Intelligent Hydrogen Fuel Cell Range Extender for Battery Electric Vehicles

Wu, Dongxiao; Ren, Jin; Davies, Huw; Shang, Jinlei; Haas, Olivier · 2019 · DOAJ

DOI: 10.3390/wevj10020029

archive: archived pipeline: cataloged verified

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Summary

This review paper addresses the commercialization challenges facing battery electric vehicles (BEVs) and fuel cell electric vehicles (FCEVs) as replacements for internal combustion engine (ICE) vehicles. Motivated by legislative mandates to reduce greenhouse gas emissions and the limitations of current zero-tailpipe emission technologies, the authors aim to identify a solution that maximizes the advantages of both BEVs and FCEVs while mitigating their respective drawbacks. The primary research question focuses on how to overcome BEV range anxiety, high costs, and infrastructure dependency without oversizing battery packs, which leads to inefficiency and raw material strain. The study employs a comprehensive review of current technologies, market data, and policy frameworks. The authors analyze the technical specifications, costs, and performance of BEVs and FCEVs, comparing them against ICEVs. They examine battery characteristics, including specific energy, density, and raw material availability (specifically lithium and cobalt), alongside infrastructure statistics and user driving behavior patterns. Based on this analysis, the paper proposes a novel design: a demountable, trailer-based intelligent hydrogen fuel cell range extender for BEVs. This approach allows BEVs to be sized for common daily journeys, with the fuel cell trailer providing additional range for infrequent long-distance trips. The findings highlight significant limitations in current BEV technology. While BEVs offer high energy conversion efficiency (92% compared to 21% for ICEs), their range is constrained by battery weight and cost. Oversizing batteries to match ICE ranges reduces overall well-to-wheel efficiency and exacerbates raw material shortages, particularly for lithium and cobalt, which face supply-demand discrepancies and geostrategic risks. Furthermore, BEVs suffer from slow charging times and insufficient infrastructure compared to petrol stations. Conversely, FCEVs offer longer ranges and faster refueling but face high costs and hydrogen infrastructure challenges. The proposed hybrid solution addresses these issues by allowing BEV manufacturers to design smaller, more efficient battery packs for the majority of user requirements (average daily driving of 25–50 miles). The demountable fuel cell trailer can extend the range of small BEVs by more than 50% and large BEVs by 25%, enabling vehicles to exceed 250 miles of range. The significance of this work lies in its potential to accelerate the transition to zero-emission transport by bridging the gap between BEV and FCEV technologies. The proposed "rent and drop" business model for the fuel cell trailers reduces the demand for raw materials, decreases the cost and weight of the primary vehicle, and alleviates pressure on charging infrastructure. By tailoring BEVs to common usage patterns and using fuel cells only for extended range needs, the design improves overall efficiency, reduces manufacturing costs, and extends battery lifespan. This approach offers a pragmatic pathway to commercialize electric vehicles by addressing range anxiety and infrastructure gaps without relying solely on expensive battery expansion or fully developed hydrogen networks.

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