Simulation-based Assessment of Fuel Economy Performance in Heavy-Duty Fuel Cell Vehicles

This work aims at addressing the challenge of reconciling the surge in road transportation with the need to reduce CO₂ emissions. The research particularly focuses on exploring the potential of fuel cell technology in long-distance road haulage, which is currently a major solution proposed by relevant manufacturers to get zero local emissions and an increased total payload.

Specifically, a methodology is applied to enable rapid and accurate identification of techno-economically effective fuel cell hybrid heavy-duty vehicle (FCH²DV) configurations. This is possible by performing model-based co-design of FCH²DV powertrain and related control strategies. Through the algorithm, it is possible to perform parametric scenario analysis to better understand the prospects of this technology in the decarbonization path of the heavy-duty transportation sector, changing in an easy way all the parameters involved. The tool used is based on the truck longitudinal dynamics model to evaluate the power required at the wheels; furthermore, the tool operates with independent control strategies that automatically adapt to the configuration under investigation. The battery and driving specifications were selected to align with the current market trends.

The Hybrid (FCH²DV) and plug-in (PFCH²DV) vehicle design and management scenarios were then compared, and the results indicated a fuel economy that is consistent with current literature and preliminary on-field/commercial vehicle tests. A parametric cost analysis was accomplished to determine the configuration’s techno-economic feasibility. Particularly, a literature search on the actual cost of electricity and green hydrogen destined to FCH²DV supply was carried-out, also relying on projected costs until 2030. The outcomes indicated that adopting battery charge-depleting energy management reduces PFCH²DV cost per kilometer and fuel consumption by 8 and 1.9%, respectively, as compared to the full hybrid (i.e., FCH²DV), enabling interesting cost abatement if convenient grid-based battery recharging is available.