Fuel Cell Drive for Municipal Commercial Vehicles

mobile future - clean environment - hydrogen

Fuel cell drive project for municipal commercial vehicles

The objective of this project is to develop a low-floor bus with fuel cell drive.

The companies participating in the project are Siemens AG Energieerzeugung KWU (fuel-cell system), Siemens AG Verkehrstechnik (electric motors), Linde AG (hydrogen supply and periphery), MAN Nutzfahrzeuge AG (low-floor bus) and MAN Technologie AG (hydrogen storage system).

The project is being coordinated by Ludwig-Bölkow-Systemtechnik GmbH and enjoys 50 % sponsorship from the Bavarian Ministry for Economics, Transport and Technology in the context of the Hydrogen Initiative Bavaria. By the year 2000 it is to be demonstrated that fuel cell drive systems can be used successfully for satisfying municipal transport requirements. Practical operation, e.g. with the City of Erlangen, will provide valuable information for the next stages in the development and market launch of hydrogen drive systems.

The road to emission-free transport is mapped out

Transport services by road vehicles are rendered predominantly using fossil fuel sources. The consequence of this is pollution, particularly in areas where there is a high traffic density. The growing world population with its increasing demand for mobility will further heighten the problems inherent in these conditions.

  • If the climate is to be protected, CO2 emissions must be reduced throughout the world, but on the other hand the rising demand for mobility must be catered for.
  • The increase in consumption of fuels is opposed by the fact that fossil energy sources will one day be exhausted.

The prime objective of avoiding both local and global pollution for human beings and the environment is coupled with the necessary protection of resources. In view of the dimension of the problems a rethink is unavoidable. Only a responsible and sparing use of energy sources will lead to a compatible supply of energy worldwide that is orientated towards long-term objectives.

Hydrogen - the fuel of the future

Hydrogen is the earth's most common chemical element. Most of it, however, is bound in water and cannot therefore be used as a fuel directly. An input of energy, e.g. by electrolysis, allows hydrogen to be produced. The availability of hydrogen is thus almost unlimited.

Used as a fuel for vehicles, hydrogen operating with a fuel cell produces no emissions. If hydrogen is generated with renewable energy in future, fuel cell vehicles will potentially be able to ensure completely emission-free transport of goods and persons.

Fuel cell drive - clean and efficient

The fuel cell reverses the electrolysis process. Here hydrogen and oxygen are transformed to water direct, whereby electrical energy is released. The special feature of the PEM fuel cell is a proton-conducting membrane which is coated on both sides with a catalyst and at which the chemical transformation of hydrogen and oxygen takes place.

PEM fuel cells occupy an important position among the various fuel cell types. They are particularly suitable for use in mobile systems.

PEM technology offers:

  • efficient use of energy (high efficiency);
  • high power and energy densities;
  • low-noise and vibration-free operation;
  • low operating temperatures (60-80°C);
  • long service life;
  • hydrogen-air mode;
  • short starting times.

The fuel-cell bus

To demonstrate the advanced drive concept to the public at large an MAN low-floor bus will be equipped with the components for a fuel-cell drive system. The hydrogen storage system consisting of lightweight composite cylinders will be mounted on the roof of the bus. In these cylinders sufficient hydrogen for a range of about 200 to 300 km will be stored in compressed form. Fuel-cell modules with a total output of 120 kW will generate electrical energy for operation of the bus with two asynchronous motors. These two motors will be linked by a summation gearbox. Other components of the fuel cell system and the electric drive system will be housed at the rear of the vehicle. If fuel cell drive is used there will be no local emissions. In addition the electric drive system makes the bus extremely quiet and gives it a very high level of ride comfort.

Composite materials compressed hydrogen storage

Prospects

Hydrogen as fuel can considerably improve the environmental balance in the transport sector. Its use in vehicles is characterised by an excellent emission balance. If renewable energy sources are used the process of preparing hydrogen too can be designed on environmentally friendly lines. Fuel-cell drive has a number of features which make it a promising alternative to conventional vehicle propulsion systems. At present, however, fuel cells are very expensive and their use is limited because of the space they require in the vehicle and because of their weight. Intensive further development of fuel cell technology, the vehicle drive systems, the storage technology and the entire infrastructure will be necessary as preparation for switching to non-fossil energy sources if this switch is to be made in good time. As an almost inexhaustible source of energy hydrogen offers the best basis for this.

Vehicle MAN Nutzfahrzeuge AG

Model

NL 223 low-floor bus

Length

12 m

Gross weight (permissible)

18 t
Vehicle drive system Siemens AG, Verkehrstechnik

ELFA drive system

Asynchronous motors, model 1 PV5135

Max. output of traction motor

2 x 75 kW via summation gearbox and cardan shaft to rear axle

Traction motor converter

IGBT pulse-controlled inverter, model ELFA-DUO
Fuel cell system Siemens AG, KWU

Fuel cell modules

4 modules

Rated output

120 kW in total

Voltage at max. output

approx. 400 V

Operating temperature

60 °C

Operating pressure, air

1.5 barabs

Air ratio

2

Hydrogen consumption at rated output

8 kg/h
Hydrogen storage system MAN Technologie AG

Max. filling pressure

250 bar

Number of cylinders

9

Total capacity

approx. 1530 l

Operating range

200 - 300 km
Hydrogen fuelling system, periphery Linde AG

Gas tract in vehicle

Main shut-off cock, fuelling coupling, pressure reducer etc.

Hydrogen filling station

Storage and fuelling system including safety devices

Table: Technical data on MAN low-floor bus with fuel-cell drive

Contacts:

MAN Nutzfahrzeuge AG · Postfach 50 06 20
D-80976 München · Tel. +49-89-1580-0

Siemens AG· Energieerzeugung (KWU) · FRN 4
Postfach 32 20 · D-91050 Erlangen · Tel. +49-9131-18-01

Siemens AG · Verkehrstechnik · VT 51
Postfach 32 40 · D-91050 Erlangen · Tel. +49-9131-7-0

MAN Technologie AG · Postfach 13 47
D-85751 Karlsfeld · Tel. +49-8131-89-01

Linde AG· Werksgruppe Technische Gase · Seitnerstraße 70
D- 82049 Höllriegelskreuth · Tel. +49-89-7446-0

Ludwig-Bölkow-Systemtechnik GmbH · Reinhold Wurster
Daimlerstraße 15 · D-85521 Ottobrunn · Tel. +49-89-608110-33