently deploying
A porous material can absorb hydrogen molecules, but gen- safe, low cost and high-performance storage systems that
erally, an attractive capacity can only be obtained at cryogenic support a driving range of more than 300 miles (US
temperatures. The most commonly used material for solid- Department of Energy 2017b). The technical system targets
state hydrogen storage is interstitial metal hydride. Metals are that FCTO has set for onboard hydrogen storage systems in
the only reversible solid-phase hydrogen storage that have light-duty FCVs is shown below in Table 3.
been commercialized, primarily for stationary applications. By 2020, there will be 100 hydrogen refueling stations
The available tanks for FCVs to the public utilize com- constructed in California. The targets are set to assure the
pressed hydrogen carbon-fiber Type IV tanks that store about initial and operational costs of the storage system is compar-
5%wt when pressurized at a global standard of 700 bar. Bus able to the incumbent technology by 2020.
fuel tanks are generally 350 bar composite tanks since energy The most favorable method of hydrogen storage is physical
density is less important in larger vehicles. Another type of containment, specifically compressed tanks, because they are
compressed hydrogen tank is the composite Type III tanks readily available (Jorgensen 2011). The fill time of these tanks
(Lee et al. 2018b). The tanks are composed of an aluminum is competitive with fossil fuels when the hydrogen is pre-
liner wrapped in epoxy resin-coated, aerospace-grade carbon cooled (Maus et al. 2008). Cost is the main setback for the
fiber. The aluminum liner does not have any seams, is more wide scale use of compressed hydrogen (CH2) tanks because
tolerant to impacts than traditional gas tanks, is resistant to the material and assembly are expensive. Another potential
heat, can be filled in all weather conditions, fills as quickly as setback is the public’s concern of using such high pressure (70
a gasoline tank, has a burst safety factor of 3.0, and has a built- MPa) storage tanks in vehicles. An alternative to traditional
in leak-before-burst fatigue failure design. Liquid hydrogen is CH2 tanks that is still being researched is a tank with an
compatible with electrolyzers and FCs, but the complexity and internal skeleton, which is a complex design of struts in
cost of a cryogenic liquefier make it impractical for small-scale tension within the tank to resist the forces of the compressed
use; therefore, storing hydrogen in liquid form at low pres- hydrogen (Aceves et al. 2006). Liquid hydrogen (LH2) storage
sures is commonly employed for bulk hydrogen storage and has improved significantly, achieving the best specific mass
transport (Zhang et al. 2005). Currently, limited development (15%) of other onboard hydrogen storage systems (Fieseler
has been made for onboard liquid hydrogen fuel tanks for and Allidiers 2006). Energy efficiency is decreased when
automotive use (Salvi and Subramanian 2015). The least liquid hydrogen is used. To widely develop LH2 systems, the
expensive technique for creating high-performance composite boil off property should be improved. A promising alternative
fuel tanks is filament winding (Vasiliev and Morozov 2001). design is a cryo-compressed tank in which hydrogen is highly
Cold (sub-ambient but higher than 150 K) or cryogenic compressed at cryogenic temperatures. More studies must be
(below 150 K) storage methods are being investigated because done on this method to determine long-term durability and
higher fuel density can be achieved at reduced temperatures public acceptance of the system. Hydride storage systems
(“Physical Hydrogen Storage | Department of Energy,” n.d.). require substantial research and progress to meet the require-
Ahluwalia et al. (Ahluwalia, Hua, and Peng 2012) claimed that ments for large-scale use. The most well studied hydride is
the cryo-compressed storage system is the best storage NaAlH4, but it does not have the capacity necessary for
method at this point because it met all the storage targets application. Based on the results of the few studies, it is
18 S. E. HOSSEINI AND B. BUTLER

Table 3. Technical system targets: On-board hydrogen storage for light-duty FCVs (US Department of Energy 2017b).
Storage Parameter Units 2020 2025 Ultimate
System Gravimetric Capacity: kWh/kg 1.5 1.8 2.2
Usable, specific-energy from H2 (kgH2/kg (0.045) (0.055) (0.065)
(net useful energy/max system mass) system)
System Volumetric Capacity: kWh/L 1.0 1.3 1.7
Useable energy density from H2 (kgH2/L (0.030) (0.040) (0.050)
(net useful energy/max system mass) system)
Storage System Cost: $/kWh net 10 9 8
($/kg H2) 333 300 266
Durability/Operability:
• Operating ambient temperature °C −40/60 (sun) −40/60 (sun) −40/60 (sun)
• Min/max delivery temperature °C -40/85 -40/85 -40/85
• Operational cycle life (1/4 tank to full) Cycles 1500 1500 1500
• Min delivery pressure from storage system bar (abs) 5 5 5
• Max Delivery pressure from storage system bar (abs) 12 12 12
• Onboard efficiency % 90 90 90
• “Well” to powerplant efficiency % 60 60 60
Charging/Discharging Rates:
• System fill time min 3–5 3–5 3–5
• Minimum full flow rate (e.g.,1.6 g/s target for 80kW rated fuel cell power) (g/s)/kW 0.02 0.02 0.02
• Average flow rate (g/s)/kW 0.004 0.004 0.004
• Start time to full flow (20 °C) $ 5 5 5
• Start time to full flow (−20 °C) $ 15 15 15
• Transient response at operating temperature 10%-90% and 90%-0% (based on full flow rate) $ 0.75 0.75 0.75
Fuel quality (H2 from storage) % H2 Meet or exceed SAE J2719
Dormancy:
• Dormancy time target (Minimum unit first release from initial 95% useable capacity) Days 7 10 14
• Boil-off loss target (max reduction from initial 95% useable capacity after 30 days) % 10 10 10
Environmental Health& Safety:
• Permeation & leakage – • Meet or exceed SAE J2579 for system safety
• Toxicity – • Meet or exceed applicable standards
• Safety – • Conduct and evaluate failure analysis

indicated that tanks with no internal heat transfer elements volume density than LH2 (Zhou 2005). Figure 1 demonstrates
could be constructed based on the moderate heat of absorp- a comparison between different onboard hydrogen storage
tion of hydrogen on surfaces (Paggiaro et al. 2010). systems with respect to volume-mass of fuel sufficient for
Cold hydrogen must be used in this system to double as 418 km of vehicle operation. According to this figure, the
the fuel and the coolant. High surface area, low-density pow- storage tank mass of compressed hydrogen is very high,
ders are used in absorption storage systems. The storage which limits the suitability of this method; however, the
media must be compressed into pellets or pucks to increase stored mass of metal hydrides is low, while the storage system
the amount of media in the tank, but this decreases the volume is high (xPetkov, Veziroǧlu, and Of n.d.).
specific hydrogen capacity of the media. The system mass
and cost are reduced by decreasing the system’s volume and
compressing the media, which makes up for the lost capacity. 3.3. Hydrogen transport and delivery
Hydrogen stored via reactive chemicals usually involves bor- A successful hydrogen-based transportation system needs
ohydride hydrolysis which is a method of fast hydrogen infrastructure to deliver hydrogen from production plants
production. This method for use on transportation engines
is limited by the high level of heat generation during the
reaction, high energy needed to recycle boron oxide and
hydroxide by products, and the severe wear on parts in con-
tact with the borohydride solution. Progress has been made in
organic liquid carriers which have lower temperature reac-
tions and higher hydrogen capacity than other chemical sto-
rage systems (Hovland et al. 2003).
Hydrogen storage requires extensive research and a major
technological breakthrough to develop alternative methods to
compressed and liquefied hydrogen (Aasadnia and
Mehrpooya 2018). There are various types of materials for
solid-state hydrogen storage that have higher energy density
than liquid hydrogen, but extensive investigations are
required to ameliorate the materials hydrogen desorption
and absorption characteristics. In future, the widely used
hydrogen storage method could be solid materials that either
chemically bind or physically absorb hydrogen at a greater Figure 1. On-board hydrogen storage with respect to volume-mass (Petkov,
Veziroǧlu, and Of n.d).
INTERNATIONAL JOURNAL OF GREEN ENERGY 19

