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Development: Challenges
Many challenges, technical and otherwise, must be overcome before fuel cell vehicles will be a successful, competitive alternative for consumers. Quote: "FreedomCAR will require a significant investment by both the federal government and industry and will involve a concerted long-term effort."  DOE Press Release (January 9, 2002)

Onboard Hydrogen Storage. It is currently difficult to store enough hydrogen onboard a FCV to allow it to travel as far as a conventional vehicle on a full tank of fuel. Fuel cells are more energy-efficient than internal combustion engines in terms of the amount of energy used per weight of fuel and the amount of fuel used vs. the amount wasted. However, hydrogen gas is very diffuse, and only a small amount (in terms of weight) can be stored in onboard fuel tanks of a reasonable size. This can be overcome by increasing the pressure under which the hydrogen is stored or through the development of chemical or metal hydride storage options. Researchers are developing high-pressure tanks and hydride systems that will store hydrogen more effectively and safely.

Cold-weather Operation. Cold-weather operation can also be problematic since fuel cell systems always contain water, both as a byproduct and for humidifying the fuel cell, which can freeze at low temperatures. The fuel cells must also reach a certain temperature to attain full performance.

Photo: Refueling an FCV.Getting Hydrogen to Consumers. The extensive system used to deliver gasoline from refineries to local filling stations cannot be used for transporting and storing hydrogen. New facilities and systems will be required to get hydrogen to consumers-this will take significant time and money.

Cost. FCVs are currently expensive: far too expensive for most consumers to afford. Manufacturers will have to find efficient, cost-effective ways to produce FCVs and the fuel cell systems they use. In particular, they must reduce the costs of the electrolyte membrane and catalyst-the catalyst is made of platinum-used in the fuel cell. Onboard reformers used in some vehicles to produce hydrogen from other fuels are also quite expensive.

Safety. Hydrogen, like gasoline or any other fuel, has safety risks and must be handled with due caution. While we are quite familiar with gasoline, handling compressed hydrogen will be new to most of us. Therefore, developers must optimize new fuel storage and delivery systems for safe everyday use, and consumers must become familiar with hydrogen's properties and risks.

Competition with Other Technologies. Manufacturers are still improving the efficiency of gasoline-and diesel-powered engines, and gasoline-electric hybrids are gaining popularity. FCVs will have to offer consumers a viable alternative, especially in terms of performance, durability, and cost, to survive in the ultra-competitive automobile market.

Public Acceptance. Finally, fuel cell technology must be embraced by consumers before its benefits can be realized. Consumers may have concerns about the dependability and safety of these vehicles, just as they did with the first automobiles-which were considered a radically different techology at the turn of the century.

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EPA DOE