At the heart of the project there is a hybrid, bi-modal drive system that combines the electrical power supply from the overhead line with a “fuel cell hybrid power pack” (consisting of hydrogen fuel cells and batteries) that works independent of the overhead line. The project FCH2RAIL was already launched in January and the reference routes and operating scenarios for the prototype have now been defined as a first result.
An alternative are purely battery-powered trains, but they have a limited range of operation (30 to 70 kilometres), depending on the route profile and outside temperatures. Current diesel trains have lower performance in terms of top speed and acceleration compared to vehicles powered by electric motors from overhead lines.
Therefore, the drive unit can be designed for use in both passenger and freight transport. With a budget of 14 million euros, the project aims to develop, demonstrate and approve such a system within the next four years. The project is funded with 10 million euros by the Fuel Cells and Hydrogen 2 Joint Undertaking (FCH 2 JU).
To understand the environmental impacts of such a system, from its production, to its use, up to its disposal and to evaluate the performance under real conditions, it is planned to convert a CIVIA electric commuter train (manufactured by the Spanish manufacturer CAF) and to integrate a fuel cell hybrid power pack in this train. The Spanish state railway operator Renfe is providing the train. One of the central components of the on board energy system are the packaged fuel cell system modules from Toyota Motor Europe (TME), while the batteries and power converters will be provided by CAF.
Initial functional tests and trial runs for approval will take place on Spanish and Portuguese tracks with the support of the infrastructure managers Administrador de Infrastructuras Ferroviarias (ADIF) and Infraestruturas de Portugal (IP). The Spanish hydrogen research centre Centro National de Hidrogeno (CNH2) has been entrusted with the construction of a hydrogen fuelling station to refuel the prototype and in FCHPP testing before train integration.
Until the first trial runs, the international project team still has a number of technological challenges to solve: For the design, fuel cell and battery modules must be combined and controlled in such a way that the system meets all requirements and can be implemented cost-effectively at the same time.
In addition, it should be possible to use the waste heat from the fuel cell modules in an efficient way to heat and air-condition the train. The air conditioning manufacturer Faiveley / Stemmann Technik (STT) and DLR are investigating innovative solutions for reducing the energy demand for heating, ventilation and air conditioning (HVAC) as part of the project.
The project also examines norms and standards in the fields of hydrogen and rail transport and attempts to bring the two together assuring safe interaction between the hydrogen technology and overhead catenary at all times. Based on this, the project team is developing proposals for responsible authorities to make approvals across EU of such trains easier in the near future.
For more information please contact: DLR: H. Dittus, Holger.dittus@dlr.de - Toyota Motor Europe: Vasilis Kopelas, Vasilis.Kopelas@toyota-europe.com