to refueling stations (Grüger et al. 2018). The potential ICEs. Nevertheless, innovative techniques have been proposed
hydrogen delivery methods are compressed gas pipelines, to improve ICEs efficiency and emission characteristics to
cryogenic liquid trucks, and compressed tube trailers (Yang meet the ever-rising challenges of environmental crisis and
and Ogden 2007). Any combination of these methods could petroleum demand (Yan, Xu, and Wang 2018).
be utilized at varying stages of the hydrogen automotive
transportation. Delivery distance and the number of stations
are the crucial factors affecting the cost of delivering hydro-
4.1. Hydrogen-only ICEs
gen (Yang, Nicholas, and Ogden 2006). Pipelines could be
used for transporting hydrogen farther distances, while Since the octane number of hydrogen is higher than that of
trucks carry smaller amounts shorter distances. Due to the gasoline fuel, it can be considered as a serious candidate to use
low density of hydrogen, transportation of liquid or pressur- in IC transportation engines. Some hydrogen properties, such
ized hydrogen is inefficient (Lasn and Echtermeyer 2014). as its higher diffusivity compared to gasoline and methane,
High-purity stainless steel piping with a maximum hardness lower ignition energy requirement, and higher flame velocity
of 80 HRB is preferred for pipelines (Cadwallader and are desirable for spark ignition (SI) engines (Luo and Sun
Herring 1999). The lowest cost choice depends upon market 2016). Since hydrogen flame speed is approximately five times
and specific geographical characteristics. For the past 50 higher than gasoline and methane and ten-times higher than
years, pipelines have been used to transport hydrogen. diesel, hydrogen-fueled SI engines can be run with lower
Currently, there are approximately 16,000 km of hydrogen cyclic variations (Bradley et al. 2007).
pipelines throughout the world that transfer hydrogen to Hydrogen in SI engines is used in one of the following
chemical plants and refineries (Ball and Wietschel 2009). ways (Acar and Dincer 2018):
Although the capital cost of pipelines is high, their operation
cost is low especially for compressor power. Liquid hydrogen ● Manifold induction: Low-temperature hydrogen is
could be transported on ships, railcars or trucks, but its injected to the manifold via a passage which is con-
operating cost is very high because of the electricity required trolled by a valve.
for liquefaction (about 30–60% of the total liquefaction ● Direct introduction: A cryogenic cylinder is used to
costs), which may leave a considerable carbon footprint. store hydrogen. A pump sends the liquid hydrogen to
Distance is an important factor to select the hydrogen deliv- a heat exchanger to evaporate it and then cold hydrogen
ery method. Investments in the construction of pipelines of gas is injected into the engine. By using cold hydrogen
high-quality materials must be made due to the specific gas, pre-ignition is avoided and NOx formation in the
physical and chemical characteristics of hydrogen (Ball and combustion process is reduced.
Weeda 2015). ● Hydrogen addition to gasoline: In this method,
a hydrogen-gasoline mixture is introduced to the ICE
where the compressed mixture is ignited by a spark.
4. Hydrogen-fueled internal combustion engines
The transportation system is heavily reliant on ICEs, which Hydrogen also can be employed in a compression ignition
consume huge amounts of liquid fossil fuels in the form of (CI) engine. The generated power from a CI engine has been
diesel and gasoline. The energy conversion of petroleum fuel found to be twice that of the same engine worked in the
in ICEs via combustion releases various pollutants such as premixed system (Ganesan 2012). In hydrogen-based CI
carbon monoxide (CO), nitric oxide (NOx), unburned hydro- motors, an injector is used to inject high-pressure hydrogen
carbons (UHCs), particulate matter (PM) and GHGs (Reitz into the cylinder (Naber and Siebers 1998). Therefore, not
2013). Compared to gasoline engines, the high energy content only the design of engine structure is important, but the
of H2ICEs combined with their physical and chemical proper- design of the injector is crucial because the injection nozzle
ties allow these engines to operate more effectively on exces- controls how the pressurized hydrogen is injected into the
sively lean mixtures. Hydrogen has greater diffusivity, much system (Gomes Antunes, Mikalsen, and Roskilly 2009).
lower ignition energy (0.02 MJ), and higher ignition tempera- Hydrogen supply in CI engines has illustrated significant
ture compared to the other fuels (Schlapbach and Züttel reductions in CO2, CO, HC and smoke levels that under
2010). Hydrogen possesses greater dispersion in air than gaso- optimum circumstances can reach as much as over 50%. An
line, which is majorly accredited to the ease constitution of apparent effect of using high amounts of hydrogen in IC
a uniform air/fuel mixture, and the rapid dispersion of hydro- engines (high load conditions) is a sharp rise in heat release
gen when a leak develops. Because of the low density of rate (and consequently the increased in-cylinder temperatures
hydrogen, two main issues arise when it is used in ICEs. and high rates of NOx formation) and brake thermal effi-
First, to give the vehicle the ability to drive an adequate ciency (Dimitriou and Tsujimura 2017).
range, a large storage volume is required. Second, the power Szwaja and Grab-Rogalinski (Szwaja and Grab-Rogalinski
output is mitigated by the energy density of the hydrogen/air 2009) used pure hydrogen in homogeneous charge compres-
mixture (Balat 2008). sion ignition (HCCI) engine. To achieve hydrogen auto-
In recent decades, many investigations have been per- ignition under the HCCI mode, a compression ratio of at
formed to find adequate substitutions for ICEs in transporta- least 16 was used. It was found that using a stoichiometric
tion systems; however, none of those efforts have yet hydrogen–air mixture in the HCCI mode generates an extre-
succeeded in challenging the dominant role of fossil-fueled mely high combustion knock. Therefore, various methods
20 S. E. HOSSEINI AND B. BUTLER

such as leaning combustible mixture or EGR should be point set at 2 bar brake mean effective pressure (bmep) at
employed to reduce the knock effect. 1500 rpm, and “Tier II Bin 5” emissions (which limit NOx
In the pressure-boosted H2ICE structure, a hydrogen gas emissions to 0.07 g/mile) (FreedomCAR and Fuel Partnership
compression chamber is used to raise the intake-air/hydrogen Plan -March 2006). The National Traffic Safety &
pressure to maximize engine power density of ICEs. In this Environment Laboratory (NTSEL) project aimed a peak
condition, the hydrogen pressure is increased to achieve power output of 100 kW from a 4-cylinder naturally aspirated
hydrogen volumetric efficiencies closer to the gasoline fuel engine with less than 0.05 g/kWh of NOx on a JE05 transient
(White, Steeper, and Lutz 2006). Using liquid hydrogen is emission testing cycle.
another method which does not require significant changes Sopena et al. (Sopena et al. 2010) modified an SI gasoline-
in conventional ICEs. In this system, liquefied hydrogen is fueled ICE of a transportation vehicle (suitable for both inter-
injected to an expansion chamber to convert to a cold hydro- urban and city) to operate on hydrogen fuel only. The most
gen gas and ultimately it is conducted to the combustion important modifications were performed on the electronic
chamber. Using cold hydrogen decreases NOx emission as management unit, gas injectors, inlet manifold, and oil radia-
well as pre-ignition (Gurz et al. 2017). Figure 2 shows these tor. Verhelst and Sierens (Verhelst and Sierens 2001)
two types of H2ICEs. upgraded a GM/Crusader V8 engine from fossil fuels to
Currently, direct injection (DI) and PFI are the injection hydrogen only to investigate its capability in public transpor-
methods being investigated for H2ICEs. DI offers high effi- tation bus. The specifications of a hydrogen port fuel injection
ciencies and controlled emissions, but the durability of DI (PFI) GM 454 spark ignition test engine are shown in Table 4.
injectors is low. Injection needs high pressure, which further The engine was equipped with a port fuel injection system,
limits the storage options. Hydrogen could be stored in cryo- which supplied hydrogen at 3 bar. The compressed hydrogen
genic tanks in the liquid state and injection pressure are was stored in steel bottles at 200 bar. Since backfire is an
generated onboard, or compressed hydrogen is stored, which important issue in hydrogen-fueled engines (Dhyani and
limits the tank capacity and onboard compression would Subramanian 2018), the authors claimed that this problem
negate the efficiency benefits of DI (Peschka 1998). can be avoided by using a lean mixture. Limiting the air–
Numerous labs and organizations have been conducting fuel ratio caused the power output of the engine to decrease.
research in direct injection for hydrogen fuels. The DOE The minimum 90 kW power output and 300 N  m torque
program targeted demonstrating a peak brake thermal effi- required for a city bus were reached. The necessity of smaller
ciency (BTE) of 45%, a part-load BTE of 31% with part load spark plug gaps, the choice of injection pressure, the

Figure 2. Schematic of (a) Pressure-boosted H2ICE (b) Liquid hydrogen internal combustion engine (Gurz et al. 2017).
INTERNATIONAL JOURNAL OF GREEN ENERGY 21

