Germany
In Situ Neutron Radiography Investigations of Hydrogen Related Processes in Zirconium Alloys
Jun 2021
Publication
In situ neutron radiography experiments can provide information about diffusive processes and the kinetics of chemical reactions. The paper discusses requirements for such investigations. As examples of the zirconium alloy Zircaloy-4 the hydrogen diffusion the hydrogen uptake during high-temperature oxidation in steam and the reaction in nitrogen/steam and air/steam atmospheres results of in situ neutron radiography investigations are reviewed and their benefit is discussed.
Experimental Investigation on the Burning Behavior of Homogenous H2-CO-Air Mixtures in an Obstructed Semi-confined Channel
Sep 2021
Publication
In the current work the combustion behavior of hydrogen-carbon monoxide-air mixtures in semiconfined geometries is investigated in a large horizontal channel facility (dimensions 9 m x 3 m x 0.6 m (L x W x H)) as a part of a joint German nuclear safety project. In the channel with evenly distributed obstacles (blockage ratio 50%) and an open to air ground face homogeneous H2-CO-air mixtures are ignited at one end. The combustion behavior of the mixture is analyzed using the signals of pressure sensors modified thermocouples and ionization probes for flame front detection that are distributed along the channel ceiling. In the experiments various fuel concentrations (cH2 + cCO = 14 to 22 Vol%) with different H2:CO ratios (75:25 50:50 and 25:75) are used and the transition regions for a significant flame acceleration to sonic speed (FA) as well as to a detonation (DDT) are investigated. The conditions for the onset of these transitions are compared with earlier experiments performed in the same facility with H2-air mixtures. The results of this work will help to allow a more realistic estimation of the pressure loads generated by the combustion of H2-CO-air mixtures in obstructed semi-confined geometries.
Monte-Carlo-Analysis of Minimum Burst Requirements for Composite Cylinders for Hydrogen Service
Sep 2021
Publication
For achieving Net Zero-aims hydrogen is an indispensable component probably the main component. For the usage of hydrogen a wide acceptance is necessary which requires trust in hydrogen based on absence of major incidents resulting from a high safety level. Burst tests stand for a type of testing that is used in every test standard and regulation as one of the key issues for ensuring safety in use. The central role of burst and proof test is grown to historical reasons for steam engines and steel vessels but - with respect for composite pressure vessels (CPVs) - not due an extraordinary depth of outcomes. Its importance results from the relatively simple test process with relatively low costs and gets its importance by running of the different test variations in parallel. In relevant test und production standards (as e. g. ECE R134) the burst test is used in at least 4 different meanings. There is the burst test on a) new CPVs and some others b) for determining the residual strength subsequent to various simulations of ageing effects. Both are performed during the approval process on a pre-series. Then there is c) the batch testing during the CPVs production and finally d) the 100% proof testing which means to stop the burst test at a certain pressure level. These different aspects of burst tests are analysed and compared with respect to its importance for the resulting safety of the populations of CPVs in service based on experienced test results and Monte-Carlo simulations. As main criterial for this the expected failure rate in a probabilistic meaning is used. This finally ends up with recommendations for relevant RC&S especially with respect to GTR 13."
Complex Hydrides for Hydrogen Storage – New Perspectives
Apr 2014
Publication
Since the 1970s hydrogen has been considered as a possible energy carrier for the storage of renewable energy. The main focus has been on addressing the ultimate challenge: developing an environmentally friendly successor for gasoline. This very ambitious goal has not yet been fully reached as discussed in this review but a range of new lightweight hydrogen-containing materials has been discovered with fascinating properties. State-of-the-art and future perspectives for hydrogen-containing solids will be discussed with a focus on metal borohydrides which reveal significant structural flexibility and may have a range of new interesting properties combined with very high hydrogen densities.
