c




 



Syed Najam Haider

Automotive Technology, Dept. of Mechanical Engineering,
NUST College of E&ME, Rawalpindi, Pakistan

 
This review paper gives and introduction and explains briefly the working of Fuel Cell Hybrid vehicles, the
motive behind the development of fuel cell vehicles along with the design considerations. Some popular types
of fuel cells in automotive industry are explained and compared. Methods of hydrogen (primary fuel for fuel
cells) production and storage are also discussed along with hydrogen reforming techniques. Brief working of
Hybrid fuel cell vehicle in different modes and design of its drive train are also discussed. Different
comparison factors are used to compare fuel cell hybrid vehicles with other competing hybrid technologies
and conventional IC engine vehicles.



(3 maximum):
Fuel cell vehicle, Green Power, Hybrid technology

  a fuel cell is closely associated with the energy released


 

   

 

  
 and the number of electrons transferred in the reaction.



    !
  

" These sources
can be different types of energy storage devices, power
converters, and inverters. It is understood that power
losses will occur due to conversion of energy from one
form to the other but still the hybrid vehicles are more
efficient than conventional Internal Combustion engine
vehicles.
The fuel cell hybrid vehicle, as the name suggests
contains a stack of fuel cells (most commonly used:
Hydrogen Fuel cells) and an electric battery making a
hybrid vehicle. The fuel cell is not like a battery, it cannot
store energy rather it requires some chemical (depending
on the type of fuel cell) as a fuel in order to generate
electric current. This electric current is used to power the
battery when it is depleted. Figure 1 : Working of a general fuel cell. REF [1]
In case of most commonly used Hydrogen fuel cell hybrid
vehicle, hydrogen is used to power the fuel cell and thus it Fuel cells are of many types depending on the type of fuel
requires continuous supply of gaseous hydrogen to they use, construction and output but following three
produce current. Chevrolet Equinox FCEV, Ford Edge types of technologies are popular in automotive
Hyseries Drive and Honda FCX are some examples of engineering for design of FCHVs (Fuel cell hybrid
fuel cell hybrid vehicles. vehicles)
# c$%%$%%& V






#" !
 ' 
!
(c

 
 






 





A fuel cell is a galvanic cell in which the chemical energy
of a fuel is converted directly into electrical energy by
means of electrochemical processes. The fuel and
oxidizing agents are continuously and separately supplied
to the two electrodes of the cell, where they undergo a
reaction. An electrolyte is necessary to conduct the ions
from one electrode to the other. The fuel is supplied to the
anode or positive electrode, where electrons are released
from the fuel under catalyst. The electrons, under the
potential difference between these two electrodes, flow
through the external circuit to the cathode electrode or
negative electrode, where, in combination with positive
ions and oxygen, reaction products, or exhaust, are
produced. The chemical reaction in a fuel cell is similar to
that in a chemical battery. The thermodynamic voltage of
v )*$c$%$%%
The basic chemical reaction of Hydrogen fuel cell is very
simple in which pure hydrogen reacts with oxygen to
produce electricity and water as by-product. Since there
are no harmful by-products at all so Hydrogen fuel cell
vehicles are highly environment friendly which is the
major motive behind their popularity. Hydrogen is stored
on board the vehicle in pressurized tanks and a peak
power source (PPS) usually Ultracapacitors are employed
to provide high power bursts when required. A power
control unit controls the output according to the demand
of driver.
 v"# *  
 



 
(




!

 (

c





Following are some general goals which are necessary to
achieve to make hydrogen fuel cell vehicles commercially
successful
p %
  

 ( 

- Hydrogen is
Figure 2: Basic layout of Hydrogen fuel cell hybrid car.
REF [2]
v" +, 




- Another big issue
Many types of Hydrogen fuel cells are available
depending on their construction but the most popular
among automotive engineers is the Proton Exchange
Membrane (PEM) type. In a general hydrogen fuel cell
the PEM lies between the anode and the cathode. When
hydrogen gas pumped from the fuel tanks arrives at the
anode, which is made of platinum, the platinum acts as a
catalyst to ionizes the gas. Ionization means breaking of
hydrogen molecules (H2) down to its positive ions
(hydrogen protons) and negative ions (electrons). Both

&


four times as more expensive than currently
competing gasoline power source even when
produced from its most affordable source i.e.
Natural gas. Advancement in hydrogen
producing methods from renewable energy
sources like nuclear energy or a cheaper source
like coal is needed for this purpose.
p  ( c
 