Table 4. Specifications for a hydrogen PFI GM 454 spark ignition test engine remaining constant thereafter. The inevitable backfiring was
(Verhelst and Sierens 2001).
controlled by slowing the IVO and by applying lean boosting.
Engine type GM 454 spark ignition From Eq (1), the gas temperature; Tg , in the engine is propor-
Fuel type Hydrogen PFI
Number of cylinders 8 tional to the supplied energy and inversely proportional to the
Bore  stroke 107.95  101.60 mm specific heat at constant volume and the mass of fresh
Displacement volume 7.4 dm3 air (mi ).
Compression ratio 8.5:1
Engine speed 750–4000 rpm
Ignition sequence 18436572 !1
Intake valve timing IVO 42 C A before TDC; IVC 95 C A after BDC X
n
mk
Exhaust valve timing EVO 93 C A before BDC; EVC 62 C A after TDC Tg ¼ T1  ε n1
þ Q mi  Cvk (1)
k¼1
mi

deterioration of the lubricating oil, and the calibration of the Where T1 is the temperature at position one,Q is energy
oxygen sensors for use in extremely low mixtures in hydrogen supplied by the combustion process, mi is the mass of fresh
ICEs were analyzed. Additionally, the advantages of using lean air and Cv is the specific heat of the species.
mixtures to operate at low-load conditions without using Due to hydrogen’s high specific heat, the maximum tem-
a throttle valve was analyzed. The disadvantage of removing perature mitigation rate from lean boosting was greater than
the throttle valve was an increased hydrogen concentration in other fuels. Hydrogen can achieve stable combustion at ultra-
lean equivalence ratios (ϕ ¼ 0:2), which allows for nearly NOx
the exhaust gas when the engine was idling, which led to the
-free emissions when operated at power outputs equivalent to
undesirable result of increased fuel consumption.
Lee et al. (Lee et al. 2014) experimentally assessed the gasoline-level outputs. The experiment was successful with the
potential of simultaneously obtaining high output without single cylinder engine, but further detailed analysis is neces-
backfire, like a gasoline engine, by using lean boosting in sary to achieve similar results from a multi-cylinder engine,
a single cylinder hydrogen engine with Mechanical turbocharger, and at other various operating conditions.
Continuous Variable Valve Timing (MCVVT). The specifica- Bai-gang et al. (Bai-gang, Hua-yu, and Fu-shui 2014) inves-
tions of the engine used in the experiment are shown in tigated various characteristics of the combustion duration in
Table 5. The MCVVT is a timing belt that continuously varies hydrogen H2ICE through engine experimentation and analy-
the opening and closing periods of the intake and exhaust sis of the physical properties of hydrogen in comparison to
valve during ignition. In the test engine, a low-pressure sole- gasoline. Graphing the pressure rise rate versus the crank
noid injector was used to inject gaseous hydrogen. angle at 4000 rpm showed a proportional relationship
Through experimentation, the equivalence ratio was between the richness of the mixture, the peak cylinder pres-
increased at 0.1 increments to observe the occurrence of sure and the increasing pressure rate, which are dependent on
backfire and locate the backfire limit. The amount of residual combustion speed. Graphing pressure versus crank angle
gases present in the cylinder affects the likelihood of backfire shows that with the augmentation of equivalence ratio, the
occurring at certain cylinder wall temperatures and equiva- heat release rate increases while the combustion duration
lence ratios. The amount of exhaust gases is dependent on the decreases. The combustion duration tends to the same value
amount of residual gases, thus the change in exhaust pressure as the engine speed increases regardless of mixture concentra-
is related to the change in residual gases. The backfire limit tion as long as the equivalence ratio is above 0.6.
was observed to not be significantly impacted by the exhaust Port fuel injection is another method of fuel injection that
pressure, as well as the exhaust valve closing (EVC) timing. is currently being heavily reviewed due to its ability to pro-
This indicates that the inlet valve opening (IVO) timing duce high part load efficiency and extremely low emissions;
impacts backfiring more significantly than EVC timing. however, it has a low power output. Sun et al. (Sun, Zhang,
Through experimentation, it was determined that backfiring and Liu 2013) studied how the covariance of indicated mean
occurred consistently beyond stoichiometric combustion, effective pressure (COVimep) effected the cycle variations in
above ϕ ¼ 1:3 at 1000 rpm when the intake valve timing a PFI hydrogen-fueled ICE. The specifications for the PFI test
was IVO (intake valve opening) BTDC 10  C A due to engine are shown in Table 6. It was verified that COVimep is
a rich air–fuel mixture. The equivalence ratio where the back- the most appropriate parameter for assessing cycle variations
fire limit occurred decreased as the engine speed increased, in H2ICEs. Through experimentation, it was found that 150
cycles were enough to evaluate the cycle variations in H2ICEs.
leveling out at ϕ ¼ 0:7 at approximately 1600 rpm and
When the COVimep was less than 5% and the fuel–air ratio
was greater than 0.2, the COVimep decreased as the fuel–air
Table 5. Specifications for a single cylinder hydrogen test engine with mechan-
ical continuous variable valve timing (Lee et al. 2014).
Table 6. Specifications for employed hydrogen-fueled ICE to evaluate how the
Fuel type Hydrogen DI
covariance of indicated mean effective pressure (COVimep) effected the cycle
Valve mechanism Double overhead cam (DOHC) variations (Sun, Zhang, and Liu 2013).
Bore  stroke 86  86 mm
Compression ratio 10.5 Fuel type Hydrogen PFI
Displacement volume 0.4996 dm3 Number of cylinders 4
Valve timing control MCVVT system Bore  stroke 86  86 mm
Duration of IVO 257 C A Compression ratio 10
Duration of EVO 224 C A Length of connecting rod 142.8 mm
Range of valve timing 50 C A Displacement volume 1.998 dm3
22 S. E. HOSSEINI AND B. BUTLER

ratio increased at 1000–5000 rpm. The engine speed had no addition and with HHO gas addition. The effects of operating
significant impact on the COVimep as the variation trend of the engine with 5.9% additive HHO gas are decreased fuel
COVimep with fuel–air ratio tended to be the same at differ- consumption (gasoline) from 0.57 kg/h to 0.49 kg/h, a 14%
ent engine speeds of the H2ICE. For all ignition advance decrease. The CO concentration in the exhaust gases
angles, the COVimep decreased as fuel–air ratio increased. decreased from 1.12% to 0.65%. The UHC concentration
With a rich mixture, the effect of ignition advance angle on decreased from 262 ppm without HHO gas addition to 225
COVimep lessened, and gradually varied with ignition ppm with HHO gas addition. The NOx concentration
advance angle, which proves that ignition advance angle decreased as well from 48 ppm to 42 ppm while in idle
does not affect COVimep as significantly as fuel–air ratio mode; however, when the engine was operating in a low-
does. At less than 20% throttle, COVimep quickly decreased load mode the NOx concentration increased from 1290 ppm
as throttle position increased. No notable changes in to 1360 ppm. Adding HHO to the combustion process causes
COVimep were observed with larger throttle positions. The the engine cylinder temperature to increase, thus NOx pro-
hydrogen injection process significantly affected COVimep duction is increased, which is not a desirable effect. Overall,
when the engine was at idle, but minimal affects were the indicated engine efficiency improved by 6.7% with HHO
observed at high speed conditions. addition and the indicated power increased by 2.8%. Using
Wang et al. (Wang et al. 2017) reported that nozzle posi- hydrogen or HHO gas addition in diesel engines, especially
tion does not have a significant impact on the uniformity of biodiesel engines, aids to raise the lower heating value (LHV).
the hydrogen–air mixture in an H2ICEs; however, a larger Hydrogen has a high LHV compared to diesel and biodiesel,
distance between the inlet valve and the nozzle, increased the so when it is used as an additive in a diesel or biodiesel
probability that backfiring would occur. The closest position engine, the engine performance increases (Arat 2018).
to the inlet valve would be the optimal nozzle position. Although adding hydrogen to the liquid/gas fossil fuels has
Due to wide flammability range of hydrogen and its low demonstrated several benefits, performance improvement of
ignition energy, fast combustion of hydrogen–air mixture in ICEs is not guaranteed by simply blending hydrogen with
ICEs is unavoidable; therefore, undesired backfiring and pre- fossil fuels. Several design factors and operation parameters
ignition should be controlled (Duan, Liu, and Sun 2014). should be optimized to achieve the desirable hydrogen/fuel
Engine malfunctions like sudden increases in pressure, high blend. Reduction of combustion duration and augmentation
engine temperature, acoustic oscillations, and high waste heat of in-cycle temperature in ICEs are the main consequences of
release are the results of pre-ignition (Ferguson and adding hydrogen to the conventional fuels; therefore,
Kirkpatrick n.d.). Moreover, pre-ignition reduces the peak a complete combustion with higher efficiency and lower CO
power output of the system and consequently decreases the and UHCs emissions is expected. However, due to the high
efficiencies of H2ICEs (Das 2016). combustion temperature in this condition, higher rate of NOx
formation is unavoidable. Consequently, many research inves-
tigations have been implemented to determine the optimal
5. Mixing hydrogen with conventional fuels in ICEs
condition of ICEs when hydrogen is added to the conven-
Utilization of hydrogen fuel in ICEs has recently been inves- tional fuel (Ma et al. 2009; Moreno et al. 2012).
tigated, which has presented several practical barriers such as Yu et al. (Yu et al. 2016) studied combustion variations of
hydrogen production, storage and fueling infrastructures that a four-cylinder gasoline direct injection spark ignition (DISI)
are preventing the fast development of this technology. engine under lean burn conditions (Table 7). The engine was
Therefore, at the current step, using hydrogen as an additive modified from gasoline to a dual-fuel engine with gasoline
to hydrocarbon fuels in ICEs is a method that can instigate PFI and hydrogen DI for the tests. The impacts of hydrogen
the use of hydrogen in transportation engines (Juste and fraction of 10% with different amounts of excess air ratio and
Benavides 2008; Tartakovsky and Sheintuch 2018). throttle positions were experimentally observed. A self-
Internal combustion engines do not require pure hydrogen developed hydrogen electric control unit (HECU) was
gas to achieve power generation like fuel cells do; therefore, employed to regulate the duration of hydrogen injection
oxyhydrogen gas can be used as an additional fuel type to the into the cylinder. To adjust the amount of air/fuel mixture
combustion process. Oxyhydrogen (HHO) gas in an effective and the excess air ratio, a throttle controlled by a step motor
additive in fossil fuel combustion because it has only two was used. It was reported that the coefficient of variation
combustible atoms, whereas hydrocarbon fuels consist of (COV) at indicated mean effective pressure decreases initially,
thousands of large carbohydrate molecules (EL-Kassaby then increases afterward with the retardation of ignition
et al. 2016). HHO gas has been observed to increase the
thermal efficiency of the engine as well as reduce the specific
fuel consumption. Another benefit to introducing HHO gas to Table 7. Specifications of a Dual-fuel (gasoline PFI, hydrogen DI) engine test (Yu
the combustion process is the decrease of unburned hydro- et al. 2016).
carbons in the exhaust gases. In a study conducted by Fuel type Dual-fuel: gasoline PFI, hydrogen DI
Gutarevych et al. (Gutarevych et al. 2018) the effects of adding Number of cylinders 4
HHO gas to a gasoline-powered MeM3-245 engine operating Displacement volume 1.798 dm3
Bore  stroke 82.5  84.2 mm
in the idle mode were investigated. The fuel consumption, CO Compression ratio 9.6:1
emissions, UHC emissions, NOx, excess air, and engine effi- Rated power/speed 118 kW/(50008 rpm–62008 rpm)
ciency were observed when the engine ran without HHO gas Rated torque/speed 250 N m/(15008 rpm–42008 rpm)
INTERNATIONAL JOURNAL OF GREEN ENERGY 23

