A study conducted by a European group of experts on decarbonizing heavy-duty vehicles aims to compare and simulate different scenarios. One aspect of this study is the analysis of the assumptions regarding the maintenance of hydrogen fuel cell-powered trucks. Often, certain assumptions are found to be unreliable after detailed analysis, despite being considered credible.
A fuel cell-powered truck is essentially an electric vehicle with an additional hydrogen fuel cell-based propulsion module. This means that the electric drive operates based on batteries, an electric charging system without moving parts, an energy management unit, and a motor. Sensors, computer control, and other components have very few moving parts and require infrequent maintenance. This has been confirmed by studies on electric vehicles based solely on batteries.
As fuel cell vehicles are hydrogen-electric hybrids, they also include advanced hydrogen tanks at a pressure of 700 atmospheres or even more complex tanks for liquid hydrogen with pressure sensors and safety systems. The hydrogen dispensing system must be able to handle significant pressure changes in the case of pressurized tanks or large volume changes, and thus pressure, in the case of heating liquid hydrogen to gaseous form. Additionally, these vehicles face significant temperature management challenges, which require temperature sensors and components, as well as expensive, time-limited fuel cells that require clean hydrogen and clean air. As a result, an air intake and filtering system, as well as an exhaust system to remove the water vapor resulting from the reaction of hydrogen with oxygen, are also required without the risk of freezing hoses.
It is clearly evident from the diagram depicting the air management system in fuel cell vehicles that the additional elements of these vehicles are complex. There are many potential failure points and components that require regular maintenance.
The closest example is hybrid electric vehicles. Data on passenger cars shows that the maintenance costs of hybrid vehicles are significantly higher than those of vehicles based solely on batteries and similar to the maintenance costs of vehicles with internal combustion engines.
In a study conducted by the International Council on Clean Transportation on the transportation sector, which compared ownership costs for different types of vehicles, an improvement in the maintenance costs of fuel cell-powered trucks was taken into account, but no improvement was seen for battery-powered electric vehicles. The hypothesis assumed that long-range heavy-duty vehicles, the only segment in which some organizations still have hope for fuel cell technology, would have nearly identical maintenance costs as battery-powered electric vehicles after 2030, as well as immediate maintenance costs comparable to diesel vehicles.
All the data is provided in euros per 100 kilometers.
Upon initial review of this study, there was some surprise that it is worth considering the maturity of fuel cell technology, especially considering that fuel cell buses have been tested worldwide since 2000 and hydrogen-powered forklifts even longer. In comparison, electric battery-powered trucks and buses are relatively new.
However, doubts arise as to the reasons why everyone believes in low maintenance costs for fuel cell-powered trucks.
I have spoken with various individuals and collected informal data on maintenance costs. The local carrier Pau in France withdrew its hydrogen buses in 2023 after four years of operation, admitting that the maintenance costs were exceptionally high and keeping them running posed constant challenges.
“Our service stations had more problems than we expected, and the buses had many minor breakdowns. I spend three-quarters of my day there, even if it’s just one of the 17 lines!” said a representative of the fleet management company.
Similar experiences of increased maintenance costs occurred in Whistler, British Columbia many years earlier, as confirmed by data obtained from Ballard itself.
According to Canadian company Ballard Power Systems, which produces engines for fuel cell vehicles, maintaining hydrogen buses in Whistler cost $1.34 per kilometer compared to 65 cents per kilometer for diesel buses.
Two different carriers, separated by many years and an ocean, had identical experiences with buses from different manufacturers. But these are just anecdotal accounts. If this were the only available information, it could be dismissed as a few bad experiences.
However, when the director of rail vehicle sales at German company Stadler speaks about hydrogen trains, I wonder what the truth really is.
“In addition, fuel cell drive systems require significantly higher maintenance costs than batteries alone, which need to be replaced on average every three years (…). Due to the presence of a hydrogen tank, maintenance is naturally more complex than for battery-powered trains,” explains Obst. “Hydrogen trains also require batteries as emergency power supply.”
Therefore, when I saw that the study I am reviewing assumes very low maintenance costs, I presented this information and suggested that the presumed near-identical maintenance costs are inappropriate. The lead researcher pointed me to the source, so I reviewed it. It turned out to be a German research working group conducting a study in the same direction as the one I reviewed a few months ago.
This study, translated using a very helpful website that continuously asks me for donations, is the “Commercial Vehicle Propulsion Change: Ways to Decarbonize More Demanding Trucks with an Emphasis on Electrification” workshop report from 2020 by the German National Platform for Mobility.
I began reading with the hope of finding references to research and empirical analysis. However, it turned out that three researchers from two institutions – Wolfgang Schade from M-Five and Patrick Fieltsch and Heike Flamig from Haus der Technik – participated in this project.
FAQ (Frequently Asked Questions) based on the main topics and information presented in the article:
1. What is a fuel cell-powered truck?
A fuel cell-powered truck is an electric vehicle that utilizes hydrogen as an energy source through the conversion of hydrogen and oxygen in the fuel cell, generating electric power.
2. What are the main challenges related to the maintenance of fuel cell-powered trucks?
These vehicles have many complex elements such as advanced hydrogen tanks, hydrogen dispensing systems, temperature management, and air filters that require regular maintenance. They also have high fuel replacement costs.
3. What are the data on maintenance costs for fuel cell-powered trucks compared to other types of vehicles?
Studies indicate that maintenance costs for fuel cell-powered trucks are significantly higher than the maintenance costs for vehicles based solely on batteries or internal combustion engines.
4. Are there examples that confirm the higher maintenance costs of fuel cell-powered trucks?
Yes,
The source of the article is from the blog foodnext.nl