Fuel Cell Powertrain Research Articles

Experimental validation of a predictive energy management strategy for agricultural fuel cell electric tractors

Efficiency and durability are critical challenges for the large-scale adoption of fuel cell powertrains in agricultural tractors due to the demanding nature of farm-related tasks. This study presents a novel predictive energy management strategy that uses forecasts of the average load of the farming cycle to achieve stationary fuel cell operation, thus limiting degradation caused by load cycling, high-power, and low-power operation. The recurrent characteristics exhibited by agricultural duty cycles allow the calculation of highly accurate average load prediction, which can be sufficient for a predictive energy management strategy to reduce degradation without hindering fuel consumption. As a result, this forecast is utilized in conjunction with a straightforward and real-time-capable energy management strategy, which foresees the operation of the fuel cell system at the level of the average load. The work is structured into two main contributions: model-based design of the energy management strategy, and experimental validation on a fuel cell powertrain testbed. Three typical agricultural duty cycles were studied to evaluate the benefits of the proposed strategy, demonstrating that energy management strategies can mitigate fuel cell degradation without compromising system efficiency. In particular, the predictive energy management strategy offers the potential to mitigate the negative impact of tractor operational idling time at the headland turns through the reduction of fuel consumption, thereby enhancing overall tractor performance. The experimental powertrain setup stands as an innovative contribution within the research landscape concerning fuel cell powertrains for tractors and validates the benefits of the proposed strategy. Furthermore, the conducted testbed analyses assume significance in highlighting the effects of the energy management strategy on the physical fuel cell operating factors and emphasizing the comprehensive benefits across the powertrain system, particularly with regard to the thermal management of the fuel cell system, where the prevention of derating is achievable through the implementation of the proposed energy management approach. Overall, the findings of this study have important implications for the development of sustainable and efficient farming procedures through the adoption of fuel cell technology in agricultural machinery.

Optimal performance and preliminary parameter matching for hydrogen fuel cell powertrain system of electric aircraft

Fuel cells are true net-zero carbon emission power sources for aircraft, which is highly sensitive to weight. In the initial phase of adapting hydrogen fuel cell systems for aircraft powertrains, preliminary design parameter matching remains premature. An explicit method for the performance optimization of aircraft hydrogen fuel cell powertrain systems and a process of preliminary parameter matching are proposed to address this problem. Performance and weight models of the fuel cell stack and its auxiliaries, the cathode air compressor subsystem, and the cooling subsystem are designed, and system performance at various altitudes and power output levels is calculated. The aircraft flight mission performance is synthesized and considered in the optimization process. The optimization result of system performance and the corresponding design parameters are then graphically illustrated as tern plots. Unlike the traditional iterative preliminary system parameter matching and optimization method, which explores the design space non-directionally and converges to a single local optimal point, the proposed explicit method sweeps the design space globally and obtains a group of design points with acceptable optimality. The system design process is boosted by a compact iterative loop. In the optimization practice, the cruise powertrain specific energy is improved by 6.5%. The relationship between specific system design parameters and system performance is displayed globally by the resulting tern plots. Multiple design guidelines are observed and proposed, and design scenarios are directly obtained from the graphs for further engineering processes.

Carbon Footprint Enhancement of an Agricultural Telehandler through the Application of a Fuel Cell Powertrain

The growing awareness about climate change and environmental pollution is pushing the industrial and academic world to investigate more sustainable solutions to reduce the impact of anthropic activities. As a consequence, a process of electrification is involving all kind of vehicles with a view to gradually substitute traditional powertrains that emit several pollutants in the exhaust due to the combustion process. In this context, fuel cell powertrains are a more promising strategy, with respect to battery electric alternatives where productivity and endurance are crucial. It is important to replace internal combustion engines in those vehicles, such as the those in the sector of Non-Road Mobile Machinery. In the present paper, a preliminary analysis of a fuel cell powertrain for a telehandler is proposed. The analysis focused on performance, fuel economy, durability, applicability and environmental impact of the vehicle. Numerical models were built in MATLAB/Simulink and a simple power follower strategy was developed with the aim of reducing components degradation and to guarantee a charge sustaining operation. Simulations were carried out regarding both peak power conditions and a typical real work scenario. The simulations’ results showed that the fuel cell powertrain was able to achieve almost the same performances without excessive stress on its components. Indeed, a degradation analysis was conducted, showing that the fuel cell system can achieve satisfactory durability. Moreover, a Well-to-Wheel approach was adopted to evaluate the benefits, in terms of greenhouse gases, of adopting the fuel cell system. The results of the analysis demonstrated that, even if considering grey hydrogen to feed the fuel cell system, the proposed powertrain can reduce the equivalent CO2 emissions of 69%. This reduction can be further enhanced using hydrogen from cleaner production processes. The proposed preliminary analysis demonstrated that fuel cell powertrains can be a feasible solution to substitute traditional systems on off-road vehicles, even if a higher investment cost might be required.