timing at different throttle positions and excess air ratio. of hydrogen addition lead to increased thermal efficiency,
Thus, it is proven that a minimum cycle-by-cycle variations mean effective pressure and combustion speed. The highest
(MCV) ignition timing for various throttle position and thermal efficiency was obtained at 1.2 excessive air ratio. As
excess air ratio exists. The second conclusion reached was the hydrogen fraction increased at a certain excess air coeffi-
that the maximum rate of pressure rise increases, the peak cient and throttle opening, the development of flame and
cylinder pressure increases, and the cycle-by-cycle variations combustion durations decreased while the maximum pressure
mitigate when hydrogen is added to the engine operating at rise rate, maximum mean temperature, maximum heat release
MCV ignition timing. When hydrogen is introduced to the rate and the maximum cylinder pressure increased. Under
mixture, a strong correlation between peak cylinder pressure, this circumstance, as the hydrogen fraction addition
maximum rate of pressure rise, and the corresponding crank increased, the CO and HC emissions decreased, but the NOx
angle, which weakens as the excess air ratio increases. The formation increased as a result of the increased mean tem-
combustion stability is kept down by the increase of excess air perature. The volumetric efficiency did not decrease by using
ratio, but the cycle-by-cycle variations reduce by enlarging the the hydrogen DI and gasoline port injection. With the given
throttle opening. Lastly, hydrogen addition extended the system, the addition of hydrogen allowed the engine to have
engine lean burn limit, which indicated that the addition of stable combustion at 1.5 excessive air ratio. The thermal
hydrogen by DI enhanced the stable combustion for the efficiency of the system was increased by the addition of
reduction of cycle-by-cycle variations. hydrogen. The similar results for pollutants formation were
Ezzat and Dincer (Ezzat and Dincer 2018) proposed a novel reported by Kim et al. (Kim et al. 2017) when they experi-
carbon-free ammonia-hydrogen fuel ICEV and claimed that the mentally ran an in-line four-cylinder 2.0 L T-GDI gasoline
overall energy and exergy efficiencies of the system are 31.1% engine with the specifications denoted in Table 9.
and 28.94%, respectively. Kamil and Rahman (Kamil and To inject hydrogen into a diesel power generator, Oliveira
Rahman 2015) evaluated the performance of an SI engine et al. (de Oliveira et al. 2013) tested an electronic control
using methane–hydrogen and gasoline-hydrogen blends. It was system using a multipoint gas fuel injection rail with an
stipulated that using methane–hydrogen blend indicates better electronic control unit (ECU), a speed sensor, and injection
results compared to the gasoline–hydrogen blends. The authors valves. The injector was designed to operate a dual fuel (die-
concluded that the benefits of hydrogen addition are signifi- sel/hydrogen) system. The engine and generator specifications
cantly stronger than the limitations. are shown in Table 10. The generator used was a 3-phase
According to Tsujimura et al. (Tsujimura and Suzuki 2017) generator with a 55 kVA power rating and 60 Hz frequency.
tests (Table 8), as the hydrogen fraction increases up to 50% The system was tested under eight different conditions at 5%,
under higher engine load operations, pre-ignition occurs. 10%, 15%, and 20% hydrogen concentration at different
Under this circumstance, the temperature of cylinder head is power and pressures. The comparison between hydrogen
strongly dependent on the hydrogen fraction which is related mass flow rate and the load power in kilowatts demonstrated
to the change in combustion behavior. Abnormal combustion that as the hydrogen mass flow rate increased so did the load
of hydrogen takes place at the hot region of the chamber power and hydrogen concentration in the fuel.
when the equivalence ratio exceeds 0.35. In hydrogen-fueled Shi et al. (Shi et al. 2017) studied the effects of spark timing
engines, because of the faster flame speed of hydrogen, the net on the characteristics of combustion and pollutant emissions
heat release rate is two times higher and the peak cylinder
pressure is 1.36 times higher compared to the gasoline SI
engine (Navale, Kulkarni, and Thipse 2017). Table 9. Specifications for in-line, T-GDI, DOHC test engine ran by Kim et al. (Kim
Du et al. (Du et al. 2016) experimentally evaluated the et al. 2017) [122].
influences of hydrogen fractions (0% −11.09%) on lean burn Engine type In-line, T-GDI, DOHC
combustion, as well as the emissions of an SI gasoline engine Fuel type Gasoline DI with hydrogen addition
on a premixed gasoline engine with hydrogen DI under the Number of cylinders 4
Displacement volume 1.998 dm3
condition of the excessive air coefficient from 1.0 to 1.5. Bore  stroke 86  86 mm
A gasoline direct-injection engine was modified into Compression ratio 9.5:1
a hydrogen DI system with gasoline port fuel injection. The Maximum power 204 kW at 6000 rpm
Maximum torque 352 N m at 1750–4500 rpm
hydrogen volume fraction was set at 0%, 3.99%, 5.87%, 7.68%,
9.41%, and 11.09%, respectively. The authors reported that at
different throttle openings and excessive air coefficients, the Table 10. Specifications for test engine and generator ran by Oliveira et al. (de
various levels of hydrogen addition ratio had great impacts on Oliveira et al. 2013) [123].
the emissions and engine performance. The increasing levels Engine Cycle Four strokes
Fuel type Diesel DI
Number of cylinders 4, in-line
Displacement volume 3.922 dm3
Table 8. Specification for dual-fuel (hydrogen PFI, diesel DI) test engine ran by Bore  stroke 102  120 mm
Tsujimura et al. (Tsujimura and Suzuki 2017) [119]. Intake system Naturally aspirated
Rated power 44 kW
Fuel type Dual-fuel: hydrogen PFI, diesel DI Generator Number of poles 4
Number of cylinders 1 Voltage 220 V
Displacement volume 1.3 dm3 Number of phases 3
Bore  stroke 115  125 mm Rated power 55 kVA
Compression ratio 17.5:1 Frequency 60 Hz
24 S. E. HOSSEINI AND B. BUTLER

of a hydrogen DI stratified gasoline engine. The engine used compression work is highly dependent on the injection strat-
in the experiment was a 1.8 L four-cylinder gasoline engine egy, such as timing and duration, which can increase the
with the original injection system modified to a hydrogen engine efficiency up to 4% when the system is optimized
injection system. To control hydrogen/gasoline injection tim- (Wallner 2004).
ing as well as the spark timing, a gasoline port fuel injection
system and a hydrogen–gasoline ECU were considered in the
engine design. The engine was worked at 1500 rpm; the intake 6. Exhaust gas recirculation in H2ICEs
hydrogen volume fraction (αH2 ) was regulated between 0% In addition to modifying the combustion process itself,
and 10% and the excessive air ratio (λ) was maintained at 1.2 exhaust gas recirculation (EGR) has been used to improve
using the following equations: the performance of hydrogen-only and hydrogen-fossil fuel
 . .  engines. To investigate the influences of exhaust gas recircula-
mH 2  . 
αH2 ¼ ρH2 mH2  100% (2)
ρ þ Vair
H2
tion (EGR) on the pollutant formation and combustion char-
acteristics under various hydrogen ratios, Du et al. (Du et al.
 