- Hydrogen fuel cells are
currently too expensive to manufacture and thus
are not suitable for use in commercial vehicles.
The high cost is mostly due to the expensive
platinum used in them. If we are able to find an
alternative method for ionizing hydrogen other
than using platinum then the manufacturing cost
can be significantly reduced.
p $((

is the onboard storage of hydrogen on the car.
This is because hydrogen has to be stored at
very high pressure than competing CNG
alternative fuel. This high pressure requirement
calls for making thicker storage vessels which in
turn further increases the overall cost of vehicle.
Safety of the passengers also becomes a factor
due to presence of high pressure inside vehicle.
v"v 


types of ions are naturally drawn to the cathode situated
on the other side of the membrane, but only the protons
can pass through the membrane (hence the name
"proton-exchange"). The electrons are forced to go
around the PEM, and along the way they are passed
through a circuit, thus generating the electricity that runs
the car's systems. The protons after reaching the cathode
react with oxygen to produce water. Since the production
of water is an exothermic reaction so some waste heat is
also produced, water maybe used for other systems of
car (if needed elsewhere) or it is simply exhausted
through exhaust tail pipe of vehicle. A single fuel cell
output voltage is not enough to drive the car¶s systems so
manufacturers are compelled to use several stacks of fuel
cells in a single vehicle. As a general rule the output
voltage of a fuel cell depends on the surface area of its
electrodes, the greater the surface area the greater will
be its output voltage. REFERENCE [7]
Following are some of the technologies currently under
development for onboard hydrogen storage.
  V



 


Hydrogen can be stored in gaseous form in pressure
vessels like CNG but unlike CNG the pressure vessel
must be able to withstand much higher pressure. Due to
low energy density of hydrogen the range of vehicle is
however limited. It has been found that low temperature
storage of liquid hydrogen is not suitable for vehicles
because more pressure will be needed and it has to be
maintained at 20K temperature, moreover the losses by
boiling during refilling will be too much.
Keeping the weight and cost under consideration we have
to find the optimum between the thickness of cylinder and
the strength of material used for construction, because
higher strength materials are more expensive
  





Some metal based compounds have the tendency to
absorb and release hydrogen under certain conditions.
This technique has the advantage of storing hydrogen at
low temperature and pressure which is desirable however
the metallic compounds introduce too much additional
weight to the vehicle.
  






Slurries and solutions can be used to absorb hydrogen
and release it again upon reaction with water, however
this will require additional chemical reaction and
regeneration plant to be installed inside the vehicle.

Figure 2: Working of PEM fuel cell. REF [3]
A .$%c$%$%%&
Methanol fuel cells are a sub category of PEM fuel cells
and use methanol as fuel. Methanol is an energy dense
yet quite stable liquid at all environmental conditions.
Methanol is basically used as a hydrogen carrier and
2 t

  
l f 2
 i i
  t f
 l  ll 
 
 


f
2 2 t l.

2 j

t  f 2 t l f l  ll i t 
2 f  t
   

 t

t f 2 t l i

il . 


it   il
f ll  t 

f lli t ti
it 2 t l i i 2.



  
i t  f 2 t l f l  lli. . O    
  &        
    
  "

I t2ti
t  l 
 i i  
 f
2  2 t l f l  ll f

i
il   t 

f t
i
ffii ,
i
2 ll
t 

f f l  ll,
i
 t
2   2 t    

 tt

l t 2
t
iti. A 2 t l t

 
f
2
i it ll  
 t
il  i


t 2 t l it 
 .


  

i t t t  
t t i
t 2
t
  t 
i

 t
2   2 t  il ti t  i . At


  i t t 2 t l t 
  

i

  
  2 2t f o


it i till

 l  t  
   
ti l  li

il .

>i
4: L t f?5 t  


?  t 
 
 
f
2  li . BE C [ DEYSLE E O EP]

4 9 5
´"F G. 10 78& 3 . 3
H 5 4


t t  f
f
2i $/ .076 G. 10 78 i
 i  li i 

5
t  4t 
   f
it i  t

t f l  ll   7 .076 G. 10 78 i 
i

f
2i
t   l  it
i t
f l  ll.
>
t2ti
   

f
2
     
! 
i
  

t lii  li Hf l t

  i
i
: O


i  f  
l " f
2  2 t
l f l 
 
tt 
 t t
f l  ll.
i ill 
il 
 ll "E # [4] 2l it  t t t


il  f l t 2.
% >lli
2 

tl  
f
2i t 
li 
´ $ & &'($ )*$ ' +$ '' P
´ I I


 JKL
 J MNL O

4 5 4 4 5
,-. /012.33 1  0673
4 104 78 -9 :01260;17 <.3 1
9
= :018.7 326 .: <.0. 10 78"
I t 2
f
2i 
  t
t 2 i   t