Novel custom-made design and analysis of hydrogen PEM fuel cell for high endurance small UAV applications.

The purpose of this paper is to propose a new methodology to devise a custom-made hydrogen-based proton-exchange membrane fuel cell (PEMFC) system for a class of experimental fixed-wing small unmanned aerial vehicles (SUAVs). The proposed fuel cell provides three times higher flight endurance than the conventional battery-based powertrain. The chosen SUAV represents a class of high-altitude UAVs, having an operational altitude of 4500m (14,760ft), cruising speed of 12-20m/s (39.4-65.6 ft/s), take-off weight of 4kg, wing-span of 1.61 m (5.28 ft) and battery-powered flight endurance of 1 h. The characteristic parameters and design configurations of the fuel cell are determined by employing the first principles of electrochemistry and thermodynamics. Corresponding simulations are performed using popular development tools like MATLAB/Simulink. The vital results in the form of - polarization and power curves for fuel cells, against the current density are obtained, which are further narrowed down to meet the target power requirements for determining the size of the hydrogen storage tank. The paper also comments on the auxiliary systems and fuel cell powertrain for SUAVs. Finally, the design efficiency of 54% for the fuel cell is achieved with respect to equivalent voltage for heating value with the calculated hydrogen storage tank size of 5.688ls. This yields three times higher flight endurance as compared to the flight time found in literature for the same class of SUAVs.

CFD-3D and 1D modeling of fuel cell powertrain for a hydrogen vehicle

As it is known the transport sector represents a major contributor to climate change. In particular, private transport contributes to the degradation of the air quality inside the cities or the residential areas. To address this issue, a progressive reduction of the use of fossil fuels as a primary energy source for these vehicles and the promotion of cleaner powertrain alternatives is in order. This study focuses on designing a fuel cell powertrain for a hydrogen-powered passenger car using numerical modeling. To this purpose, we initially modeled a base fuel cell and optimized its performance by using various materials for the bipolar plates and adjusting the platinum loading between the anode and cathode. Then, a preliminary design of the new powertrain has been proposed in order to achieve a nominal power of 100 kW and it has been tested on a WLTP 3b homologation cycle. Finally, we have been able to numerically estimate the behavior of the three main feeding line: hydrogen line, air line and cooling line. In conclusion, the obtained results demonstrate how numerical modelling can be successfully used in the design of complex systems such as those related to alternative energy. This work also provides a solid basis for the future development of increasingly efficient and environmentally friendly hydrogen vehicles.

Investigation of drive cycle simulation performance for electric, hybrid, and fuel cell powertrains of a small-sized vehicle

The powertrain simulations of electric, hybrid, and fuel cell hybrid vehicles for the determination of vehicle performance and powertrain efficiency have been studied in the last few decades. Related investigations on fuel cell hybrid vehicles mainly focus on the improvement of a specific powertrain component or vehicle performance for a specific hybrid type. Therefore, this study aims to investigate the effects of not only a specific hybrid configuration but also various electric and fuel cell hybrid powertrain alternatives comparatively including fuel cell, battery, and supercapacitor as energy sources on component efficiency via drive cycle simulations depending on the same vehicle parameters and capacity of the components. Four powertrain cases that differ from each other in terms of the electric power sources (battery, supercapacitor, and fuel cell) were modeled and simulated according to the ECE-15, JPN 10–15, and WLTP drive cycle using MATLAB® - Simulink® environment. The simulations gave the power outputs of powertrain components and component efficiencies, state of charge of the battery, hydrogen consumption, and airflow rate of the fuel cell during the drive cycle. The results showed that better battery efficiency is obtained in Case-1; better vehicle range and lower battery power output than Case-1 can be achieved in Case-2; better fuel cell efficiency is obtained in Case-3; and the lowest H2 consumption is obtained in Case-4. Thus, desired powertrain performance and powertrain efficiency can be achieved by choosing the proper powertrain component in hybrid vehicles.