λ ¼ Vair ρair mH2 AFH2 ;ST þ mgas AFgas;ST (3) 2017) employed an engine with a gasoline intake port injec-
tion and hydrogen DI. For hydrogen addition ratios of 0%,
The authors claimed that a good stratified effect with the 5%, and 25%, the engine’s output torque, in-cylinder pressure,
hydrogen injection timing at 110°C A before top dead center cylinder temperature, exhaust temperature, NOx emissions
(BTDC) is achievable which improved fuel economy and BTE, (ppm), HC emissions (ppm), and CO emissions (%) were
and reduced emissions (Shi et al. 2017). The volumetric effi- measured. From the experiments, it was found that when
ciency was increased by using direct injection when the intake a small amount of hydrogen was added into the combustion
valve was closed. The BTE was first increased then reduced as process, the peak cylinder pressure increased by 9.8% and the
the spark advance angle increased. Overall, the BTE and the engine torque increased by 11%. Using a 20% EGR ratio and
combustion rate increased as the hydrogen volume fraction a 5% hydrogen ratio improved the engine torque output about
increased. Optimal spark advance angle for maximum BTE 20% and reduced the NOx formation by 54.8% compared to
was 10°C A BTDC at 9% hydrogen volume fraction. The the original engine without hydrogen addition. The fuel econ-
maximum pressure raised with the spark advance angle, omy of engine raised after the addition of hydrogen and the
which further raised with the addition of hydrogen. The trend in brake specific fuel consumption changed slowly,
maximum rate of pressure rises resulted from the augmenta- which created a wider economical range for the engine. The
tion of spark advance angle and hydrogen volume fraction for CO and HC emissions were decreased significantly by adding
each volume fraction. NOx emissions rose quickly; the spark hydrogen to the system. The fuel consumption is greatly
advance angle increased at specific hydrogen volume frac- decreased with the co-control of EGR and hydrogen addition
tions, while CO and HC emissions rose slowly. By increasing in the engine.
the hydrogen volume fraction, NOx rose, but CO and HC A similar test was performed by Fennell et al. (Fennell,
emissions reduced. Herreros, and Tsolakis 2014) modifying a conventional EGR
The thermal efficiency (ηth ) of an Ideal Otto Cycle is system to a reformed exhaust gas recirculation (REGR) to
calculated by (Faizal and Saidur 2017): improve the performance of a gasoline DI system. In the REGR
1 design, hydrogen and CO were supplied into the EGR system as
ηth ¼ 1  ð Þγ1 (4) shown in Figure 3. The results indicated that the REGR improved
cr
the engine efficiency in comparison to the gasoline engine, and the
Compared to gasoline (γ = 1.1), the molecular structure of REGR outperformed EGR due to the extended dilution limit. The
hydrogen is simpler its specific heat ratio (γ = 1.4) is larger. REGR largely decreased NOx formation and had moderately
Hence, the thermal efficiency of H2ICEs is theoretically increased HC emissions. Both the EGR and REGR reduced or
higher than gasoline-powered engines (Amrouche et al. eliminated knock, as well as reduced the particulate matter num-
2016). Overall, the actual thermal efficiency of an H2ICE is ber and mass emissions.
much lower than the Ideal Otto Cycle efficiency due to losses
from incomplete combustion and heat loss. Combusting
hydrogen in an ICE can be achieved at a very lean air–fuel 7. Hydrogen fuel cell
ratio (ϕ = 0.19), which decreases the fuel consumption, but
7.1. Application of HFC in transportation engines
also results in higher instances of incomplete combustion of
the fuel in comparison to gasoline- or diesel-only engines. The Electricity generation is continually moving away from cen-
losses due to incomplete combustion in a gasoline engine are tralized generation based on fossil fuels as the technology is
approximately 3%, whereas in a hydrogen engine the losses becoming more complex and diverse. Hydrogen and fuel cells
are slightly higher (Verhelst and Wallner 2009). To create can be incorporated into the global energy sector, but it will
a homogeneous mixture inside the engine cylinder, the hydro- be difficult due to the intricacy of the structure of the energy
gen is directly injected during the compression stroke. Adding sector. HFCs are static energy conversion systems that gen-
hydrogen during the compression stroke allows the lower erate electrical energy through an electro-chemical reaction of
heating value of the mixture to increase. Theoretically, to hydrogen and oxygen. The electrical energy will be generated
decrease the amount of work required for compressions, the by HFCs as long as hydrogen/oxygen is conducted into the
specific heat ratio must be decreased. The actual amount of system. FCs have low-efficiency ratings, around 50% at lower
INTERNATIONAL JOURNAL OF GREEN ENERGY 25

Figure 3. Schematic of a modified hydrogen-fueled engine with reformed exhaust gas recirculation (Fennell, Herreros, and Tsolakis 2014).

heating value, which is inferior to batteries; however, the hydrogen is supplied to the anode. Electrons are separated
volumetric energy density of an HFC is much higher than from hydrogen atoms at the anode and the process is accel-
the equivalent electricity capacity of a battery (Gray et al. erated by a catalyst. The electrons are conducted through
2011). Unlike in batteries, FCs do not self-discharge the a path to power an attached device and leading to the cathode,
hydrogen stored, because the FC itself is not the storage decreasing oxygen whereas the generated protons pass
device which is important for long-term storage. A unique through a proton-conducting electrolyte. At the cathode
and appealing characteristic of hydrogen fuel cells is the side, the protons and oxygen are combined to form water.
decoupling of energy and power ratings (Eriksson and Gray Generally, the HFC system employs oxygen and hydrogen to
2017). These are proportional in a battery, which is why generate electricity and water with no other pollutants
battery-electric vehicles (BEVs) with a large driving range (Kraytsberg and Ein-Eli 2014).
are expensive, heavy, and very powerful. HFCs are superior Alkaline Fuel Cells (AFCs) or Alkaline Membrane Fuel
to BEVs in the aspect of power availability because, the FC Cells (AMFCs) and Proton Exchange Membrane Fuel Cells
itself dictates the power capacity while the hydrogen storage (PEMFCs), also known as Polymer Electrolyte Membrane
sets the duration of the energy supply, similar to an ICE. Fuel Cells, are the two main types of FCs. AMFCs are similar
HFCs alone can be used to replace a traditional ICE in the to PEMFCs, the difference being that PEMFCs use an acid
transportation sector on this similarity. Since 2007, more than membrane instead of an alkaline membrane. AFCs can use
100 automobiles of the generation HydroGen4 illustrated in a variety of non-precious metal catalysts at the anode and
Figure 4 were manufactured in countries like the United cathode, making them more affordable than PEMFCs. The
States and Germany (Harrop and Das n.d.). challenges for AMFCs are tolerance to carbon dioxide, mem-
Although experiments with different types of FCs in brane durability and conductivity, higher temperature opera-
hydrogen transportation engines have been conducted, the tion, power density, water management, and anode
principal behind their function is similar. Generally, an electrocatalysis (Alesker et al. 2016; Deng et al. 2016).
anode, a cathode, and an electrolyte are the main components The second type of FC is PEMFC which operates at tem-
of an HFC engine where oxygen is charged to the cathode and peratures less than 120°C using perfluorosulfonic acid as the

Figure 4. GM HydroGen4 vehicle (Harrop and Das n.d).


