Hydrogen has long held promise in delivering environmentally conscious power for transportation, homes, and life in general, but it’s been a long road. There are reasons. Holding hydrogen back has been its high cost, a near-complete lack of pipelines and fueling infrastructure, and the environmental impact of sourcing this amazingly clean fuel. At the same time, driving continuing interest is the very real benefit of moving on from hydrocarbons and transitioning to this energy source not only for hydrogen vehicles, but also for use as civilization’s primary fuel source. Let’s dive deeper to examine hydrogen’s story.
Why hydrogen? That’s easy. Hydrogen is the simplest and most abundant element on the planet, and in fact, in the universe. Hydrogen, with oxygen, makes up water (H2O) and is also found in nearly all organic compounds. Hydrogen is so highly combustible it has served as a primary rocket fuel, including in the U.S. Space Shuttle program. Hydrogen is also being explored by NASA for hydrogen hybrid fuel cell/gas turbine engines for commercial aviation and other missions.
More importantly to us here on Earth, hydrogen burns in air without carbon emissions and its only byproducts are water vapor and oxides of nitrogen (NOx), the latter because air contains nitrogen. When used to create electricity through an electrochemical fuel cell, there is no combustion and thus no unwanted emissions at all, just heat and water vapor. This is the high-profile environmental calling card of hydrogen fuel cell vehicles. It’s also a growth market, with Research and Markets projecting the hydrogen fuel cell vehicle market growing from $8.21 billion this year to $20.49 billion in 2030. Overall, all this would appear to make hydrogen an ideal fuel for our time.
Ah, but things are not so simple. Pure geologic ‘white’ hydrogen does exist in its natural gaseous state but has been considered rare, found deep in the earth and deemed economically and logistically unrealistic as a resource. So, while we may be surrounded by hydrogen, the fact that it’s typically bonded with other elements means it must be separated to yield the ideal fuel we seek.
Today most hydrogen is created by steam reforming natural gas, a thermo- chemical process that extracts hydrogen from methane. The resulting product is known as ‘grey’ hydrogen because of the carbon created and a less-than-ideal over- all environmental impact. When steam reforming is combined with carbon capture and storage it’s known as ‘blue’ hydrogen, with the process considered low carbon or carbon neutral since the carbon created is sequestered from the atmosphere.
A more environmentally compatible way of creating hydrogen is by electrolyzing water. This electrochemical process strips water’s two hydrogen atoms from its oxygen atom to produce hydrogen gas. Electrolysis requires significant electrical energy so where this energy is sourced is paramount. If the electrolytic process uses electricity from renewable sources like solar, wind, or hydroelectric power, this is known as ‘green’ hydrogen. That color designator changes to ‘pink’ hydrogen if the electricity comes from nuclear energy. Color palette aside, today’s challenge is to devise the most efficient, low cost, low carbon, and environmentally positive ways to source clean hydrogen to help drive us to a zero carbon future.
Not so long ago, hydrogen generated serious interest among most of the auto industry’s major players as it competed with the commercialization of other alter- native fuels, most notably alcohol fuels, natural gas, propane autogas, and electricity. We’ve all seen battery EVs surge ahead with many breakthroughs, product commitments, and not inconsequentially, enormous government funding. But that doesn’t mean hydrogen is down and out.
There have been many hydrogen vehicles developed and fielded in relatively small numbers over the past three decades. While some early models like Honda’s FCX were available in limited numbers to consumers, most others were exclusive to fleets, destined for field trials, or introduced as driveable prototypes or concepts. Among these zero-emission fuel cell vehicles were the Ford Focus FCV, GM HydroGen3 and Sequel FCEV, Hyundai Tucson FCEV, Mercedes-Benz F-Cell, Nissan Xterra FCV, Toyota FCHV, and VW Touran HyMotion. Taking another approach, models like the Mazda RX8-RE and BMW Hydrogen 7 sedan burned hydrogen in their internal combustion engines, nearly emissions-free with the exception of minimal NOx.
Efforts to commercialize hydrogen vehicles continue, though in ways different than what was seen in the recent past. There are fewer automakers making hydrogen a priority these days, though the ones that are involved count for a lot. Toyota, Honda, and Hyundai – and to a lesser extent GM and BMW – are seriously in the game on the light-duty side. Among the most notable hydrogen models are today’s Toyota Mirai and Hyundai Nexo hydrogen fuel cell vehicles, and in our recent past the Honda Clarity Fuel Cell sedan that was with us for a few short years until 2022.
