[Auto] Toyota to supply hydrogen fuel cells for zero-emission trains

[SougarLord]

 

Diesel engine trains are used on the rest of the lines. Within the framework of the UE FCH2RAIL project —Fuel Cell Hybrid Power Pack for Rail Applications—, a consortium with partners from Belgium, Germany, Spain and Portugal is developing and testing a new emission-free train prototype, using a hybrid bimodal system that It combines the electricity supply from the overhead network with a hybrid fuel cell power pack, consisting of hydrogen fuel cells and batteries and operating independently of the former.

 

The FCH2RAIL project was launched last January and the baseline routes and operational scenarios for the prototype have now been defined.

 

Aerial network and hybrid system: bimodal displacement and without emissions
Whenever the overhead network is available, the train is fed by the energy provided by it, whereas when this option does not exist, the energy is obtained from the fuel cell and battery system, called the fuel cell hybrid power group - Fuel cell hybrid power pack.

 

"We want to show that this type of bimodal train is a competitive and environmentally friendly alternative to the diesel train", explains Holger Dittus, project manager and researcher at the German Aerospace Center - Automotive Prototype Institute (DLR).

 

Currently, overhead networks are being set up on many European railway lines, a rather expensive and long-term project that depends on geographical conditions. An alternative is trains powered solely by batteries, but they have a limited range - 30 to 70 kilometers - which also depends on the characteristics of the route and the ambient temperatures. Current diesel trains have lower performance, in terms of maximum speed and acceleration, than vehicles powered by electric motors powered from overhead networks.

 

"Our bimodal fuel cell and battery hybrid system combines the advantages of both technologies: energy from the airlines or the on-board system. In this way, rail transport is even more sustainable and energy efficient," says Sergio Gascon , Head of the Technical Project for Construction and Railway Auxiliary (CAF).

 

The energy supply system must be designed in such a way that both power and autonomy can be expanded on the basis of a modular principle. Thus, the number of fuel cell and battery modules determines the traction power, while the number of hydrogen tanks determines the autonomy on non-electrified lines. Therefore, the tractor unit can be designed for the transportation of passengers as well as for the transportation of goods.

 

With a budget of 14 million euros, the project aims to develop, demonstrate and validate this system within four years. The project has a financing of 10 million euros by the business union Joint Venture Fuel Cells and Hydrogen 2 (FCH 2 JU).

 

“Our studies on hydrogen and fuel cells in the railway environment have shown that there is considerable potential for FCH technologies in this area, and that hydrogen-based trains will be an important element of a future sustainable European transport system. ”Declares Bart Biebuyck, CEO of FCH 2 JU. “The European Commission has made it clear in its hydrogen strategy that this fuel is a promising option where electrification is more difficult, such as in specific sections of the rail network. The FCH2RAIL project will demonstrate that the technology provides a flexible, zero-emission solution to replace diesel trains in these areas, and it will be interesting to see the results, ”says Biebuyck.

 

Implementation: functional testing with a converted commuter train

To know well the environmental impact of this system, from its production, through its use and until its scrapping, and to evaluate its performance in real conditions, it is planned to convert a CIVIA electric commuter train, manufactured by the Spanish company CAF , and install in it a fuel cell hybrid power pack. Renfe, for its part, will provide the train. One of the essential components of the on-board energy system is Toyota Motor Europe's (TME) integrated fuel cell modules, while batteries and electrical converters will be supplied by CAF.

 

The first tests will be carried out on the Spanish and Portuguese railway networks with the support of the infrastructure managers - Administrator of Railway Infrastructures (ADIF) and Infraestruturas de Portugal (IP) -. The National Hydrogen Center (CNH2), based in Puertollano (Ciudad Real), has been commissioned to build a hydrogen station to refuel the prototype during the prototype tests, prior to integration into the trains.

 

“We want to take this opportunity to work with the consortium to bring our fuel cell technology to another type of hydrogen application. Hydrogen has an important role to play in helping to decarbonize the European rail network, and we are very pleased to be able to integrate Toyota's fuel cell modules into the fuel cell hybrid power group, ”said Thiebault Paquet, Director of the Fuel Cell Division of Toyota Motor Europe (TME).

 

System design and control, energy management and approval

Until the first pilot tests are carried out, the international project team has before it a series of technological aspects to solve. For example, in the design section, the fuel cell and battery modules must be combined and controlled in such a way that the system meets all requirements, and can also be installed cost-effectively.

 

In addition, it must be able to use the waste heat from the fuel cell modules efficiently for heating and air conditioning the train. As part of the project, air conditioning equipment manufacturer Faiveley / Stemmann Technik (STT) and DLR are investigating innovative solutions to reduce the energy demand of heating, ventilation and air conditioning (HVAC) systems.

 

The project also examines norms and standards in the fields of hydrogen and rail to ensure a safe interaction between hydrogen technology and the catenary. On that basis, the project team is developing proposals for the relevant authorities to more easily authorize these trains across the EU in the near future.