26 S. E. HOSSEINI AND B. BUTLER

charge carrier material (Ye et al. 2015). They are ideal for Vinicio et al. (Oro, de Oliveira, and Bazzo 2018) used the
transportation applications because they can achieve faster waste heat from a PEMFC to operate a chemisorption chiller,
start-up times than other types of FCs. PEMFCs do require using sodium bromide impregnated in expanded graphite as the
a significant amount of precious metals for construction, adsorbent and ammonia as refrigerant. A thermosiphon acted as
particularly platinum, which must be minimized or elimi- the heat reservoir to decrease the temperature drop in the
nated to improve the cell durability and manage water trans- PEMFC stack and to integrate the thermal energy between the
port within the cell. Flooding is a common problem in chemisorption system and the PEMFC. A simulation of the
PEMFCs operation which accrues due to enhancement of system was produced and validated by experimental results.
gas humidity which accelerates Platinum dissolution–precipi- The HFC power output range increased the useful energy of
tation and carbon support corrosion (Gang and Kwon 2016; the hydrogen fuel, increasing the overall efficiency to 63%.
Pei and Chen 2014). Zakaria et al. (Zakaria et al. 2018) used Al2O3 nanofluid as
A schematic of the AFC and PEMFC is shown in Figure 5. an alternative coolant for a PEMFC system and studied the
thermo-electrical performance of the system. The volume
concentrations of Al2O3 nanoparticles were 0.1%, 0.3%, and
7.2. Technical challenges in hydrogen FCVs 0.5% in both water and a 60:40 water and Ethylene glycol
During the chemical reaction within hydrogen FCs, electricity mixture. The 0.5% volume concentration nanofluid in water
is produced with H2O and heat as byproducts. PEMFCs had superior thermal conductivity compared to the base fluid,
achieve approximately 50% efficiency and the energy that is water, resulting in the cooling rate increasing by 187%. The
not converted into electrical power is lost in the form of low- use of nanofluids resulted in a high voltage/pressure drop.
temperature heat (between 60°C and 80°C) (Barbir 2013). Upon analyzing the thermo-electrical ratios, it was deter-
There are opportunities to recover the waste heat in an inte- mined that the 0.1% volume concentration of Al2O3 in
grated system to raise the overall efficiency of the system. The water was the most advantageous nanofluid for use in
membranes used in HFCs are sensitive to temperature, so a liquid-cooled PEMFC system.
a thermal control system should be employed to avoid causing Hydrogen FCs have lower power density and slower power
any damage to the membrane and to optimize the perfor- response than batteries or ICEs so supercapacitors (SCAPs),
mance of the FC system. Typically, the temperature of the batteries, and energy storage systems can be combined with
HFC is controlled using forced convection of air or water (Lee the FC to make the system more comparable to an ICE (Ayad,
and Skala 2002). Because of a thermal boundary layer, high Becherif, and Henni 2011; Ren, Ma, and Cong 2015; Tie and
thermal gradient was produced using this method, which Tan 2013). Compared to the traditional batteries, SCAPs have
decreased the performance of the HFC. To combat this a higher power density because the employed electrodes in
issue, alternative techniques have been proposed. One techni- SCAPs have lower internal resistance (Bauman and Kazerani
que is the using of capillary pumping systems to create higher 2008). Furthermore, SCAPs offer higher longevity/efficiency
thermal homogeneity, which improves the system perfor- and their charging is done faster (Zhang et al. 2008). SCAPs
mance (Oro and Bazzo 2015; Silva et al. 2012). can supply enough power to the engine system with little or

Figure 5. The operation diagram of HFC (a) Alkaline Fuel Cell (b) Proton Exchange Membrane Fuel Cell (Hames et al. 2018).
INTERNATIONAL JOURNAL OF GREEN ENERGY 27

no time delay, thus integrating them into an FC system is ηWW ¼ ηWT  ηTW (5)
a great way to improve the power of the system. To optimize
The resulting well-to-wheel efficiency for gasoline and diesel
the output power management of the system, an advanced
ICEs is approximately 17% and 20%, respectively.
control system must be employed.
The well-to-wheel efficiency for hybrid electric vehicles,
Control systems record data from the traction motor and
electric vehicles, and fuel cell vehicles. The figure depicts the
energy storage systems, the nominal output power of the FC is
wheel-to-well efficiency for a parallel hybrid electric vehicle,
compared to the vehicle power demand and the parameters
which utilizes a dual-clutch transmission that allows either the
are continually calculated and adjusted (Emadi et al. 2005).
electric motor or the ICE to be coupled with the drive axel.
Using an energy storage device, such as a SCAP or a battery,
The well-to-tank efficiency for an HEV is the same as
in the FC system allows regenerative braking to be utilized. It
a traditional ICE at ηWT ¼ 84%. The efficiency of the IC
is claimed that because automobiles are used for a limited
engine, ηeng , is approximately 35%. On the electric side of the
amount of time, energy stored in the on-board hydrogen
tanks of FCVs can be employed to generate power when system from the electric motor to the driveshaft, the power-
they are parked (Alavi et al. 2017). train-to-wheel efficiency, ηptW , is approximately 80%. The
Fangzhu and Philip (Fangzhu and Cooke 2009) compared wheel-to-well efficiency for the system with a gasoline IC
characteristics of an HFC car (FCX Clarity made by Honda) engine is calculated using the following equation:
and an electric car (E6 model made by Chinese Company
ηWW ¼ ηWT  ηeng  ηptW (6)
BYD) as demonstrated in Table 11.
According to this table, the HFC automobile is lighter and The resulting well-to-wheel efficiency of a parallel hybrid
refill time is significantly faster compared to the electric car. electric vehicle is approximately 24%.
The energy storage in HFC car could increase to 136 kWh by For battery electric vehicles, there is no well-to-tank effi-
improving storage technologies, which promises ciency because the vehicle is energy storage system is a battery
a considerable potential for the future of the transportation instead of a tank-like ICE vehicles, HEVs, and FCVs. The grid
system (Wilberforce et al. 2017). efficiency, ηgrid , is the efficiency for the generation, transmis-
Figure 6. summarizes well to wheel (WTW) efficiencies of sion, and distribution of electricity from the average public
an ICE vehicle, hybrid electric vehicle (HEV), BEV and HFC grid. The estimated grid efficiency is 40% based on fossil-
vehicle (Tanç et al. 2018). The WTW efficiency is character- fueled power plants. The charging efficiency of the battery,
ized as the overall efficiency from the point where the fuel is ηC , is approximately 85%. The battery-to-wheel powertrain
obtained and refined into an useable product, through all of efficiency, ηBW , is approximately 80% for the average BEV.
the internal components of the drivetrain, to the final power The overall well-to-wheel efficiency for the BEV is calculated
output that propels the vehicle on the road. The intermediate using the following equation:
efficiencies vary based upon drivetrain type in the vehicle,
which will be detailed further following the figure. ηWW ¼ ηgrid  ηC  ηBW (7)
This figure illustrates the efficiency differences between the The resulting well-to-wheel efficiency of a battery electric
listed. For a traditional gasoline or diesel ICE, the well-to-tank vehicle is approximately 27%.
efficiency, ηWT , is approximately 84%. The engine efficiency, Similar to the HEV, the FCV system involves an energy
ηeng , of a gasoline engine is approximately 30% and 40% for storage system that absorbs transient power demands on the
a diesel engine. The tank to wheel efficiency, ηTW , for electric motors and regenerative power from the braking
a gasoline engine is approximately 17% and 20% for a diesel system. The hydrogen used as fuel in the FCV is assumed to
engine. The well-to-wheel efficiency for an ICE is calculated be produced via steam reforming of natural gas, which results
using the following equation: in the well-to-tank efficiency of 60%. In this vehicle, the fuel

Table 11. Comparison between an electric car and a hydrogen FCV (Fangzhu and Cooke 2009).
Characteristics of vehicle Electric car Fuel cell hydrogen car

L  W  H (m) 4.55  1.82  1.63 4.83  10.85  1.47


Curb weight (kg) 2100 1600
Max. power (kW) 115–200 100
Max. speed (km/h) 160 160
Range (km) >300 430
Energy storage Li- ion battery pack Hydrogen (at 350 bar)
Type kWh >60 -
Refill time: home >20 h -
Refill time: fast 50% in 10 min 2-3 min
28 S. E. HOSSEINI AND B. BUTLER

Figure 6. Well to wheel efficiencies of IC engine vehicle, HEV, BEV, and HFC vehicles (Tanç et al. 2018).

cell stack acts in place of a motor or a power inverter. The The FCV and BEV have the highest well-to-wheel effi-
efficiency of the fuel cell stack, ηfc , is approximately 58% when ciency in comparison to the ICE and HEV. There are many
operating in optimum power mode and a battery is used to factors that can affect the well-to-tank efficiency of the FCV
supplement the power output. The powertrain-to-wheel effi- and BEV. The grid power is dependent on the type of power
ciency is 78%, which is slightly lower than that of HEVs due plant used to produce electricity; therefore, the location of the
to the FC boost converter. The overall well-to-wheel efficiency user will affect the well-to-wheel efficiency of the vehicle.
of the FCV is calculated using the following equation: Coal- and oil-fired power plants, the most common type of
power plant in the United States, generally operate around
ηWW ¼ ηWT  ηfc  ηptW (8) 40% efficiency. On the higher end of efficient power plants,
there is combined-cycle gas-fired power plants that operate
The overall well-to-wheel efficiency of the hydrogen fuel cell from 56% to 60% efficiency, and hydropower plants that
vehicle is approximately 27%. operate from 85% to 90% (Theus 2010). Conversely,
INTERNATIONAL JOURNAL OF GREEN ENERGY 29