Design and Experimental Validation of a Scaled Test Bench for the Emulation of a Hybrid Fuel Cell Powertrain for Agricultural Tractors

Hybrid fuel cell powertrains are a promising strategy to reduce the environmental impact of vehicles and non-road mobile machinery. To preserve the state-of-health of fuel cells, an energy storage system with sufficient power capacity, such as ultra-capacitors or batteries, should be introduced in the system to help the fuel cell during sudden and abrupt changes in power demands. However, the presence of two or more energy sources necessitates the development of an energy management strategy. The energy management strategy should properly split the power request between the different energy sources. In this paper, the design and the experimental validation of a scaled test bench for the emulation of a fuel cell/battery powertrain for a vehicular application is presented. The fuel cell is emulated through an analogically controlled DC power source that reproduces its real voltage–current curve. To split the power between the emulated fuel cell and the batteries, controlled DC-DC is used and a simple energy management strategy based on a proportional-integral controller is developed. The external load is reproduced using a load unit composed of a programmable electronic load and a power supply. Experimental tests are performed to evaluate the system behaviour and to characterize its main components. The experimental results show that the system successfully emulates the powertrain in accordance with the proposed energy management strategy.

Flexible Test Platform for Accelerating the Validation of Fuel Cell Powertrains

Flexible Test Platform for Accelerating the Validation of Fuel Cell Powertrains

Vehicle-cycle and life-cycle analysis of medium-duty and heavy-duty trucks in the United States

Medium- and heavy-duty vehicles account for a substantial portion (25 %) of transport-related greenhouse gas (GHG) emissions in the United States. Efforts to reduce these emissions focus primarily on diesel hybrids, hydrogen fuel cells, and battery electric vehicles. However, these efforts ignore the high energy intensity of producing lithium (Li)-ion batteries and the carbon fiber used in fuel-cell vehicles. Here, we conduct a life-cycle analysis to compare the impacts of the vehicle manufacturing cycle for Class 6 (pickup-and-delivery, PnD) and Class 8 (day- and sleeper-cab) trucks with diesel, electric, fuel-cell, and hybrid powertrains. We assume that all trucks were manufactured in the US in 2020 and operated over 2021–2035, and we developed a comprehensive materials inventory for all trucks. Our analysis reveals that common systems (trailer/van/box, truck body, chassis, and lift-gates) dominate the vehicle-cycle GHG emissions (64–83 % share) of diesel, hybrid, and fuel-cell powertrains. Conversely, propulsion systems (lithium-ion batteries and fuel-cell systems) contribute substantially to these emissions for electric (43–77 %) and fuel-cell powertrains (16–27 %). These vehicle-cycle contributions arise from the extensive use of steel and aluminum, the high energy/GHG intensity of producing lithium-ion batteries and carbon fiber, and the assumed battery replacement schedule for Class 8 electric trucks. A switch from the conventional diesel powertrain to alternative electric and fuel-cell powertrains causes an increase in vehicle-cycle GHG emissions (by 60–287 % and 13–29 %, respectively) but leads to substantial GHG reductions when considering the combined vehicle- and fuel-cycles (Class 6: 33–61 %, Class 8: 2–32 %), highlighting the benefits of this shift in powertrains and energy supply chain. Finally, payload variation significantly influences the relative life-cycle performance of different powertrains, while LIB cathode chemistry has a negligible effect on BET life-cycle GHGs.

A techno-economic analysis of ammonia-fuelled powertrain systems for rail freight

All diesel-only trains in the UK will be removed from services by 2040. High volumetric density, rapid refuelling ability, and sophisticated experience in infrastructure and logistics make ammonia a perfect hydrogen carrying fuel for rail freight, which urgently requires an economically viable solution. This study conducted a novel techno-economic study of ammonia-fuelled fuel cell powertrains to be compared with current diesel engine-based system and emerging direct hydrogen-fuelled fuel cell system. The results demonstrate that hydrogen-fuelled Proton-Exchange Membrane Fuel Cells (PEMFCs) and ammonia-fuelled PEMFCs (using an ammonia cracker) are more cost-effective in terms of Levelized Cost of Electricity. The ammonia fuel storage requires 61.5-75 % less space compared to the hydrogen storage. Although the ammonia-fuelled Solid Oxide Fuel Cells (SOFCs) powertrain has the highest electricity generation efficiency (56%), the overall cost requires a major reduction by 70% before it could be considered as an economically viable solution.

