Hybridisation: A new technology for electric commercial vehicles

Aluminium Fuel Cells are a much more commercially viable and practical option for India's long-haul transportation sector.

Li-ion batteries are currently the most popular choice for electric mobility all over the world. Li-ion combination stands out in the EV mobility market due to its efficient power density, small size, higher cycle life, high cell voltage, and optimal energy-to-weight ratio. However, Li-ion batteries have some drawbacks, including long charging times and limited driving range. Furthermore, the scarcity of lithium, the high cost of batteries, the high rate of degradation, and safety concerns are slowing the widespread adoption of Li-ion batteries.

One of the primary reasons why people continue to prefer IC engine vehicles is a lack of high-range Li-ion powered electric vehicles on the market. The limited number of electric vehicles with ranges of more than 250-300 kilometres, as well as their high acquisition costs, frequently limit business stakeholders' willingness to adopt EVs for long-distance commercial vehicles.

So, if Li-ion batteries alone are insufficient, what is the preferred and most effective energy solution for today's long-distance commercial vehicles? Li-ion and Aluminum Fuel Cell hybrid energy solution Aluminium Fuel Cells (AFCs) are a new technology that has the potential to solve the problems that Li-ion batteries face. AFC has a high energy density and can provide vehicles with a long driving range. It is an energy generation system that runs on aluminium. The technical process entails consuming aluminium and converting it to aluminium hydroxide, which can then be converted back to aluminium at the smelters.

This complete cycle of using aluminum as a fuel in AFC, collecting the aluminum hydroxide, converting it to aluminum, and then using the recycled aluminum as a fuel in AFC makes AFC technology highly reliable and scalable.

AFC is a much more commercially viable and practical option for India's long-haul transportation sector. Because India is one of the largest producers of aluminum, the cost of aluminum fuel is kept low. However, there are some unresolved issues in AFC as well. One of the most significant challenges is the availability of sudden power required by vehicles in situations such as rapid acceleration.

This problem can be solved by combining AFC with Li-ion batteries in electric vehicles. The combination of a Li-ion battery as an energy storage solution for consistent power delivery to vehicles and an AFC as an onboard refuellable energy generation solution could be the next-generation ultimate solution for the electric mobility sector.

Solution for long charging hours

While the Li-ion battery can power the vehicle directly, the AFC can charge the installed Li-ion battery. This combination has the potential to solve the individual problems of both technologies. The hybrid energy solution can provide a driving range of more than 1000 kilometers, reducing the need for multiple charging stations as well as long charging hours.

When the Li-ion battery's storage of charge(SOC) falls below a certain threshold, the AFC can kick in and provide an onboard charging solution. Because the vehicle will run on a combination of AFC and Li-ion battery, the rate of consumption of Aluminium in the AFC will be slow, reducing the need for Aluminium refuelling. Aluminium refuelling in AFCs typically takes 20-30 minutes, depending on the size of the system, and thus the issue of long charging hours of Li-ion batteries at charging stations is also resolved.

To summarize

The sustainability of any technology and its entire supply chain define its overall credibility for the planet. The combination of Li-ion batteries and Aluminium Fuel Cells could be the ultimate energy solution for heavy long-haul commercial vehicles, addressing issues such as range anxiety, long charging times, and a lack of charging stations while remaining environmentally friendly.

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