 f l t
i
t 2
t
 i t

Q
( li f l  ll

il   f l
f
2i t 
i  f  i 2 t l  t lt t 


   OR.
t 

t


 f l it

  
i
i t
 St 2
f
2i
ti f
 t
l   i i
  l
li  t

  f l  ll. Q T Q
S4 + SRO OR + 4 SR
Si t

i 

tl  iti if
t
t
t U

i 2 t
 i t
2t
i
l 
l   t
22
i ll 
  t


   f l  l
 ff ti
f
 
ti

  VW  i W l t
2t
 l t    i

 

il , 

t t
i f ffii t, i
i 

i
t  f t 8 
 t 
t
lt
 ti
. ( li f l  ll
t
2t 
t l
  l .
ft
t 
l f


i 
     f t
f t P
´ I X


 KN K
! YK MO
 J MNL O

t
t iti  li if
t
t
     t 
U
f l  ll t
i 2  
? t


i f l  ll

il 
i 2 t
 i
l
 t

ti f  t
l   
t


it
 
i
ill t > @V 

 




 it
  t li
t

 


it
l t t
i
22
i l  ff
 lA 
ti. It ill 
  l  2t f

  t
 t 2
f
2i.

 t l i2

ffii   5A %  ill
l i U


2i l
ti i
l
 i t
i 
  i

i

2fl 2ii  9 % 
i
i

 t

2i  t

f
it    iiti t  it
i2l
iifi t fi
. 2ti 
  l i t i t
t . O t

t 2 i
i it  l

i
 f
t

iti
U Q f

t. Z f
2i f it  i i
  l.
O

t
T f
t

it
 t
t i
2
S
   

i
ti


 
o   
 
 o  
 


 
 source (PPS), electric motor drive (motor and its
Å
 Å
   Å  Å
 controller), vehicle controller and an electric interface

between fuel cell and PPS.
´ V 


"
[ 

!

Autothermal Reforming process is a combination of both
the steam reforming and partial oxidation reforming
process. Because steam reforming is an endothermic
process and partial oxidation reforming is exothermic so
Autothermal reforming process supplies the heat
produced by partial oxidation to steam reforming process,
thus the waste heat is effectively utilized.
This system is very fast starting, compact and productive.
Many auto companies are currently working to further
improve this technology and eliminate any problems
might caused. Autothermal reforming is currently
demonstrated by fuels such as methanol, natural gas and
gasoline.
w c$% $%% )0 $%$ $ 
$&*
Fuel Cells are considered to be one of the most advanced
power sources for applications in transportation.
Compared with the internal combustion engines (ICE),
fuel cells have the advantages of high energy efficiency
and much lower emissions. This is due to their directly
converting the free energy in fuel into electrical energy,
without it undergoing combustion. However, vehicles
powered solely by fuel cells have some disadvantages,
such as a heavy and bulky power unit caused by the low
power density of the fuel cell system, long start up time,
PPS is a device which is capable of providing higher
bursts of power. Usually devices called 
are used. Ultracapacitors are just like batteries but deliver
high power bursts whenever required. Function of PPS is
to deliver high power burst according to the power or
torque command received from the accelerator or the
brake pedal and other operating signals, the vehicle
controller controls the motor power or torque output and
the energy flows between the fuel cell system, PPS, and
the drive train. For peak power demand, for instance, in a
sharp acceleration, both the fuel cell system and the PPS
supply propulsion power to the electric motor drive. In
braking, the electric motor, working as a generator,
converts part of the braking energy into electric energy
and stores it in the PPS. The PPS can also restore its
energy from the fuel cell system, when the load power is
less than the rated power of the fuel cell system. Thus,
with a proper design and control strategy, the PPS will
never need to be charged from outside the vehicle.
The conversion of waste mechanical energy from braking
into electrical energy makes the system highly efficient.
Fuel cell-alone powered vehicles are not capable of
providing high power bursts or storing
_ electrical energy
due to lack of PPS. REFERENCE [ ]
Vehicle controller is an ECU which controls the power
flow between fuel cells, PPS and the rest of drive train.
The control strategy should be such that
and slow power response.Furthermore, in propulsion
applications, the extremely large power output in sharp
acceleration and the extremely low power output in low-
speed driving lead to low efficiency,
Hybridization of the fuel cell system with a peaking power
source is an effective technology to overcome the
p The power output of electric motor always meets
the power demand. It means that motor must
supply power to the wheels according to the
signal sent by the accelerator.
p The energy level in PPS must always be
maintained within its optimal range.
disadvantages of the fuel cell- alone-powered vehicles. p The fuel cell system must operate between its
The fuel cell hybrid electric vehicle is totally different from optimum region.
the conventional ICE-powered vehicles and ICE-based w"    !
  

 (


 

hybrid drive trains. Therefore, a totally new design 
!