Hydrogeochemical Modeling to Identify Potential Risks of Underground Hydrogen Storage in Depleted Gas Fields
Nov 2018
Publication
Underground hydrogen storage is a potential way to balance seasonal fluctuations in energy production from renewable energies. The risks of hydrogen storage in depleted gas fields include the conversion of hydrogen to CH4(g) and H2S(g) due to microbial activity gas–water–rock interactions in the reservoir and cap rock which are connected with porosity changes and the loss of aqueous hydrogen by diffusion through the cap rock brine. These risks lead to loss of hydrogen and thus to a loss of energy. A hydrogeochemical modeling approach is developed to analyze these risks and to understand the basic hydrogeochemical mechanisms of hydrogen storage over storage times at the reservoir scale. The one-dimensional diffusive mass transport model is based on equilibrium reactions for gas–water–rock interactions and kinetic reactions for sulfate reduction and methanogenesis. The modeling code is PHREEQC (pH-REdox-EQuilibrium written in the C programming language). The parameters that influence the hydrogen loss are identified. Crucial parameters are the amount of available electron acceptors the storage time and the kinetic rate constants. Hydrogen storage causes a slight decrease in porosity of the reservoir rock. Loss of aqueous hydrogen by diffusion is minimal. A wide range of conditions for optimized hydrogen storage in depleted gas fields is identified.
Seasonal Storage and Alternative Carriers: A Flexible Hydrogen Supply Chain Model
May 2017
Publication
A viable hydrogen infrastructure is one of the main challenges for fuel cells in mobile applications. Several studies have investigated the most cost-efficient hydrogen supply chain structure with a focus on hydrogen transportation. However supply chain models based on hydrogen produced by electrolysis require additional seasonal hydrogen storage capacity to close the gap between fluctuation in renewable generation from surplus electricity and fuelling station demand. To address this issue we developed a model that draws on and extends approaches in the literature with respect to long-term storage. Thus we analyse Liquid Organic Hydrogen Carriers (LOHC) and show their potential impact on future hydrogen mobility. We demonstrate that LOHC-based pathways are highly promising especially for smaller-scale hydrogen demand and if storage in salt caverns remains uncompetitive but emit more greenhouse gases (GHG) than other gaseous or hydrogen ones. Liquid hydrogen as a seasonal storage medium offers no advantage compared to LOHC or cavern storage since lower electricity prices for flexible operation cannot balance the investment costs of liquefaction plants. A well-to-wheel analysis indicates that all investigated pathways have less than 30% GHG-emissions compared to conventional fossil fuel pathways within a European framework.
Production Costs for Synthetic Methane in 2030 and 2050 of an Optimized Power-to-Gas Plant with Intermediate Hydrogen Storage
Aug 2019
Publication
The publication gives an overview of the production costs of synthetic methane in a Power-to-Gas process. The production costs depend in particularly on the electricity price and the full load hours of the plant sub-systems electrolysis and methanation. The full-load hours of electrolysis are given by the electricity supply concept. In order to increase the full-load hours of methanation the size of the intermediate hydrogen storage tank and the size of the methanation are optimised on the basis of the availability of hydrogen. The calculation of the production costs for synthetic methane are done with economics for 2030 and 2050 and the expenditures are calculated for one year of operation. The sources of volume of purchased electricity are the short-term market long-term contracts direct-coupled renewable energy sources or seasonal use of surpluses. Gas sales are either traded on the short-term market or guaranteed by long-term contracts. The calculations show that an intermediate storage tank for hydrogen adjustment of the methanation size and operating electrolysis and methanation separately increase the workload of the sub-system methanation. The gas production costs can be significantly reduced. With the future expected development of capital expenditures operational expenditure electricity prices gas costs and efficiencies an economic production of synthetic natural gas for the years 2030 especially for 2050 is feasible. The results show that Power-to-Gas is an option for long-term large-scale seasonal storage of renewable energy. Especially the cases with high operating hours for the sub-system methanation and low electricity prices show gas production costs below the expected market prices for synthetic gas and biogas.
Risk-adjusted Preferences of Utility Companies and Institutional Investors for Battery Storage and Green Hydrogen Investment
Feb 2022
Publication
Achieving climate-neutrality requires considerable investment in energy storage systems (ESS) to integrate variable renewable energy sources into the grid. However investments into ESS are often unprofitable in particular for grid-scale battery storage and green hydrogen technologies prompting many actors to call for policy intervention. This study investigates investor-specific risk-return preferences for ESS investment and derives policy recommendations. Insights are drawn from 1605 experimental investment-related decisions obtained from 42 high-level institutional investors and utility representatives. Results reveal that both investor groups view revenue stacking as key to making ESS investment viable. While the expected return on investment is the most important project characteristic risk-return preferences for other features diverge between groups. Institutional investors appear more open to exploring new technological ventures (20% of utility respondents would not consider making investments into solar photovoltaic-hydrogen) whereas utilities seem to prefer greenfield projects (23% of surveyed institutional investors rejected such projects). Interestingly both groups show strong aversion towards energy market price risk. Institutional investors require a premium of 6.87 percentage points and utilities 5.54 percentage points for moving from a position of fully hedged against market price risk to a scenario where only 20% of revenue is fixed underlining the need for policy support.
