As fuel-cell-powered on-highway and off-highway vehicles increasingly achieve net-zero emissions targets, efficient thermal management has become essential to maintaining performance and longevity.
AKG, a manufacturer of high-performance heat exchangers, offers innovative thermal management solutions designed to address the unique challenges of fuel cell cooling systems.
Fuel cell vehicles rely on hydrogen fuel cells to generate electricity for traction motors and battery charging. These systems produce heat as a by-product and must be maintained within a temperature range of 55° to 80° C to prevent degradation.
Unlike internal combustion (IC) engines, which operate with higher coolant loop temperatures of up to 110° C, fuel cell cooling systems face much smaller temperature differentials of 20° to 30° C, requiring specialized thermal management solutions.
Fuel-cell thermal management challenges and solutions
- Temperature differential management: The smaller temperature differential in fuel cell systems demands larger heat exchangers to dissipate excess heat efficiently. Space and cost optimization are key considerations in commercial vehicle applications where packaging constraints are challenging.
- Low-conductivity coolant optimization: Maintaining low-conductivity coolant is critical to fuel cell efficiency and preventing corrosion. Vacuum-brazed (VAC) heat exchangers, combined with ion-capturing filtration, help keep conductivity within industry standards (<5-25 µS/cm), reducing thermal runaway risks and ensuring long-term durability.
- Direct loop vs. indirect loop cooling:
- Direct loop: A liquid-to-air heat exchanger allows low-conductive coolant to cool the fuel cell stack in a closed-loop system directly.
- Indirect loop: A liquid-to-liquid heat exchanger reduces cooling loop size and minimizes coolant volume, improving space efficiency and lowering ionic emissions.
- Duty cycle considerations: Fuel cell-powered vehicles vary in power requirements. Some rely on a single fuel cell, while others integrate multiple fuel cell systems based on application demands. AKG collaborates with fuel cell manufacturers and OEMs to design customized thermal management solutions that align with specific duty cycles.
- Fan noise and airflow optimization: Due to low temperature differentials, fuel cell cooling requires high-powered fans operating at 460VAC or 12/24/48/350/650VDC, often stacked in series. Proper fan placement and noise-areduction strategies are essential to prevent hot air recirculation and ensure optimal cooling performance.
AKG continues to advance fuel cell thermal management technology, offering scalable, high-performance cooling solutions tailored for on-highway and off-highway applications. As the demand for zero-emission powertrains grows, AKG remains committed to delivering efficient and reliable thermal management solutions that support next-generation vehicle electrification.
Filed Under: Fuel Cells, Technology News