Comprehensive analysis of cathode air pressure of fuel cell powertrain system of aircraft: Performance, efficiency, and control

Fuel cells are ideal power sources for aircraft. However, fuel cells are highly sensitive to operating pressure, which complicates the operating characteristics of fuel cells at various altitudes. A globally optimal cathode pressure control method of aircraft fuel cell powertrain system is proposed to address the abovementioned problem. Simplified PEM (Polymer Electrolyte Membrane) fuel cell and electric motor driven two stage centrifugal compressor supercharger models are designed and validated, with the fuel cell model focusing on a wide range of variable cathode air pressures and the supercharger model focusing on a wide range of altitudes, to consider both calculation accuracy and amount. Compared with a physical fuel cell model and a CFD supercharger model, the simplified model boosts the calculation speed by approximately 107 times. The performance and efficiency of the fuel cell system at different altitudes, current densities, and charged air pressures are analyzed using the simplified model. With massive 3-dimensional data, an optimal pressure strategy is proposed to ensure that the system operates at the highest efficiency at any flight altitude and system output power. A near-optimal air pressure strategy is also proposed for better system stability and lower stress at an acceptable efficiency loss. The advantage of the two strategies over the commonly used fixed pressure strategy is demonstrated using a simple flight profile, where they reduce system hydrogen consumption during aircraft take-off and climbing by up to 3.4 % and 1.5 %.

Assessing the performance of a demonstrative hydrogen fuel cell power train in the chassis of an internal combustion engine vehicle

In the present day in the global context, approximately 2 billion internal combustion engines (ICEs) are estimated to be in use. Nearly 7.3 billion metric tons of carbon dioxide (CO2) were released into the atmosphere as per the survey on the transportation sector in 2020, making up 41% of all emissions. To solve pollution challenges related to ICEs, recent advancements of alternatives to ICEs have pushed the globe to establish clean energy sources such as hydrogen fuel cells. The conversion of an ICE vehicle to a fuel cell vehicle is able to add further support to its development besides the 30% emission reduction since the old ICE vehicle would not be discarded. FCEVs are seen as a true replacement between BEVs and ICEs since more energy can be stored in less space as compared to BEVs. The objective of this paper is to analyse the energy consumption of a fuel cell-driven motor in the internal combustion engine vehicle chassis of Maruti 800, through mathematical modelling, then compare the specifications with that of an ICE-driven system. The analysis provides details on the optimization of drive system components to maximise the fuel cell energy consumption efficiency based on fuel cell power source requirements for a range of velocities and road gradients. The modifiable specifications of drive system components in the mathematical model ensure reproducibility for any drive cycles and system scenarios.

The future technological potential of hydrogen fuel cell systems for aviation and preliminary co-design of a hybrid regional aircraft powertrain through a mathematical tool

The growing demand for air travel in the commercial sector leads to an increase in global emissions, whose mitigation entails transitioning from the current fossil-fuel based generation of aircrafts to a cleaner one within a short timeframe. The use of hydrogen and fuel cells has the potential to reach zero emissions in the aerospace sector, provided that required innovation and research efforts are substantially accomplished. Development programs, investments and new regulations are needed for this technology to be safe and economical. In this context, it makes sense to develop a model-based preliminary design methodology for a hybrid regional aircraft assisted by a battery hybridized fuel cell powertrain. The technological assumptions underlying the study refer to both current and expected data for 2035. The major contribution of the proposed methodology is to provide a mathematical tool that considers the interactions between the choice of components in terms of installed power and energy management. This simultaneous study is done because of the availability of versatile control maps. The tool was then deployed to define current and future technological scenarios for fuel cell, battery and hydrogen storage systems, by quickly adapting control strategies to different sizing criteria and technical specifications. In this way, it is possible to facilitate the estimation of the impact of different sizing criteria and technological features, at the aircraft level, on the onboard electrical system, the management of in-flight power, the propulsion methods, the impact of the masses on consumption and operational characteristics in a typical flight mission. The proposed combination of advanced sizing and energy management strategies allowed meeting mass and volume constraints with state-of-the-art PEM fuel cell and Li-ion battery specifications. Such a solution corresponds to a high degree of hybridization between the fuel cell system and battery pack (i.e., 300 kW and 750 kWh), whereas projected 2035 specs were demonstrated to help reduce mass and volume by 23 % and 40 %, respectively.