photovoltaic solar power plants operate at the lowest effi- ΔH 


ηF ¼ (10)
ciency of approximately 12% (Green et al. 2019). It is impor- ΔH
tant to note that the FCV has higher well-to-wheel efficiency Pe þ Ph
than the ICE despite the well-to-tank efficiency being lower ηfuel;stack ¼ (11)
n_ fuel;stack  ðΔH  Þ
for the FCV, as natural gas reforming is less efficient than
refining crude oil to gasoline. Where ΔH  is the effective HHV enthalpy change of the fuel
Hames et al. (Hames et al. 2018) analyzed four different FC cell reaction at stack inlet conditions and ΔH is the HHV
control systems available and selected the ideal one based on enthalpy change of ideal fuel cell reaction at stack inlet con-
safety, low cost, and high efficiency. The four different control ditions. The measured electric power output of the stack and
systems investigated are peak power source strategy (PPSS), the calculated heat power output of the stack were, respec-
operating mode control strategy (OMCS), fuzzy logic control tively, defined as:
strategy (FLCS), and equivalent consumption minimization
strategy (ECMS). The PPSS determines the acceleration or Pe ¼ U  I (12)
deceleration of the vehicle and regenerative braking energy, Ph ¼ ðUth  U Þ  I (13)
if regenerative braking is incorporated into the vehicle. The
Where Uth the thermal stack voltage and I is the measured
OMCS controls power variances and sharing between the fuel
stack current. The thermal stack voltage is defined as:
cell and battery, ensuring that enough battery power is used to
meet the demand of the vehicle that is not provided by the ΔH 
fuel cell. The OMCS can indicate the operating mode at three Uth ¼ N (14)
z:F
different charging states: fast charge mode, charge mode, and
Where z is the number of electrons exchanged in fuel cell
discharge mode. The FLCS controls the power between energy
reaction, F is Faraday’s constant, and N is the number of cells
storage systems to increase system efficiency and optimize the
per stack.
fuel economy of the vehicle. The downside of the FLCS was
The Balance-of-Plant (BoP) causes energy losses from the
that it had the highest computation time due to its complex-
conditions of the input and output of the stack, namely the
ity. The ECMS controls changes in vehicle performance bat-
pressure, pumping, humidification, etc. Fuel loss can also
teries, while the system utilizes SCAPs in addition to an FC.
occur at the BoP when there is an excess of fuel inputted
The battery is charged by the FC and the energy exchange is
into the stack, thus a leak in the BoP occurs. Considering all
controlled by the ECM system. From comparing the four
of the stated losses, the BoP efficiency is defined as:
control strategies, they all have similar results. The preferred
strategy is ECMS because the hydrogen consumed by the FC Pu;net
ηBoP ¼ η (15)
and battery/SCAP equivalent hydrogen consumption were Pu  Pmcloss fuel;BoP
minimized, it has the simplest parameters, and can be used
where Pu;net is the fuel cell system net useful power and
in many vehicles while keeping the performance high. The
ηfuel;BoP is the fuel efficiency of fuel cell system BoP, which is
PPSS, OMCS, and ECMS can be easily applied to different
FCVs with only minor modifications due to the simplicity of defined as:
the systems. n_ fuel;stack
Piela et al. (Piela and Mitzel 2015) suggested a new defini- ηfuel;BoP ¼ (16)
n_ fuel;system
tion of FC efficiency at stack level for PEMFCs. Stack losses
are the stack polarization loss and reaction losses from the Where n_ fuel;stack and n_ fuel;system are the molar rate of fuel con-
fuel cell itself. The reaction losses include entropy and sumed by fuel cell stack and the molar rate of fuel consumed
enthalpy losses due to the fuel oxidation reaction occurring by the fuel cell system, respectively.
incompletely. There are some losses from the fuel not being The system efficiency is defined as:
completely used to produce useful energy due to leaks or fuel ηsys ¼ ηstack  ηBoP (17)
crossover through the stack membranes. The stack energy
conversion efficiency, which includes electrical performance The equation for energy conversion efficiency at the stack
of the FC stack and considers the theoretical energy expendi- level was experimentally verified using a hydrogen-fueled,
tures for altering the conditions of the stack feed streams and liquid-cooled PEMFC stack that had 10 cells of 96 cm2 geo-
the fuel loss in the stack, was defined as: metrical working area and a nominal electric power of 480
W each. Grade 5.0 hydrogen and 5.2 grade nitrogen were used
Pu  Pmcloss with deionized water and ambient air. The tests involved stack
ηstack ¼  ηF  ηfuel;stack (9)
Pe þ Ph startup and shutdown, testing at constant load, and polariza-
tion-curve test which followed the procedures outlined in the
Where Pu is the useful power of the stack, Pmcloss is the European Stack-Test project (Ju et al. 2015). The approach to
minimum theoretical power expense for stack feed streams designing an effective FC power system includes the selection
conditioning, Pe is the measured electric power output of of a stack for the system, selection of the components, making
stack, Ph is the calculated heat power output of stack, ηF is schematics for the operating scenario, and optimization of the
the Faradaic efficiency of the fuel cell reaction, and ηfuel;stack is operating conditions of the stack to obtain the highest com-
the fuel efficiency of the stack. The Faradaic efficiency of the bined system efficiency. Through the tests, it was determined
reaction and the fuel efficiency were, respectively, defined as: that the equations developed in this experiment provide an
30 S. E. HOSSEINI AND B. BUTLER

accurate way of calculating the efficiency and optimizing the The numerous aforementioned government plans to
stack operating parameters of stationary hydrogen-fueled implement FCV fleets in the form of public transportation
combined heat and power (CHP) system, hydrogen-fueled will allow the hydrogen refueling station networks to maintain
power-only mobile systems, and direct methanol fuel cell steady usage and help improve the public’s perception of
(DMFC) systems. The results obtained from the stack polar- hydrogen FCVs.
ization tests showed that the calculated quantities were accu- Colmenar-Santos et al. (Campíñez-Romero et al. 2018)
rate in the test bench environment. designed a strategy to overcome the dilemma of implementing
FCVs or creating hydrogen refueling infrastructure first by
using a fleet of taxis as a stable market for hydrogen con-
7.3. Economic challenges of hydrogen FCVs
sumption. There are three objectives of the design: ensuring
The market entry of FCVs is dependent on early adopters a consistent hydrogen supply, having alternative refueling
purchasing or leasing the vehicles. The early adopters are stations throughout the city, and achieving a maximum utili-
people generally characterized by having a high household zation rate of the infrastructure. The city used for this model
income, high level of education, being in larger household was Madrid, Spain with 15,000 HFC taxis. A base case busi-
units, being willing to accept lifestyle changes, and other ness plan that is technically viable and financially feasible for
similar attributes (Rogers 2003). As of June 2018, there have the construction and operation of the hydrogen refueling
been more than 6500 FCVs delivered to consumers. California station (HRS) network capable of supplying the hydrogen
is the leading market for FCVs with nearly 3000 vehicles being demand for the fuel cell electric taxi (FCET) fleet. The case
delivered due to its largest network of hydrogen refueling is a simulation of the first year of operation where utilization
stations (Hardman and Tal 2018). In Europe, it is projected is at its lowest and the construction and operation costs are at
to have 600 HFC vehicles added to the current taxi fleet by the their highest. Internal Rate of Return (IRR) and Annual Debt
end of 2020. Zero Emission Fleet vehicles for European Roll- Service Coverage Rate (ADSCR) methods were used to quan-
out (ZEFER) project, will add a total of 180 HFC vehicles, in tify the feasibility and financially viability of HRS. The Net
60 vehicle fleets, of to London, Paris and Brussels, for use in Present Value (NPV) of the investment was evaluated from
urban fleets such as police cars, private-hire vehicles and taxis yearly income, accounting for costs assumed by the investor
(“Hype hydrogen fuel cell taxi fleet in Paris reaches 100 with 0% interest rate. From the study, it was determined that
vehicles 2018). South Korea plans to expand the number of the development of an HRS network is only feasible if govern-
HFCVs from 100 in 2016 to 10,000 in 2020 (Yoo, Kim, and ment support is received in the form of politics and subsidies
Song 2018). According to the International Energy Agency that promote and fund the hydrogen retail infrastructure. The
(IEA) Technology Roadmap, about 150 million FCVs seals is allocation of funds would need to aid in the construction of
expected by 2050 (Ambrose et al. 2017). the HRSs, operation costs, and give tax exemptions. The
Presently, several automakers are manufacturing various optimal solution would be a subsidy package with 50% of
HFCVs, which are often compared to BEVs. Both FCVs and Capex executed at the beginning of the investment, 50% of
BEVs offer zero tailpipe emissions, the ability to be fueled operating costs and 50% of tax exemption over 25 years. This
using renewable energy sources, and use electric motors. The ensures around 10% of shareholder IRR in the first 25 years,
most notable differences between FCVs and BEVs are the which is reasonably feasible. The estimated cost of imple-
driving range and refueling style. FCVs have above a 300- menting the HRS in Madrid is $415 million over 25 years,
mile driving range and can be refueled in less than 10 min at which an attainable amount in a large city. The substitution of
a hydrogen refueling station, which is more comparable to the whole taxi fleet by FCETs in a large city would cut down
a traditional ICE fossil fuel-powered vehicle, whereas BEVs CO2 emissions by around 300 kilotons per year (kt/year),
require up to several hours to recharge completely (Lipman, which is about 3% of GHG emissions from transportation in
Elke, and Lidicker 2018). The most recent FCV can be the city.
refueled in 4–5 min and have driving ranges of approximately
450–580 km (Oak Ridge National Laboratory n.d).
8. Future aspects of hydrogen utilization in
The four FCVs currently on the market in North America,
transportation system
Europe, and Asia are the Hyundai Tuscon/ix35 FCEV, Nexo
(“Hyundai Nexo – Sign Up For Updates | HyundaiUSA.com,” The future hydrogen market depends upon potential long-
n.d.), Toyota Mirai FCEV (with a range of approximately term restrictions on GHGs, the cost of hydrogen and the
650 km, a maximum speed of 175 km/h, and full tank refuel- advancement rates of different technologies that employ
ing in less than 3 min) (“2018 Toyota Mirai Hydrogen Fuel hydrogen (Forsberg 2005). The hydrogen required for FCVs
Cell Vehicle | The Future of Everyday [WWW Document] n. must be of high purity to improve the performance and life of
d), Honda Clarity FCEV (“2018 Honda Clarity Fuel Cell – the stack which increases the cost of the fuel. An efficient and
Hydrogen Powered Car | Honda [WWW Document] n.d) and economical method for monitoring hydrogen purity must be
Daimler manufacturing the Mercedes-Benz GLC F-CELL integrated into the refueling network and production facil-
(“The new Mercedes-Benz GLC F-CELL.,” n.d.). All four of ities. The motor companies must be able to achieve an accep-
these vehicles utilize proton exchange membrane fuel cells table return on investment when implementing the hydrogen
(PEMFCs) and use composite compressed hydrogen tanks. FCV to the market. The vehicles must be sold at a reasonable
Increasing the performance and efficiency of FCVs is being profit after the engineering and manufacturing costs are
heavily researched currently. recovered (Frenette and Forthoffer 2009).
INTERNATIONAL JOURNAL OF GREEN ENERGY 31