Optimal Supply Chains and Power Sector Benefits of Green Hydrogen
Jul 2021
Publication
Green hydrogen can help to decarbonize parts of the transportation sector but its power sector interactions are not well understood so far. It may contribute to integrating variable renewable energy sources if production is sufficiently flexible in time. Using an open-source co-optimization model of the power sector and four options for supplying hydrogen at German filling stations we find a trade-of between energy efficiency and temporal flexibility. For lower shares of renewables and hydrogen more energy-efficient and less flexible small-scale on-site electrolysis is optimal. For higher shares of renewables and/or hydrogen more flexible but less energy-efficient large-scale hydrogen supply chains gain importance as they allow to temporally disentangle hydrogen production from demand via storage. Liquid hydrogen emerges as particularly beneficial followed by liquid organic hydrogen carriers and gaseous hydrogen. Large-scale hydrogen supply chains can deliver substantial power sector benefits mainly through reduced renewable curtailment. Energy modelers and system planners should consider the distinct flexibility characteristics of hydrogen supply chains in more detail when assessing the role of green hydrogen in future energy transition scenarios. We also propose two alternative cost and emission metrics which could be useful in future analyses.
Deployment of Fuel Cell Vehicles and Hydrogen Refueling Station Infrastructure: A Global Overview and Perspectives
Jul 2022
Publication
Hydrogen fuel cell vehicles can complement other electric vehicle technologies as a zeroemission technology and contribute to global efforts to achieve the emission reduction targets. This article spotlights the current deployment status of fuel cells in road transport. For this purpose data collection was performed by the Advanced Fuel Cells Technology Collaboration Programme. Moreover the available incentives for purchasing a fuel cell vehicle in different countries were reviewed and future perspectives summarized. Based on the collected information the development trends in the last five years were analyzed and possible further trends that could see the realization of the defined goals derived. The number of registered vehicles was estimated to be 51437 units with South Korea leading the market with 90% of the vehicles being concentrated in four countries. A total of 729 hydrogen refueling stations were in operation with Japan having the highest number of these. The analysis results clearly indicate a very positive development trend for fuel cell vehicles and hydrogen refueling stations in 2021 with the highest number of new vehicles and stations in a single year paralleling the year’s overall economic recovery. Yet a more ambitious ramp-up in the coming years is required to achieve the set targets.
Analysis and Design of Fuel Cell Systems for Aviation
Feb 2018
Publication
In this paper the design of fuel cells for the main energy supply of passenger transportation aircraft is discussed. Using a physical model of a fuel cell general design considerations are derived. Considering different possible design objectives the trade-off between power density and efficiency is discussed. A universal cost–benefit curve is derived to aid the design process. A weight factor wP is introduced which allows incorporating technical (e.g. system mass and efficiency) as well as non-technical design objectives (e.g. operating cost emission goals social acceptance or technology affinity political factors). The optimal fuel cell design is not determined by the characteristics of the fuel cell alone but also by the characteristics of the other system components. The fuel cell needs to be designed in the context of the whole energy system. This is demonstrated by combining the fuel cell model with simple and detailed design models of a liquid hydrogen tank. The presented methodology and models allows assessing the potential of fuel cell systems for mass reduction of future passenger aircraft.
Cost-effective Technology Choice in a Decarbonized and Diversified Long-haul Truck Transportation Sector: A U.S. Case Study
Dec 2021
Publication
Achieving net-zero emissions by 2050 will require accelerated efforts that include decarbonizing long-haul truck transportation. In this difficult-to-decarbonize low-margin industry economic transparency on technology options is vital for decision makers seeking to eliminate emissions. Battery electric (BET) and hydrogen fuel cell electric trucks (FCET) can represent emission-free alternatives to diesel-powered trucks (DT). Previous studies focus on cost competitiveness in weight-constrained transportation even though logistics research shows that significant shares of transportation are constrained by volume and analyze cost only for selected technologies hence impeding a differentiated market segmentation of future emission-free trucks. In this study the perspective of a rational investor is taken and it is shown that under current conditions in the U.S. BETs outperform FCETs in various long-haul use cases despite charging times and cargo deficits and will further increase their technological competitiveness to DTs. While future energy and fueling prices are decisive for BET competitiveness the analysis reveals that autonomous driving may change the picture in favor of FCETs.