Truck makers like Freightliner, Hyundai Motor, Volvo Trucks, and Nikola are also involved on the commercial end of the spectrum. Because of government regulations and the realities of the
market, it may be that hydrogen big rigs powered by fuel cells are destined to lead the way. As hydrogen power gains momentum in the commercial space, larger commercial trucks transporting weighty loads will likely be fueled with liquid hydrogen, rather than the gaseous hydrogen used by light-duty consumer and commercial vehicles. The reason is simple: hydrogen stored as a liquid in a cryogenic state (-253 degrees C) offers much greater energy density than gaseous hydrogen, which means more fuel can be carried on board for greater driving range.
A coordinated strategy involving hydrogen vehicles and fueling opportunities has always been required since one can’t exist without the other. Government has taken a lead role in providing grants and financial incentives for hydrogen fueling over the years and energy companies have stepped up to the plate, to a limited degree. We’ve seen automakers work hand-in-hand with energy giants like Shell and Chevron as limited rollouts of hydrogen vehicles have taken place exclusively in areas where hydrogen stations are available. There have also been coordinated efforts in developing hydrogen fueling along major highway corridors to support hydrogen commercial vehicles.
Hydrogen vehicles hold a distinct advantage over EVs since they can be refueled in about the same amount of time as a gas vehicle. However, they face a significantly greater challenge in finding a place to fill up. After Shell recently closed down seven public access H2 stations in California, this left just over 50 public hydrogen stations in the entire country, all of these in the Golden State with the exception of a single station in Hawaii. Shell continues to operate commercial hydrogen stations in California.
Innovations continue apace even amid these challenges. Though Honda’s Clarity FCV is behind us, this automaker is continuing on its hydrogen journey with a new plug-in hydrogen CR-V e-FCEV built in Ohio. The CR-V e-FCEV is being leased for $459 per month with a $15,000 hydrogen fuel credit. There’s other evidence of a growing emphasis on hydrogen power, like the hydrogen fuel cell joint venture between Honda and GM that aims to manufacture fuel cells at scale in Michigan to drastically lower their cost. Toyota is also assembling fuel cell modules at its Kentucky manufacturing plant for heavy-duty truck customers. Plus, major automotive suppliers are accelerating their activities with hydrogen vehicle systems and components.
Hydrogen’s potential is illustrated in interesting ways at Toyota’s port facility in Long Beach, California, where a FuelCell Energy Tri-gen system uses renewable biogas to create up to 1200 kg per day of hydrogen, 2.3 megawatts of renewable electricity, and 1400 gallons of water to support the automaker’s port operations. Hydrogen created here supplies a nearby heavy-duty fueling station for zero emission drayage operations and fuels Mirai FCEVs arriving at the port.
One of the most important pushes for hydrogen in recent times comes from $8 billion in funding from the Bipartisan Infrastructure Law supporting the creation of regional clean hydrogen hubs. The focus at seven designated hubs includes hydrogen production and distribution, with hydrogen created by electrolysis and other means combined with carbon capture. The aim is to produce three million metric tons of clean hydrogen annually. Establishing hubs strategically located across the country will serve to create an interconnected hydrogen ecosystem that will expand nationally in an effort to support a growing hydrogen economy.
As always, technologies evolve and new innovations come to light. Such is the case with hydrogen, as a new frontier is being explored that could exploit potentially vast reserves of ‘white’ hydrogen recently discovered on multiple continents, including North America. Trapped in geologic fields like oil and natural gas, this source of naturally occurring hydrogen can be extracted in similar ways and has the potential to provide massive amounts of low carbon hydrogen in the future.
Using the most abundant element in the universe to power our vehicles and lives is a compelling proposition, especially considering its ability to do so through fuel cells that produce only water vapor as a byproduct. That’s why so many scientists, engineers, companies, and governments are hard at work addressing hydrogen’s commercial challenges. Whatever direction hydrogen power takes in the years ahead in response to changing administrations and shifting clean energy strategies, trust that it will remain of interest as a potential answer to low- or no-carbon mobility. It promises to be an interesting journey
Even amid the huge effort now underway to gain market share with new and coming battery electric vehicles, automakers show a continuing interest in keeping the potential of hydrogen vehicles alive. Indeed, the most high-profile players in this space are taking the next steps toward normalizing the way we look at zero-emission hydrogen fuel cell vehicles, models that drive on electricity generated by an electrochemical reaction of hydrogen and oxygen.