!

   
methodology is necessary.
\ ^
Figure : ]ayout of basic hybrid fuel cell vehicle. REF [ ]
Figure 6: ]ayout of FCHV with onboard fuel
^ reformer
(methanol or gasoline fuel cell). REF [ ]
The fuel cell powered hybrid drive train mainly consists of
fuel cell stack as primary power source, peaking power
w V V


#


Vehicle is said to be in idle mode when it is started but
standing still. In this mode neither the fuel cell system nor
the PPS supplies power to the drive train. The fuel cell
might operate at idle.
w V 


$ 


Vehicle is in braking mode when it is being stopped by
braking system. In the mode the fuel cell will again
operate in at idle while the PPS will absorb the
mechanical energy of the braking after it has been
converted to electrical energy by the motor which is now
acting as a generator.
w V 





Vehicle is being accelerated in traction mode. Three
different cases of power distribution can arise in this
mode depending upon the demand of power by the
accelerator.
p If the power demanded is more than the rated
maximum output of fuel cell stack then fuel cell
will operate at its maximum output power and
PPS will start operating to provide the additional
power.
p If the required power is less than rated value of
fuel cell system but the PPS is not fully charged
then the fuel cell will operate at maximum output
and the additional energy will be used to charge
PPS.
 p If t

i
 
i l   PPS l  

il  i 
i t
† 
ti f

 …  f
2
t
i


i t
 ` l  ll ill l 2 t
l 
 li .
i 
ti f |O i lt



i
t


il . 2  ti2  l  t
 
ti l I| i

il , it
 d

 f
t

t ti l t  
 if

  
i
†
ü l abc' e& bfd bg gh$ i a$ ii j) keO$jai$&  t
 t 
i 
i2

 i t
ft
.


mjbmj$e hmbcbm$m$ajfbibn$& i
 t ti l f

  l 
 f

 
pp t 
i
ill t ti ll  
 
    
ü" o $ q rsq au vwx yus
fil f l  

   2ii.
|

t 
  l i
 2
i f

i ‡ ‰
ü"1 O ˆ}€ ‚Š ‹  Š
t2ti
t 
li   t
i

 ti
ffii i 
     t
t f l  ll

il 

2

i


ffii i  t
 it
 l 2ti i

il  
t
ffii i  f z
i f l  ll

il 



i

. |

tl t

i
t ffii  i f t  f
z
i l t
i I| i  l

il  t ffii  i l 

t f t
 
i     l

t  



 2ii 
 
    
fil f l  2
 il t

f


i {|

il  

i t  t lt
 ti
 ti22
lti f
t 
ffii    
i fil
f l     .

{ l t
Ž 
2il f
iff
t t2ti
t  li .
ŒE  [ ]

Alt  f l  ll
il   t
f
2 f 
i

il 
i iiti l t, t 
2  tt

2 t  I| i
il  i t l. A  
f
2 t 

t  li
il  

t 



  
 t 
i l
.
†
iiti l t f f l  ll 
i
il   i
t ti l t  
 it t 
 2 t i f l  ll
 
  
ti t  li .
2 }~}‘&~
{ l  ll 
i i

 
2ii t  l t t
2  t lti f
ll 
ft
t

t ti 

i
2 t l  . It  t ti l t
…

ü" | }~|$  € }€ ‚ƒ„ € 
fil f l     t l  t  % 
t ti ll li2i t t 
  2ii 
l 2.
†
2 f t
i t  i t ti l t  

 
2 f t

 

t 
l

i 
t  li  t lit 
   t 
 
 f
t ft
t 2l t l
l   li .
’
j
2ti
 i i 
   
 
 f

f l… ll i t t it †   
  it t 


 littl
|O 2ii. 
 
t l 

 it f 
 , t t
 
l 2    f
l
 if
t
t
f

f lli f 
  †  t
i ffii i  f 
  
ti 2 t .
i
 lt
 ti
f
l
 if
t
t


i. . t 
 li 
 f l  ll i
il  t it 

  f fil f l     .
† “
|

l t Ei {|EV, {
 E z
i 
i

 z {|X
 2l  f f l  ll/ l t
i


i.
3 ”$ •$”$}$&
[ –]. tt://.
l  tl
 
.2/ 
 
f l ll. t2l
…
[ ] ’ Ž —
A   f
2 t 

t t f l  ll
il 
… tt://.
l. t  . /  ti/ E – 5/P
j t/ {
t f l  †ll
il 

… t l t il |O 8/ t

2ii. l |O 
ti i   f f l  ll ˜
[ ] tt://..
/ /
/t  /f l ll
. t2l
™
[ ] http://www.ultracellpower.com/sp.php?rmfc
š
[ ] http://www.altfuels.org/backgrnd/altdrive.html
[6]
http://www.altenergystocks.com/archives/industry_genera
l/
[7] http://www.greencar.com/articles/hydrogen-fuel-cells-
work.php
›
[ ]
http://www.greendesignbriefs.com/component/content/arti
›
cle/667 ?start=1