Electrofuels from Excess Renewable Electricity at High Variable Renewable Shares: Cost, Greenhouse Gas Abatement, Carbon Use and Competition
Nov 2020
Publication
Increasing shares of variable renewable electricity (VRE) generation are necessary for achieving high renewable shares in all energy sectors. This results in increased excess renewable electricity (ERE) at times when supply exceeds demand. ERE can be utilized as a low-emission energy source for sector coupling through hydrogen production via electrolysis which can be used directly or combined with a carbon source to produce electrofuels. Such fuels are crucial for the transport sector where renewable alternatives are scarce. However while ERE increases with raising VRE shares carbon emissions decrease and may become a limited resource with several usage options including carbon storage (CCS). Here we perform a model based analysis for the German case until 2050 with a general analysis for regions with a high VRE reliance. Results indicate that ERE-based electrofuels could achieve a greenhouse gas (GHG) abatement of 74 MtCO2eq yearly (46% of current German transport emissions) by displacing fossil fuels at high fuel-cell electric vehicle (FCEV) shares at a cost of 250–320 V per tCO2eq. The capital expenditure of electrolysers was found not to be crucial for the cost despite low capacity factors due to variable ERE patterns. Carbon will likely become a limiting factor when aiming for stringent climate targets and renewable electricity-based hydrocarbon electrofuels replacing fossil fuels achieve up to 70% more GHG abatement than CCS. Given (1) an unsaturated demand for renewable hydrocarbon fuels (2) a saturated renewable hydrogen demand and (3) unused ERE capacities which would otherwise be curtailed we find that carbon is better used for renewable fuel production than being stored in terms of overall GHG abatement.
Underground Hydrogen Storage: Application of Geochemical Modelling in a Case Study in the Molasse Basin, Upper Austria
Feb 2019
Publication
Hydrogen storage in depleted gas fields is a promising option for the large-scale storage of excess renewable energy. In the framework of the hydrogen storage assessment for the “Underground Sun Storage” project we conduct a multi-step geochemical modelling approach to study fluid–rock interactions by means of equilibrium and kinetic batch simulations. With the equilibrium approach we estimate the long-term consequences of hydrogen storage whereas kinetic models are used to investigate the interactions between hydrogen and the formation on the time scales of typical storage cycles. The kinetic approach suggests that reactions of hydrogen with minerals become only relevant over timescales much longer than the considered storage cycles. The final kinetic model considers both mineral reactions and hydrogen dissolution to be kinetically controlled. Interactions among hydrogen and aqueous-phase components seem to be dominant within the storage-relevant time span. Additionally sensitivity analyses of hydrogen dissolution kinetics which we consider to be the controlling parameter of the overall reaction system were performed. Reliable data on the kinetic rates of mineral dissolution and precipitation reactions specifically in the presence of hydrogen are scarce and often not representative of the studied conditions. These uncertainties in the kinetic rates for minerals such as pyrite and pyrrhotite were investigated and are discussed in the present work. The proposed geochemical workflow provides valuable insight into controlling mechanisms and risk evaluation of hydrogen storage projects and may serve as a guideline for future investigations.
Protocol for Heavy-duty Hydrogen Refueling: A Modelling Benchmark
Sep 2021
Publication
For the successful deployment of the Heavy Duty (HD) hydrogen vehicles an associated infrastructure in particular hydrogen refueling stations (HRS) should be reliable compliant with regulations and optimized to reduce the related costs. FCH JU project PRHYDE aims to develop a sophisticated protocol dedicated to HD applications. The target of the project is to develop protocol and recommendations for an efficient refueling of 350 500 and 700 bar HD tanks of types III and IV. This protocol is based on modeling results as well as experimental data. Different partners of the PRHYDE European project are closely working together on this target. However modeling approaches and corresponding tools must first be compared and validated to ensure the high level of reliability for the modeling results. The current paper presents the benchmark performed in the frame of the project by Air Liquide Engie Wenger Engineering and NREL. The different models used were compared and calibrated to the configurations proposed by the PRHYDE project. In addition several scenarios were investigated to explore different cases with high ambient temperatures.
