Mitigating Power Deficits in Lean-Burn Hydrogen Engines with Mild Hybrid Support for Urban Vehicles

Hydrogen-fueled internal combustion engines present a promising pathway for reducing carbon emissions in urban transportation by allowing for the reuse of existing vehicle platforms while eliminating carbon dioxide emissions from the exhaust. However, operating these engines with lean air–fuel mixtures—necessary to reduce nitrogen oxide emissions and improve thermal efficiency—leads to significant reductions in power output due to the low energy content of hydrogen per unit volume and slower flame propagation. This study investigates whether integrating a mild hybrid electric system, operating at 48 volts, can mitigate the performance losses associated with lean hydrogen combustion in a small passenger vehicle. A complete simulation was carried out using a validated one-dimensional engine model and a full zero-dimensional vehicle model. A Design of Experiments approach was employed to vary the electric motor size (from 1 to 15 kW) and battery capacity (0.5 to 5 kWh) while maintaining a fixed system voltage, optimizing both the component sizing and control strategy. Results showed that the best lean hydrogen hybrid configuration achieved reductions of 18.6% in energy consumption in the New European Driving Cycle and 5.5% in the Worldwide Harmonized Light Vehicles Test Cycle, putting its performance on par with the gasoline hybrid benchmark. On average, the lean H2 hybrid consumed 41.2 kWh/100 km, nearly matching the 41.0 kWh/100 km of the gasoline P0 configuration. Engine usage analysis demonstrated that the mild hybrid system kept the hydrogen engine operating predominantly within its high-efficiency region. These findings confirm that lean hydrogen combustion, when supported by appropriately scaled mild hybridization, is a viable near-zero-emission solution for urban mobility— delivering competitive efficiency while avoiding tailpipe CO2 and significantly reducing NOx emissions, all with reduced reliance on large battery packs.