A battery-fuel cell hybrid auxiliary power unit for trucks: Analysis of direct and indirect hybrid configurations

Highlights: • A battery-fuel cell hybrid auxiliary power unit for heavy duty vehicles is reported. • Comparison of direct and indirect hybrids using representative load profiles. • Evaluation based on validated fuel cell system and battery models. • Indirect hybrid with constant fuel cell load yields 29.3% hybrid system efficiency. • Fuel cell should be pre-heated using waste heat from the diesel engine during drive. - Abstract: The idling operation of engines in heavy duty vehicles to cover electricity demand during layovers entails significant fuel consumption and corresponding emissions. Indeed, this mode of operation is highly inefficient and a noteworthy contributor to the transportation sector's aggregate carbon dioxide emissions. Here, a potential solution to this wasteful practice is outlined in the form of a hybrid battery-fuel cell system for application as an auxiliary power unit for trucks. Drawing on experimentally-validated fuel cell and battery models, several possible hybrid concepts are evaluated and direct and indirect hybrid configurations analyzed using a representative load profile. The results indicate that a direct hybrid configuration is only applicable if the load demand profile does not deviate strongly from the assumed profile. Operation of an indirect hybrid with a constant fuel cell load yields the greatest hybrid system efficiency, at 29.3%, while battery size could be reduced by 87% if the fuel cell is operated at the highest dynamics. Maximum efficiency in truck applications can be achieved by pre-heating the system prior to operation using exhaust heat from the motor, which increased system efficiency from 25.3% to 28.1%, including start-up. These findings confirm that hybrid systems could offer enormous fuel savings and constitute a sizeable step on the path toward energy-efficient and environmentally-friendly heavy duty vehicles that does not necessitate a fuel switch.