Flexible Test Platform for Accelerating the Validation of Fuel Cell Powertrains

Flexible Test Platform for Accelerating the Validation of Fuel Cell Powertrains

A Review of Fuel Cell Powertrains for Long-Haul Heavy-Duty Vehicles: Technology, Hydrogen, Energy and Thermal Management Solutions

Long-haul heavy-duty vehicles, including trucks and coaches, contribute to a substantial portion of the modern-day European carbon footprint and pose a major challenge in emissions reduction due to their energy-intensive usage. Depending on the hydrogen fuel source, the use of fuel cell electric vehicles (FCEV) for long-haul applications has shown significant potential in reducing road freight CO2 emissions until the possible maturity of future long-distance battery-electric mobility. Fuel cell heavy-duty (HD) propulsion presents some specific characteristics, advantages and operating constraints, along with the notable possibility of gains in powertrain efficiency and usability through improved system design and intelligent onboard energy and thermal management. This paper provides an overview of the FCEV powertrain topology suited for long-haul HD applications, their operating limitations, cooling requirements, waste heat recovery techniques, state-of-the-art in powertrain control, energy and thermal management strategies and over-the-air route data based predictive powertrain management including V2X connectivity. A case study simulation analysis of an HD 40-tonne FCEV truck is also presented, focusing on the comparison of powertrain losses and energy expenditures in different subsystems while running on VECTO Regional delivery and Longhaul cycles. The importance of hydrogen fuel production pathways, onboard storage approaches, refuelling and safety standards, and fleet management is also discussed. Through a comprehensive review of the H2 fuel cell powertrain technology, intelligent energy management, thermal management requirements and strategies, and challenges in hydrogen production, storage and refuelling, this article aims at helping stakeholders in the promotion and integration of H2 FCEV technology towards road freight decarbonisation.

Performance Evaluation for Ultra-Lightweight Epoxy-Based Bipolar Plate Production with Cycle Time Reduction of Reactive Molding Process.

The commercial viability of fuel cells for vehicle application has been examined in the context of lightweight material options, as well as in combination with improvements in fuel cell powertrain. Investigation into ultra-lightweight bipolar plates (BPs), the main component in terms of the weight effect, is of great importance to enhance energy efficiency. This research aims to fabricate a layered carbon fiber/epoxy composite structure for BPs. Two types of carbon fillers (COOH-MWCNT and COOH-GNP) reinforced with woven carbon fiber sheets (WCFS) have been utilized. The conceptual idea is to reduce molding cycle time by improving the structural, electrical, and mechanical properties of BPs. Reducing the reactive molding cycle time is required for commercial production possibility. The desired crosslink density of 97%, observed at reactive molding time, was reduced by 83% at 140 °C processing temperature. The as-fabricated BPs demonstrate excellent electrical conductivity and mechanical strength that achieved the DOE standard. Under actual fuel cell operation, the as-fabricated BPs show superior performance to commercial furan-based composite BPs in terms of the cell potential and maximum power. This research demonstrates the practical and straightforward way to produce high-performance and reliable BPs with a rapid production rate for actual PEMFC utilization.

A framework for the replacement analysis of a hydrogen-based polymer electrolyte membrane fuel cell technology on board ships: A step towards decarbonization in the maritime sector

Maritime transport is one of the largest greenhouse gas emitting sectors of the global economy, responsible for around 1 GtCO2eq every year. To comply with the reduction of carbon dioxide emissions, the research is devoted introducing low and zero-carbon fuels and innovative propulsion technologies. In this context, hydrogen fuel cell powertrains can play a crucial role due to their high energy and environmental performances. In this paper, a techno-economic feasibility analysis for replacing an 8.3 MW diesel engine with a polymer electrolyte membrane fuel cell system is performed for a chemical tanker ship. For this purpose, a detailed method, that aims to estimate the volume and mass of the fuel cell system as well as of the hydrogen storage technologies, is developed. Three on board hydrogen storage technologies are considered: i) compressed hydrogen, ii) liquid hydrogen, iii) metal hydrides. Results highlight that the fuel cell-based powertrain is characterized by 60% less volume and 56% less mass compared to the diesel engine. As far as the hydrogen storage technologies are concerned, all solutions present significantly lower volumetric and gravimetric energy densities and therefore, additional volume and mass are required in comparison with diesel fuel configuration. These results involve a reduction of the total cargo capacity to comply with tanker ship physical constraints. The cargo should be reduced by 1.3%-1.1% for compressed hydrogen (at 350 bar and 700 bar, respectively), 0.1% for liquid hydrogen, and 9% for metal hydrides. Finally, the economic assessment in terms of Operational Expenditures, based upon the predicted hydrogen price reduction as well as the diesel price increase, in different cost scenarios (2020–2050), are evaluated. Results show that the competitiveness of the hydrogen solution with a retail price of 4 $/kg can be achieved by considering an incentive for the avoided CO2 equal to 112 $/tons.

