Role of proton exchange membrane fuel cell in efficiency improvement of ammonia–hydrogen fusion zero-carbon powertrains for long-haul, heavy-duty transportation

Ammonia fuel, a transport zero-carbon energy carrier with a much lower life-cycle greenhouse gas footprint than existing fuels and the ability to overcome the storage and transportation challenges of hydrogen fuel, is an effective means of realizing the energy transition for long-haul, heavy-duty transportation such as heavy trucks. Although the efficient use of liquid ammonia fuel cannot be realized directly at this stage, it can be realized indirectly by converting ammonia fuel into hydrogen and combining the hydrogen generated with ammonia in an ammonia–hydrogen fusion fuel supply method. In this study, we assess four ammonia–hydrogen fusion-fueled zero-carbon powertrains for heavy-duty commercial vehicles, each of which is designed to determine its most efficient green zero-carbon fuel utilization scenario at the point of steady state operation as well as over the entire power-demand interval. It was found that the required engine capacity decreases with the increase of the hydrogen energy ratio in the ammonia–hydrogen composite fuel. Considering the indicated thermal efficiency of the engine and the combustion stability in the cylinder, the ammonia–hydrogen composite fuel with 30% hydrogen energy share was selected for the matching design of the powertrains. The study results show that powertrain equipped with engine and fuel cell are more energy efficient than others. The powertrain with range extender consisting of the engine and fuel cell takes ammonia dissociation separation unit and fuel cell as an important part of engine exhaust gas heat recovery, which reduces the dependence of ammonia cracking hydrogen production on electric heating power. By regulating the energy distribution ratio between the engine and the fuel cell, the system can be maintained at a high level of energy efficiency. Under different power requirements of highway application scenarios, the system efficiency is not less than 36%, and the system energy utilization efficiency is higher than 44%. Compared to engine direct drive powertrain, engine range-extended powertrain, and fuel cell range-extended powertrain, the average system efficiency increases by 30.8%, 8.68%, and 14.24%, while the average system energy utilization increased by 41.12%, 25.26%, and 39.43%, respectively.