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Performance and Total Cost of Ownership of a Fuel Cell Hybrid Mining Truck

Author

Listed:
  • Rajesh K. Ahluwalia

    (Argonne National Laboratory, Lemont, IL 60439-4858, USA)

  • Xiaohua Wang

    (Argonne National Laboratory, Lemont, IL 60439-4858, USA)

  • Dionissios D. Papadias

    (Argonne National Laboratory, Lemont, IL 60439-4858, USA)

  • Andrew G. Star

    (Argonne National Laboratory, Lemont, IL 60439-4858, USA)

Abstract

The main objective of this work was to investigate the potential of hydrogen and fuel cells replacing diesel and internal combustion engines in the ultraclass haul trucks deployed in the mining sector. Performance, range, durability, and cost are the main criteria considered for comparing the two fuels and engine options. Fuel cell system (FCS) performance is characterized in terms of heat rejection, efficiency, and fuel consumption for a hybrid platform equivalent to a 3500 hp diesel engine operating on a representative open pit mining duty cycle. A hybrid platform was chosen because the heat rejection, with a constrained radiator frontal area, limits the maximum fuel cell-rated power by about 50% compared to that of the diesel truck. The hybrid powertrain was 81–88% more efficient than the diesel powertrain on the truck duty cycle. A liquid hydrogen storage system is required for an equal range or time between refilling, but the packaging remains a challenge. Fuel cell and battery durability were evaluated for their performance degradation and lifetime. Achieving a fuel cell lifetime comparable to the time between major overhauls for diesel trucks necessitates the oversizing of the membrane-active area, catalyst overloading, and voltage clipping. For an equal lifetime, the battery must be oversized to control its depth of discharge and charge/discharge rates. A total cost of ownership (TCO) analysis considering the initial capital expenditures, as well as the lifetime cost of fuel, operation, and maintenance, indicates that fuel cells and hydrogen can compete with diesel. A breakeven fuel cost for TCO parity is obtained if H 2 is available at USD 5.79–6.85/kg vs. diesel at USD 3.25/gal and the FCS-specific cost is USD 323/kW e relative to USD 250/kW for a diesel genset. Volume manufacturing is required for FCS cost reduction. High volume is possible through the standardization, modularity, and proliferation of class 8 long-haul truck systems across different heavy-duty applications.

Suggested Citation

  • 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.
    • Handle: RePEc:gam:jeners:v:16:y:2022:i:1:p:286-:d:1016495
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    References listed on IDEAS

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    1. Lars Lindgren & Anders Grauers & Jonas Ranggård & Rikard Mäki, 2022. "Drive-Cycle Simulations of Battery-Electric Large Haul Trucks for Open-Pit Mining with Electric Roads," Energies, MDPI, vol. 15(13), pages 1-19, July.
    2. 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).
    3. Xin Sui & Maciej Świerczyński & Remus Teodorescu & Daniel-Ioan Stroe, 2021. "The Degradation Behavior of LiFePO 4 /C Batteries during Long-Term Calendar Aging," Energies, MDPI, vol. 14(6), pages 1-21, March.
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    1. Ruifeng Guo & Dongfang Chen & Yuehua Li & Wenlong Wu & Song Hu & Xiaoming Xu, 2023. "Anode Nitrogen Concentration Estimation Based on Voltage Variation Characteristics for Proton Exchange Membrane Fuel Cell Stacks," Energies, MDPI, vol. 16(5), pages 1-16, February.

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