Photovoltaic integrated electric vehicles: Assessment of synergies between solar energy, vehicle types and usage patterns

Electric vehicles are promoting sustainable developments in the automotive industry. But the short driving range has been an inconvenience to the electric vehicle (EV) users. This paper evaluates the potential of Photovoltaic integrated into EV in real-world conditions to assess energy consumption, range and EV's charging frequency for battery and fuel cell powertrain configurations. A simulation model is developed, which estimates the energy production through onboard Photovoltaics, energy consumption, and range under diverse driving profiles for five different vehicle types, ranging from Micro-car, 5 seaters light-duty vehicle, Shuttle and heavy-duty vehicles.The results showed that the range increased with reduced energy consumption and charging frequency with onboard Photovoltaics for battery powertrain configuration. The range improved by 30–50% for Microcar and 30–100% for the 5-seater vehicle with the private driving profile. Simultaneously, for Shuttle, an increase in the range between 5 and 15% is reported. On the contrary, the results indicated the fuel cell powertrain configuration does not present an added value with onboard Photovoltaics. Further analysis showed that the higher irradiance rates improved the operational period of Photovoltaic integrated into EV by 5 more days than standard EV. Finally, the economic analysis revealed that Photovoltaics integrated into EV is profitable, reaching the break-even point on the additional photovoltaics expense before the half-life of the vehicle, which makes the total ownership cost lower than a standard EV for its lifetime.

An Optimal Fuzzy Logic-Based Energy Management Strategy for a Fuel Cell/Battery Hybrid Power Unmanned Aerial Vehicle

With the development of high-altitude and long-endurance unmanned aerial vehicles (UAVs), optimization of the coordinated energy dispatch of UAVs’ energy management systems has become a key target in the research of electric UAVs. Several different energy management strategies are proposed herein for improving the overall efficiency and fuel economy of fuel cell/battery hybrid electric power systems (HEPS) of UAVs. A rule-based (RB) energy management strategy is designed as a baseline for comparison with other strategies. An energy management strategy (EMS) based on fuzzy logic (FL) for HEPS is presented. Compared with classical rule-based strategies, the fuzzy logic control has better robustness to power fluctuations in the UAV. However, the proposed FL strategy has an inherent defect: the optimization performances will be determined by the heuristic method and the past experiences of designers to a great extent rather than a specific cost function of the algorithm itself. Thus, the paper puts forward an improved fuzzy logic-based strategy that uses particle swarm optimization (PSO) to track the optimal thresholds of membership functions, and the equivalent hydrogen consumption minimization is considered as the objective function. Using a typical 30 min UAV mission profile, all the proposed EMS were verified by simulations and rapid controller prototype (RCP) experiments. Comprehensive comparisons and analysis are presented by evaluating hydrogen consumption, system efficiency and voltage bus stability. The results show that the PSO-FL algorithm can further improve fuel economy and achieve superior overall dynamic performance when controlling a UAV’s fuel-cell powertrain.

From Microcars to Heavy-Duty Vehicles: Vehicle Performance Comparison of Battery and Fuel Cell Electric Vehicles

Low vehicle occupancy rates combined with record conventional vehicle sales justify the requirement to optimize vehicle type based on passengers and a powertrain with zero-emissions. This study compares the performance of different vehicle types based on the number of passengers/payloads, powertrain configuration (battery and fuel cell electric configurations), and drive cycles, to assess range and energy consumption. An adequate choice of vehicle segment according to the real passenger occupancy enables the least energy consumption. Vehicle performance in terms of range points to remarkable results for the FCEV (fuel cell electric vehicle) compared to BEV (battery electric vehicle), where the former reached an average range of 600 km or more in all different drive cycles, while the latter was only cruising nearly 350 km. Decisively, the cost analysis indicated that FCEV remains the most expensive option with base cost three-fold that of BEV. The FCEV showed notable results with an average operating cost of less than 7 cents/km, where BEV cost more than 10 €/km in addition to the base cost for light-duty vehicles. The cost analysis for a bus and semi-truck showed that with a full payload, FCPT (fuel cell powertrain) would be more economical with an average energy cost of ~1.2 €/km, while with BPT the energy cost is more than 300 €/km.