Many social, environmental and economic benefits of Some companies, like ULEMCo in the UK, works to retrofit
hydrogen made it a promising clean energy career for future semitrucks from diesel to a dual-fuel hydrogen-diesel engine,
transportation system (Andrews and Shabani 2014). which is slowly shifting HDV market toward a hydrogen-
Currently, there are three important barriers that should be based future (“ULEMCo to Demonstrate First Zero
solved to technically/economically move forward toward Emission Combustion Engine Truck,” n.d.).
a hydrogen-based transportation system. First, the cost of There have been numerous studies that showed ways to
hydrogen production and its delivery should be considerably improve the performance and efficiency of HFCs, and these
mitigated to introduce it on par with other fuels, such as methods can be applied to vehicles fuel cell stacks.
gasoline. Hydrogen cost depends on the process applied for Nevertheless, a lack of a harmonized standards and codes to
its production, the primary energy source, and the model ensure the insurability and safety of HFC technology in the
adopted (centralized or decentralized methods) (Lemus and transportation system is observed (US Department of Energy
Martínez Duart 2010). In centralized models, hydrogen cost is 2017a). Without a doubt, transition to hydrogen transporta-
influenced by the method of delivery from the production tion engines would lead to an augmentation in gross domestic
factories to the refueling stations (cryogenic liquid or com- product (GDP), investment and employment opportunities
pressed gas trucks, compressed gas pipelines, etc.) (Brey, (Köhler et al. 2010).
Carazo, and Brey 2018). Second, a new or improved method
of hydrogen storage for transportation vehicles should be
found to ensure reasonable driving ranges. Finally, the cost 9. Conclusion
of hydrogen-based vehicles (H2ICE or FCVs) should be This study reviewed the development and challenges toward
reduced with respect to improvement in their lifetime. The creating a clean transportation system using hydrogen-
future scenario of using hydrogen in the transportation sys- powered vehicles. As the major fuel of future, applications
tem significantly depends upon the cost of hydrogen com- of hydrogen in various types of transportation engines,
pared to the other fuels, as well as technological development namely fuel cells, and IC engines were considered.
in vehicles’ engine design toward hydrogen-based engines Compared to fossil fuel-based ICEs, using H2 ICEs obtains
(Müller and Arlt 2013). Moreover, social-cultural factors 20–25% efficiency. Due to several technical barriers in
play a crucial role on the development of hydrogen in the H2ICEs, using hydrogen as an additive to hydrocarbon
transportation system as issues related to mobility and house- fuels has been developed as a transient solution for GHG
hold equipment of current conventional fossil fuel-based reduction in transportation engines. Strong adaptability to
engines are regulated. It has been found that information rapid load changes, high energy conversion efficiency,
campaigns have a significant influence on the development appropriate dynamic features, low operating noise, and
of hydrogen technologies especially at this early stage, to zero tailpipe emissions have been found as the most impor-
enhance awareness for those with low or no knowledge and tant characteristics of FCVs. These characteristics have
to positively impact attitudes toward hydrogen vehicles (Bögel made FCVs comparable to H2ICEs in terms of storage
et al. 2018). time and range, acceleration, and speed. FC engines can
H2ICEs are not being researched as heavily as hydrogen achieve efficiencies of up to 60%, while the rest is lost as
fuel cells for cars and light-duty vehicles (LDV). Using hydro- heat. The main challenge preventing the use of hydrogen in
gen in IC engines achieves only 20–25% efficiency in compar- vehicles is the on-board storage and inaccessibility to refuel-
ison to FCs that achieve 60% or higher. A much larger fuel ing stations. Significant progress must be made to provide
storage tank is required to supply a competitive driving range an adequate solution to the storage issue. Both infrastruc-
for vehicles due to lower efficiency of IC engines. The use of ture and financial resources must be allocated to develop the
hydrogen in IC engines on heavy-duty vehicles (HDV) is hydrogen economy, which will require major political
more appealing. The existing diesel engines can be easily support.
modified to support hydrogen fuel, making the adoption of
hydrogen both easier and more affordable than adopting fuel
cells. Medium- and heavy-duty (MHD) vehicles (including Nomenclature
about one million buses and eleven million trucks) consume AFH2 ;ST Stoichiometric air-fuel ratios of hydrogen (kg/kg)
approximately 20–25% of energy in the US transportation Fgas;ST Stoichiometric air-fuel ratios of gasoline (kg/kg)
sector (“National Transportation Statistics [WWW Cv Specific heat at constant volume (J/kg.K)
Document] 2017). In the U.S. transportation sector, after F Faraday’s constant (C mol−1)
light-duty vehicles (pickup trucks, sports-utility vehicles, and I Measured stack current (A)
mi Mass of inlet air (kg)
passenger cars), MHD vehicles are the largest energy consu- _ H2
m Mass flowrate of hydrogen (kg/s)
mers and GHGs emitters (Davis, Williams, and Boundy n.d; m_ gas Mass flowrate of gasoline (kg/s)
EPA (U.S. Environmental Protection Agency) n.d.). Due to n Polytropic index
fast growing demand for MHD vehicles in the US transporta- N Number of cells in stack
tion market, H2ICEs could be deployed in HDV for clean and Pu Stack useful power (W)
Pu;net Fuel cell system net useful power (W)
sustainable transportation. In the UK, the strategy of using
Pmcloss Minimum (theoretical) power expense for stack feed streams
H2ICEs in MHD vehicles has been seriously considered; how- conditioning (W)
ever, since they cannot achieve a competitive driving range to Pe Measured electric power output of stack (W)
conventional IC engines, the strategy has not been adopted. Ph Calculated heat power output of stack (W)
32 S. E. HOSSEINI AND B. BUTLER

Q Supplied thermal energy (W) MCVVT Mechanical Continuous Variable Valve Timing
T Temperature (K) MHD Medium- and heavy-duty
T1 Temperature at position 1 ( C) NG Natural gas
U Stack voltage measured at stack electrical terminals (V) NOx Nitric oxide
Uth Thermal stack voltage (V) NPV Net Present Value
Vair Air volume flow rate (dm3/s) of at normal condition NTSEL National Traffic Safety & Environment Laboratory
Number of electrons exchanged in fuel cell reaction OMCS Operating mode control strategy
ρair Densities of air (kg/dm3) at normal condition PFI Port fuel injection
ρH2 Densities of hydrogen (kg/dm3) at normal condition PEMFC Polymer electrolyte membrane fuel cells
ε Compression ratio PFIHICE Port fuel injection hydrogen internal combustion engine
λ Hydrogen equivalence ratio PM Particulate matter
φ Equivalence ratio PPSS Peak power source strategy
ηth Thermal efficiency (%) REGR Reformed exhaust gas recirculation
γ Specific heat ratio SCAP Supercapacitors
ΔH HHV enthalpy change of ideal fuel cell reaction at stack inlet SI Spark ignition
conditions; (J.mol−1) UHC Unburned hydrocarbons
ΔH Effective HHV enthalpy change of fuel cell reaction at stack WTW Well-to-wheel
inlet conditions (J.mol−1) ZEFER Zero Emission Fleet vehicles for European Roll-out
n_ fuel;stack Molar rate of fuel consumed by fuel cell stack (mol.s−1)
ηF Faradaic efficiency of fuel cell reaction (%)
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