Automakers Forge Ahead with Hydrogen-Fuel-Cell Vehicle Development

What you'll learn:

• Details of the BMW-Toyota hydrogen-fuel-cell joint effort.
• Benefits and issues surrounding hydrogen fuel cells.
  
• How does the "Inflation Reduction" Act impact this techology's development?
  

In the fiercely competitive zero-emissions vehicle market, you’re only as good your latest innovation. So, under the category “look what we have here” is the news that BMW and Toyota will team up to produce hydrogen-fuel-cell vehicles starting mid-decade, according to a report in Nikkei Asia.

BMW sales chief Pieter Nota told the publication that the brands aim to sell jointly developed hydrogen-fuel-cell vehicles as soon as 2025. Since partnering in 2013, BMW and Toyota previously partnered on developing gasoline-powered sports cars, releasing the BMW Z4 and the Toyota Supra in 2019.

Nota said the union of Toyota and BMW could help BMW achieve its target of 50% electrification across its lineup two years ahead of its current expected date of 2030. Toyota has plenty of experience building hydrogen vehicles, as its Mirai sedan is now almost a decade old.

The German automobile giant also announced its intention to produce the iX5 sport utility vehicle on a small scale this year. The iX5 is based on BMW's X5 SUV. In the iX5, two carbon-fiber-reinforced plastic tanks house the hydrogen at 10,000 psi, which is converted into electric power inside the fuel cell.

While the fuel cell produces 170 hp, the 5,600-lb. SUV also requires an electric drive battery, which can be charged via the fuel cell or through regenerative braking. Combined, the drivetrain generates 374 hp. A single electric motor sends power to the rear axle.

BMW has pointed to a number of advantages for the technology such as quick charging time. Depending on the charging station and battery capacity, fully electric vehicles currently require between 30 minutes and several hours for a full charge. The hydrogen tanks of fuel cell cars are full and ready to go again in less than five minutes. A full hydrogen tank will last around 300 miles.

For users, this brings vehicle availability and flexibility into line with those of a conventional car. Battery-powered cars can match this with very large batteries, which in turn will lead to an increase in both vehicle weight and charging times.

How Do Hydrogen Fuel Cells Work?

Hydrogen fuel cell cars are powered by an electric motor. The common abbreviation is FCEV, short for “fuel-cell electric vehicle,” in contrast to a BEV or “battery electric vehicle.” The electricity generated in the fuel cell of a hydrogen engine can either flow to the electric motor and power the FCEV directly or it charges a battery, which stores the energy until it’s needed.

In fuel-cell technology, a process known as reverse electrolysis takes place, in which hydrogen reacts with oxygen in the fuel cell. The hydrogen comes from one or more tanks built into the FCEV, while the oxygen comes from the ambient air.

The range of fuel-cell vehicles doesn’t depend on the outside temperature. In other words, it doesn’t deteriorate in cold weather. The iX5 has been undergoing numerous driving tests on public roads as well as at the BMW Group’s test center in Arjeplog in northern Sweden. Despite harsh −20°C temperatures as well as ice and snow, all drive components of the BMW iX5 Hydrogen SUV were said to demonstrate their reliability and suitability for everyday use.

The biggest problem faced by hydrogen fuel supporters is the lack of public hydrogen filling stations in much of the world, inhibiting mass production. Also, handling and dispensing hydrogen can be difficult because it requires special storage and must be under high pressure to fill a car.

BMW unveiled the fuel cell iX5 Hydrogen concept car at the International Motor Show Germany in September 2021. BMW will build fewer than 100 iX5 Hydrogen SUVs this year for demonstration and testing purposes, but don’t expect to be able to buy one. Instead, the cars will be given out to influencers and BMW employees.

Support for Hydrogen

In the U.S., the Inflation Reduction Act of 2022, now law, gives hydrogen a stronger foundation to play a significant role in the global economy. Hydrogen production, storage, and utilization all receive multiple tax benefits.

The law introduces a 10-year production tax credit (PTC) for “clean hydrogen defined by the lifecycle greenhouse-gas emissions rate achieved at a qualifying hydrogen production facility on which construction starts before 2033.” It extends and creates Investment Tax Credits (ITCs) and Production Tax Credits (PTCs) for clean-energy generation and gives the producers the choice to opt for either ITC or PTC.

Clean energy is defined by an emissions rate that can’t exceed 4 kg of CO₂e (carbon dioxide equivalent) per kilogram of hydrogen. It provides a definition specifically including hydrogen; introduces a substantial credit for clean commercial vehicles; and expands the alternative fuel station credit to foster more hydrogen fueling stations. The hydrogen must be produced in the U.S., and the law appears to apply to all hydrogen produced in the U.S., even if such hydrogen is exported.

For its part, Germany will invest more than 8 billion euros ($9.74 billion) to fund large-scale green hydrogen projects, in a step to scale up hydrogen as an alternative to fossil fuels to meet climate targets. Most hydrogen used today is produced by reforming natural gas, which also releases a lot of carbon dioxide (CO₂). Green hydrogen is extracted from water by electrolysis, but it’s still a very energy-intensive process.

The BMW Group is on record supporting the EU Commission’s efforts to implement the Alternative Fuels Infrastructure Regulation (AFIR) for developing hydrogen filling stations and an electric charging infrastructure in parallel.

The so-called “fit for 55” legislative package, which refers to the EU's target of reducing net greenhouse- gas emissions by at least 55% by 2030​, should enable the EU to meet its climate objectives of reducing net greenhouse-gas emissions and achieving carbon neutrality by 2050. The main objective is to ensure that the public has access to a sufficient infrastructure network for recharging or refueling road vehicles with alternative fuels.

In Japan, Yamaha Motor is developing a 5.0-liter hydrogen-fueled V8 engine for Toyota. Yamaha and Toyota have previous history: the Lexus LFA’s 4.8-liter V10 was developed by Yamaha. The new hydrogen V8 started out as the 5-liter V8 deployed in the Lexus RC F. Yamaha made modifications to the injectors, cylinder heads, intake manifold, and cylinder heads to deliver 455 bhp and 398 lb-ft of torque from this engine.