A fuel cell range extender integrating with heat pump for cabin heat and power generation

Batteries, Heat Pumps (HPs), and fuel cells (FCs) are critical for transport decarbonization and a net zero future. However, cabin heating in extreme conditions leads to severe driving range reduction in current Electric Vehicles (EVs). The performance of the heat pump (HP) in EVs and its performance enhancement technologies are widely investigated but cannot, simultaneously, provide sufficient heat and high COP. The source and amount of the waste heat within a vehicle for the heat pump integrated system is a crucial challenge to improve performance. The structure becomes increasingly complicated, but the benefits are not significant. Therefore, in this study, a small Fuel Cell, battery and heat pump integrated energy management system for range extended EVs (FCBEEV) is designed. The cogeneration characteristic of the fuel cell and waste heat from battery pack are utilised by the heat pump to ensure a high-level of cabin comfort in extremely cold temperatures and an extension of the driving range. A numerical model was established in MATLAB and the results were analysed from energy, exergy, environment, and economic (4E) perspectives. In this study, we show that the highest COPsys of the proposed system is 5.8 and can improve the driving range (DR) by 65% to 110% compared to the reference systems. The exergy efficiency of the suggested system is 75% at −10 °C and the fuel cell and internal condenser are the primary causes of the exergy destruction. The environmental impact decreases by 13 kg/year per car compared to current EVs with a Positive Temperature Coefficient (PTC) and Air Source Heat Pump (ASHP) system, and the reduction is primarily sourced from the indirect emissions. The operating cost which includes driving and heating is 28.9% higher than cited for an ASHP and PTC system and 41% higher than the PTC baseline system. The payback duration is 300,000 km at current market prices, and it is predicted to be shorter to 100,000 km, if the cost of the fuel cell stack is estimated at £4000 and the H2 price is the same as electricity. We anticipate that the proposed system can significantly improve cabin comfort and driving range anxieties, as well as promote the decarbonization of transport.