Next-Generation Hydrogen Fuel Cell Systems for Heavy-Duty Transportation

Hydrogen plays a key role in sustainable mobility and can revolutionize heavy goods transport. Fuel cell systems convert hydrogen into electrical energy, whereby so-called Balance of Plant (BoP) components are crucial for efficiency and durability.

The Horizon Europe project BeBoP aims to optimize these BoP components. Over three and a half years, leading companies and research institutions are developing more efficient, compact and reliable components that can monitor the condition of the fuel cells. The focus is on improving air compressors, humidifiers and DC/DC converters:

• Air compressor: Ensures optimum oxygen supply and adapts to load changes.
• Humidifier: Regulates the humidity to ensure high performance and longevity of the fuel cell.
• DC/DC converter: Provides the required voltage for the electric motor.

BeBoP develops a more efficient air compressor, a new lightweight DC/DC converter with power distribution unit (PDU) and cell monitoring, and an innovative humidifier with improved water management. This increases the overall performance and service life of the fuel cell system.

Leading component developers such as Garrett, Freudenberg and Silver Atena are involved, providing innovative solutions for FPT's state-of-the-art fuel cell systems. DLR and SINTEF use their modelling expertise to optimize system operation. Models complement the development and testing of the BoP components to reduce power consumption and minimize hydrogen consumption of heavy-duty vehicles. In addition, an optimized architecture is being developed to increase system performance.

The new BoP components will either be integrated into FPT's 200 kW fuel cell system or tested in DLR's test stack. By testing efficiency and dynamic behavior, BeBoP ensures that the systems meet the requirements of long-distance heavy-duty transport. The project supports scaling by European manufacturers and brings the fuel cell market closer to a broad industrial introduction. In addition, the potential for standardization is being examined in order to facilitate industrialization.