Planning, Optimisation and Evaluation of Small Power-to-Gas-to-Power Systems: Case Study of a German Dairy
May 2022
Publication
In the course of the energy transition distributed hybrid energy systems such as the combination of photovoltaic (PV) and battery storages is increasingly being used for economic and ecological reasons. However renewable electricity generation is highly volatile and storage capacity is usually limited. Nowadays a new storage component is emerging: the power-to-gas-to-power (PtGtP) technology which is able to store electricity in the form of hydrogen even over longer periods of time. Although this technology is technically well understood and developed there are hardly any evaluations and feasibility studies of its widespread integration into current distributed energy systems under realistic legal and economic market conditions. In order to be able to give such an assessment we develop a methodology and model that optimises the sizing and operation of a PtGtP system as part of a hybrid energy system under current German market conditions. The evaluation is based on a multi-criteria approach optimising for both costs and CO2 emissions. For this purpose a brute-force-based optimal design approach is used to determine optimal system sizes combined with the energy system simulation tool oemof.solph. In order to gain further insights into this technology and its future prospects a sensitivity analysis is carried out. The methodology is used to examine the case study of a German dairy and shows that PtGtP is not yet profitable but promising.
Potential for Hydrogen and Power-to-Liquid in a Low-carbon EU Energy System Using Cost Optimization
Oct 2018
Publication
Hydrogen represents a versatile energy carrier with net zero end use emissions. Power-to-Liquid (PtL) includes the combination of hydrogen with CO2 to produce liquid fuels and satisfy mostly transport demand. This study assesses the role of these pathways across scenarios that achieve 80–95% CO2 reduction by 2050 (vs. 1990) using the JRC-EU-TIMES model. The gaps in the literature covered in this study include a broader spatial coverage (EU28+) and hydrogen use in all sectors (beyond transport). The large uncertainty in the possible evolution of the energy system has been tackled with an extensive sensitivity analysis. 15 parameters were varied to produce more than 50 scenarios. Results indicate that parameters with the largest influence are the CO2 target the availability of CO2 underground storage and the biomass potential.
Hydrogen demand increases from 7 mtpa today to 20–120 mtpa (2.4–14.4 EJ/yr) mainly used for PtL (up to 70 mtpa) transport (up to 40 mtpa) and industry (25 mtpa). Only when CO2 storage was not possible due to a political ban or social acceptance issues was electrolysis the main hydrogen production route (90% share) and CO2 use for PtL became attractive. Otherwise hydrogen was produced through gas reforming with CO2 capture and the preferred CO2 sink was underground. Hydrogen and PtL contribute to energy security and independence allowing to reduce energy related import cost from 420 bln€/yr today to 350 or 50 bln€/yr for 95% CO2 reduction with and without CO2 storage. Development of electrolyzers fuel cells and fuel synthesis should continue to ensure these technologies are ready when needed. Results from this study should be complemented with studies with higher spatial and temporal resolution. Scenarios with global trading of hydrogen and potential import to the EU were not included.
Hydrogen demand increases from 7 mtpa today to 20–120 mtpa (2.4–14.4 EJ/yr) mainly used for PtL (up to 70 mtpa) transport (up to 40 mtpa) and industry (25 mtpa). Only when CO2 storage was not possible due to a political ban or social acceptance issues was electrolysis the main hydrogen production route (90% share) and CO2 use for PtL became attractive. Otherwise hydrogen was produced through gas reforming with CO2 capture and the preferred CO2 sink was underground. Hydrogen and PtL contribute to energy security and independence allowing to reduce energy related import cost from 420 bln€/yr today to 350 or 50 bln€/yr for 95% CO2 reduction with and without CO2 storage. Development of electrolyzers fuel cells and fuel synthesis should continue to ensure these technologies are ready when needed. Results from this study should be complemented with studies with higher spatial and temporal resolution. Scenarios with global trading of hydrogen and potential import to the EU were not included.