One of the advantages of a hydrogen fuel cell vehicle has been its ability to refuel in five minutes and then deliver 300 or more miles of driving range. That’s about the same amount of time it takes to fill a gas tank, an important baseline. Electric vehicle batteries, on the other hand, typically take many hours to charge. Today’s electric vehicle fast-charging, and the potential for newly-developed extreme fast charging (XFC) technology, could diminish the hydrogen fuel cell vehicle’s rapid refueling advantage.
Still, high-profile players in the auto industry like Honda, Hyundai, and Toyota apparently feel strongly that hydrogen fuel cell electric vehicles (FCEVs) may play an important part in our driving future. Honda currently leases the Clarity Fuel Cell sedan to California residents living or working in areas where hydrogen fueling stations are available. Hyundai also offers its NEXO hydrogen fuel cell crossover model and Toyota its Mirai fuel cell sedan. Since there are only 47 hydrogen stations in the U.S. with 42 of these in California, it’s really no surprise that all three automakers focus their fuel cell vehicle sales exclusively to limited areas with hydrogen fueling.
Underscoring hydrogen’s continuing momentum, Toyota will shortly release its second generation Mirai sedan. Introduced five years ago as the first fuel cell model offered for sale to retail customers, Toyota’s current Mirai is as notable for its styling as it is for its advanced zero-emission propulsion. Its swoopy, angular, and stylistically forward design does speak ‘future” – which, by the way, is what ‘Mirai’ actually means in Japanese – but that design has been a bit too much for most folks’ taste. The coming, all-new 2021 Mirai changes all that.
As shown by the new model’s concept, the second-generation Mirai is nicely sculpted with smooth-flowing lines, presenting as a stylish mainstream sedan with coupe-like design influences. Evolving from the front-drive first-generation Mirai, it uses a new rear-drive platform with a more rigid body structure that’s longer, lower, and wider than its predecessor, riding on a 114.9-inch wheelbase and featuring a length of 195.8-inches with a 74.2-inch width.
This new design is accompanied by a reimagined interior that’s more spacious and now allows for five passenger seating rather than four. Its multimedia system includes navigation and dynamic audio provided by a JBL sound system with 14 speakers. The Mirai’s handsomely sculpted dash features a 12.3-inch, high resolution TFT touchscreen. Drivetrain advancements are also part of the package. While full details have not yet been disclosed, the 2021 Mirai is expected to feature a more advanced fuel cell system featuring increased performance and up to 30 percent greater driving range. Like the model before it, the new Mirai is capable of filling up its hydrogen tank in just five minutes.
Beyond light-duty vehicles, where hydrogen could become a major transportation fuel is in over-the-road trucks that travel fixed routes, where hydrogen refueling stations are available. While adding larger and heavier batteries to increase the range of personal-use electric vehicles is not a big problem, every pound of battery capacity added to increase the range of commercial trucks means a pound less of payload, impacting the bottom line. Thus, fuel cells could prove to have a large advantage over electric trucks and be appealing in the commercial world.
While adding larger and heavier batteries to increase the range of personal-use electric vehicles is not a big problem, every pound of battery capacity added to increase the range of commercial trucks means a pound less of payload, impacting the bottom line. Thus, fuel cells could prove to have a large advantage over electric trucks and be appealing in the commercial world.
Supporting this notion is Anheuser-Busch, which has ordered up to 800 Nikola Two hydrogen fuel cell semi-tractor trucks for its operations. Two prototypes are already delivering Budweiser beer. On another front, Hyundai and big-rig producer Cummins may jointly develop and commercialize fuel cell powertrains by combining Hyundai’s fuel cell systems with Cummins’ electric powertrain, battery, and control technologies. Toyota and Kenworth are building 10 fuel cell semi tractors for use in and around the Port of Los Angeles and Port Heuneme, California, where decreasing port-related emissions is a significant challenge.
Where is this all leading? Toward the future, of course…one that continues to evolve with an as-yet unknown mix of conventional, electrified, and alternative fuel vehicles being developed by legacy and newly-launched auto and truck manufacturers. Each has its own vision of what our driving future will look like. Time will tell what role hydrogen will play in this unfolding transportation world.
