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Integrated design and control optimization of fuel cell hybrid mining truck with minimized lifecycle cost

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  • Feng, Yanbiao
  • Dong, Zuomin

Abstract

Proton Exchange Membrane Fuel Cell (PEMFC) system, as a highly efficient, zero pump-to-wheel emission and quick refuelling energy conversion device, is particularly suited for heavy-duty transportation applications. An optimally designed hybrid powertrain with a battery energy storage system and optimal operation control can extend the operating life of the PEMFC system and reduce its lifecycle cost. This work focuses on the minimization of the lifecycle cost of a PEMFC hybrid electric propulsion system through the joint powertrain system design and control optimizations. The approach models and predicts the cost of hydrogen fuel determined by the energy efficiency of the powertrain, as well as the costs associated with the performance degradation and life-shortening of the PEMFC and the battery under a given vehicle operation profile. A nested, tri-level optimization problem is formulated for identifying the optimal powertrain component sizes and energy management parameters, and an advanced surrogate-based global optimization method is used to solve the complex optimization problem. The advantage of the new approach is revealed through the optimal design and control development of a representative mining truck operating under a real-world operation profile, reducing its mining tonnage specific cost by ten percent over its lifecycle. The new integrated design and control optimization method improved energy efficiency, reduced environmental pollutants, and lowered the lifecycle cost of fuel cell mining trucks, contributing to broader applications of the PEMFC technology.

Suggested Citation

  • Feng, Yanbiao & Dong, Zuomin, 2020. "Integrated design and control optimization of fuel cell hybrid mining truck with minimized lifecycle cost," Applied Energy, Elsevier, vol. 270(C).
    • Handle: RePEc:eee:appene:v:270:y:2020:i:c:s0306261920306760
    DOI: 10.1016/j.apenergy.2020.115164
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    5. Ma, Shuai & Lin, Meng & Lin, Tzu-En & Lan, Tian & Liao, Xun & Maréchal, François & Van herle, Jan & Yang, Yongping & Dong, Changqing & Wang, Ligang, 2021. "Fuel cell-battery hybrid systems for mobility and off-grid applications: A review," Renewable and Sustainable Energy Reviews, Elsevier, vol. 135(C).
    6. Alessandro Ferrara & Saeid Zendegan & Hans-Michael Koegeler & Sajin Gopi & Martin Huber & Johannes Pell & Christoph Hametner, 2022. "Optimal Calibration of an Adaptive and Predictive Energy Management Strategy for Fuel Cell Electric Trucks," Energies, MDPI, vol. 15(7), pages 1-20, March.
    7. Rajesh K. Ahluwalia & Xiaohua Wang & Dionissios D. Papadias & Andrew G. Star, 2022. "Performance and Total Cost of Ownership of a Fuel Cell Hybrid Mining Truck," Energies, MDPI, vol. 16(1), pages 1-17, December.
    8. Molina, S. & Novella, R. & Pla, B. & Lopez-Juarez, M., 2021. "Optimization and sizing of a fuel cell range extender vehicle for passenger car applications in driving cycle conditions," Applied Energy, Elsevier, vol. 285(C).
    9. Zhou, Su & Zhang, Gang & Fan, Lei & Gao, Jianhua & Pei, Fenglai, 2022. "Scenario-oriented stacks allocation optimization for multi-stack fuel cell systems," Applied Energy, Elsevier, vol. 308(C).
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    11. Bennett, Carly & Blanchet, Jocelyn & Trowell, Keena & Bergthorson, Jeffrey, 2023. "Decarbonizing Canada’s energy supply and exports with solar PV and e-fuels," Renewable Energy, Elsevier, vol. 217(C).
    12. Xun, Qian & Murgovski, Nikolce & Liu, Yujing, 2022. "Chance-constrained robust co-design optimization for fuel cell hybrid electric trucks," Applied Energy, Elsevier, vol. 320(C).
    13. Sanghyun Yun & Jinwon Yun & Jaeyoung Han, 2023. "Development of a 470-Horsepower Fuel Cell–Battery Hybrid Xcient Dynamic Model Using Simscape TM," Energies, MDPI, vol. 16(24), pages 1-22, December.
    14. Lulu Gao & Dongyue Wang & Chun Jin & Tong Yi, 2022. "Modelling and Performance Analysis of Cyclic Hydro-Pneumatic Energy Storage System Considering the Thermodynamic Characteristics," Energies, MDPI, vol. 15(18), pages 1-19, September.
    15. Zhou, Xingyu & Sun, Chao & Sun, Fengchun & Zhang, Chuntao, 2023. "Commuting-pattern-oriented stochastic optimization of electric powertrains for revealing contributions of topology modifications to the powertrain energy efficiency," Applied Energy, Elsevier, vol. 344(C).
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    17. Zhou, Su & Xie, Zhengchun & Chen, Chunguang & Zhang, Gang & Guo, Junhua, 2022. "Design and energy consumption research of an integrated air supply device for multi-stack fuel cell systems," Applied Energy, Elsevier, vol. 324(C).

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