Energy Consumption Analysis of Fuel Cell Commercial Heavy-Duty Truck with Waste Heat Utilization Under Low-Temperature Environment

Fujian Liu, Qiao Zhu, Dawei Dong, Zhichao Zhao, Xiuping Zhu, Kunyi Feng, Haifeng Dai and Hao Yuan ()
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Fujian Liu: College of Mechanical Engineering, Southwest Jiaotong University, Chengdu 610031, China
Qiao Zhu: College of Mechanical Engineering, Southwest Jiaotong University, Chengdu 610031, China
Dawei Dong: College of Mechanical Engineering, Southwest Jiaotong University, Chengdu 610031, China
Zhichao Zhao: China Automotive Engineering Research Institute Co., Ltd., Chongqing 401122, China
Xiuping Zhu: Marxist College, Chongqing Polytechnic University of Electronic Technology, Chongqing 401331, China
Kunyi Feng: Clean Energy Automotive Engineering Center, Tongji University, Shanghai 201804, China
Haifeng Dai: Clean Energy Automotive Engineering Center, Tongji University, Shanghai 201804, China
Hao Yuan: Clean Energy Automotive Engineering Center, Tongji University, Shanghai 201804, China

Energies, 2025, vol. 18, issue 11, 1-19

Abstract: Waste heat utilization in fuel cell vehicles represents a critical technology for enhancing overall energy utilization efficiency and environmental adaptability, which reduces auxiliary heating consumption, extends driving range, and minimizes thermal management parasitic losses, holding significance for promoting application of fuel cell commercial vehicles. This study investigates a 49-ton fuel cell heavy-duty truck equipped with waste heat recovery capability, conducting vehicle energy flow experiments under multiple ambient temperatures (including 7 °C, − 7 °C and − 25 °C extreme cold conditions), varying load conditions, and waste heat recovery mode switching, with focused analysis on the energy consumption and temperature response of the waste heat recover critical components, to evaluate the energy utilization of fuel cell waste heat. Experimental results demonstrate the substantial impact of waste heat recovery function on the proportion of the warm air positive temperature coefficient (PTC) energy consumption on total energy consumption, showing that deactivating waste heat recovery increased the PTC energy consumption obviously. Besides, activating the waste heat recovery function contributes to elevated the stack radiator outlet temperature under low-temperature operating conditions.

Keywords: fuel cell vehicle; waste heat utilization; thermal management; energy efficiency; environmental adaptability; heavy-duty truck (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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