Methanol Synthesis Using Captured CO2 as Raw Material: Techno-economic and Environmental Assessment
Aug 2015
Publication
The purpose of this paper is to assess via techno-economic and environmental metrics the production of methanol (MeOH) using H2 and captured CO2 as raw materials. It evaluates the potential of this type of carbon capture and utilisation (CCU) plant on (i) the net reduction of CO2 emissions and (ii) the cost of production in comparison with the conventional synthesis process of MeOH Europe. Process flow modelling is used to estimate the operational performance and the total purchased equipment cost; the flowsheet is implemented in CHEMCAD and the obtained mass and energy flows are utilised as input to calculate the selected key performance indicators (KPIs). CO2 -based metrics are used to assess the environmental impact. The evaluated MeOH plant produces 440 ktMeOH/yr and its configuration is the result of a heat integration process. Its specific capital cost is lower than for conventional plants. However raw materials prices i.e. H2 and captured CO2 do not allow such a project to be financially viable. In order to make the CCU plant financially attractive the price of MeOH should increase in a factor of almost 2 or H2 costs should decrease almost 2.5 times or CO2 should have a value of around 222 €/t under the assumptions of this work. The MeOH CCU-plant studied can utilise about 21.5% of the CO2 emissions of a pulverised coal (PC) power plant that produces 550MWnet of electricity. The net CO2 emissions savings represent 8% of the emissions of the PC plant (mainly due to the avoidance of consuming fossil fuels as in the conventional MeOH synthesis process). The results demonstrate that there is a net but small potential for CO2 emissions reduction; assuming that such CCU plants are constructed in Europe to meet the MeOH demand growth and the quantities that are currently imported the net CO2 emissions reduction could be of 2.71 MtCO2/yr.
Life Cycle Assessment of Hydrogen from Proton Exchange Membrane Water Electrolysis in Future Energy Systems
Jan 2019
Publication
This study discusses the potential of H2 production by proton exchange membrane water electrolysis as an effective option to reduce greenhouse gas emissions in the hydrogen sector. To address this topic a life cycle assessment is conducted to compare proton exchange membrane water electrolysis versus the reference process - steam methane reforming. As a relevant result we show that hydrogen production via proton exchange membrane water electrolysis is a promising technology to reduce CO2 emissions of the hydrogen sector by up to 75% if the electrolysis system runs exclusively on electricity generated from renewable energy sources. In a future (2050) base-load operation mode emissions are comparable to the reference system.
The results for the global warming potential show a strong reduction of greenhouse gas emissions by 2050. The thoroughly and in-depth modelled components of the electrolyser have negligible influence on impact categories; thus emissions are mainly determined by the electricity mix. With 2017 electricity mix of Germany the global warming potential corresponds to 29.5 kg CO2 eq. for each kg of produced hydrogen. Referring to the electricity mix we received from an energy model emissions can be reduced to 11.5 kg CO2 eq. in base-load operation by the year 2050. Using only the 3000 h of excess power from renewables in a year will allow for the reduction of the global warming potential to 3.3 kg CO2 eq. From this result we see that an environmentally friendly electricity mix is crucial for reducing the global warming impact of electrolytic hydrogen.
The results for the global warming potential show a strong reduction of greenhouse gas emissions by 2050. The thoroughly and in-depth modelled components of the electrolyser have negligible influence on impact categories; thus emissions are mainly determined by the electricity mix. With 2017 electricity mix of Germany the global warming potential corresponds to 29.5 kg CO2 eq. for each kg of produced hydrogen. Referring to the electricity mix we received from an energy model emissions can be reduced to 11.5 kg CO2 eq. in base-load operation by the year 2050. Using only the 3000 h of excess power from renewables in a year will allow for the reduction of the global warming potential to 3.3 kg CO2 eq. From this result we see that an environmentally friendly electricity mix is crucial for reducing the global warming impact of electrolytic hydrogen.
Artificial Intelligence-Based Machine Learning toward the Solution of Climate-Friendly Hydrogen Fuel Cell Electric Vehicles
Jul 2022
Publication
The rapid conversion of conventional powertrain technologies to climate-neutral new energy vehicles requires the ramping of electrification. The popularity of fuel cell electric vehicles with improved fuel economy has raised great attention for many years. Their use of green hydrogen is proposed to be a promising clean way to fill the energy gap and maintain a zero-emission ecosystem. Their complex architecture is influenced by complex multiphysics interactions driving patterns and environmental conditions that put a multitude of power requirements and boundary conditions around the vehicle subsystems including the fuel cell system the electric motor battery and the vehicle itself. Understanding its optimal fuel economy requires a systematic assessment of these interactions. Artificial intelligence-based machine learning methods have been emerging technologies showing great potential for accelerated data analysis and aid in a thorough understanding of complex systems. The present study investigates the fuel economy peaks during an NEDC in fuel cell electric vehicles. An innovative approach combining traditional multiphysics analyses design of experiments and machine learning is an effective blend for accelerated data supply and analysis that accurately predicts the fuel consumption peaks in fuel cell electric vehicles. The trained and validated models show very accurate results with less than 1% error.
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