ECO-POWER


HOW HGVS CAN BENEFIT FROM CLEANER, GREENER, FUEL TECHNOLOGIES


Simone Bruckner, managing director of resistor manufacturer Cressall, explains the pros and cons of fuel cells and battery power, and what these mean for electrifying heavy goods vehicles


B


y 2040, all new heavy goods vehicles (HGVs) sold in the UK must be zero-


emission. But while advances in green energy technology mean this is possible, automotive manufacturers are still in disagreement about what type of power source is best. Battery Electric Vehicles (BEVs) rely on


a lithium-ion battery for power; Fuel Cell Electric Vehicles (FCEVs) use a fuel cell, which combines hydrogen gas with oxygen to generate electricity.


HYDROGEN POWER As the most abundant element in existence, there won’t be hydrogen supply shortages in the future. Hydrogen power also has a much higher energy density than batteries, meaning FCEVs can travel distances comparable to petrol or diesel vehicles, and up to 100 miles further than BEVs. The main problem with hydrogen fuel


remains with its production. The ideal type of hydrogen is green, produced by separating hydrogen and oxygen molecules in water using electricity. Provided that the source of this electricity is renewable, this is the most environmentally friendly form of hydrogen. At present, the cost of production is the main barrier for this method, though it is expected to fall to a level that’s more competitive with grey hydrogen by 2035. In terms of refuelling time, FCEVs only


take around three to five minutes to refuel. In contrast, BEVs can take anywhere between 30 minutes to ten hours to recharge. And while rapid chargers operating at a higher voltage provide access to much faster recharging times, they will still not be as quick as FCEVs to refuel. There are only around 15 stations in the UK


currently providing hydrogen fuel. However, Bosch has committed to set up 4,000 hydrogen fuelling points worldwide by 2030, and as the cut-off deadline looms for new petrol and diesel vehicles, it’s likely that similar schemes will follow.


BATTERY LIFE PRESERVATION Most BEVs are powered by lithium-ion batteries, and their decreasing price makes electric lorry fleets a lot more financially viable. However, high global demand of lithium is predicted to result in chronic shortages by 2030. Manufacturers should therefore be looking


for ways to ensure that their HGVs can get the maximum value out of their fuel. One of the


ways that battery life preservation can be achieved is through regenerative braking to take excess energy away from the braking system and puts it back into the battery. Batteries only have a limited capacity,


and a full battery has nowhere for the excess electricity to go – which can lead to component damage as well as overheating. To dissipate the excess electricity safely and prevent this from happening, a dynamic braking resistor, or DBR, can be used. DBRs are also useful in ensuring that


emergency braking can be done safely, which is essential in heavier vehicles. FCEVs struggle with fast acceleration and deceleration, as fuel cell output is not consistent due to the method of generating electricity. The solution is to install cells that have a higher output than what is needed, meaning that there is always sufficient energy available, and using


the DBR to safely remove the excess. Choosing a lightweight DBR like Cressall’s


EV2 helps to reduce the overall weight of a HGV. The EV2 has a modular design, allowing multiple modules to be combined to give up to 125 kW in one single unit, which could be then put in parallel or series with others for higher power for safe emergency braking. And at only a tenth of the size of conventional convection cooled DBRs, the liquid cooled EV2 provides a compact solution to safer braking. So, while it’s clear that there’s still a long


way to go to providing cost-effective and sustainable fuel for heavy vehicles, boosting battery life can go a long way in meeting overall demand.


Cressall Resistors T: 0116 273 3633 www.cressall.com


“Battery Electric


Vehicles (BEVs) rely on a lithium-ion battery for power; Fuel Cell Electric


Vehicles (FCEVs) use a fuel cell, which combines hydrogen gas with oxygen to generate electricity”


24


ENERGY & SUSTAINABILITY SOLUTIONS - Summer 2023


www.essmag.co.uk


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