Skip navigation

Category Archives: Honda FCX

Automobile industry has come a long way since the time of Henry Ford. The internal combustion engine that drives the modern car is slowly but steadily evolving into an emission free engine. The carbon pollution has caused globe to warm and changed the climate and also caused respiratory illness for millions of people around the world for decades. The Carbon pollution was completely ignored in the past while other design features of the car have undergone massive changes. However, when the smog and deteriorating air quality of Delhi and Beijing was beamed around the world in our TV sets, people realized how vulnerable they are to carbon pollution.

But how to eliminate the Carbon emission from our automobiles?

1.The simple answer is to substitute the fossil fuels we use every day such as Petrol and Diesel with Carbon free fuel such as Hydrogen.  Hydrogen being a light gas it has to be compressed and liquefied so that it can occupy less space. However, it requires a special ‘cryogenic tank’ to store liquid Hydrogen at – 253 C. BMW has already produced a commercial vehicle and it is in the market. However, the Hydrogen dispensing stations are limited in numbers. It uses existing internal combustion engine suitably modified for Hydrogen fuel so that they can use existing infrastructure that produces their petrol engines. There is no carbon emission except for water vapour. However, Hydrogen should be generated using renewable energy sources such as solar or wind. Hydrogen generated by reformation of natural gas will still have a Carbon foot print. It can be classified as a Carbon free car depending upon how Hydrogen is generated. However, producing liquid hydrogen or filling in a cryogenic tank is not commercially feasible for individual household. Hydrogen supply will have to be a centralized filling station. BMW has recently focussing their attention towards Fuel cell car. While those early vehicles were fun to drive, they suffered from the inefficiencies of super-cooling the liquefied hydrogen, and the hydrogen vaporizing in storage. Around the turn of the century, BMW began to research the hydrogen-powered, fuel-cell electric vehicle as an alternative to the hydrogen-powered combustion engine.

2.The other alternative is to substitute fossil fuel with compressed Hydrogen that generates an electric power using Fuel cell that drives the motor and the car. Here both fossil fuel and internal combustion engine are substituted with Hydrogen fuel and Fuel cell. This is a marked deviation from a conventional car. Honda of Japan was the first to introduce a commercial car using a Fuel cell. It uses compressed Hydrogen at 70 Mpa pressure that supplies Hydrogen to PEM (proton exchange membrane) Fuel cell that generates power that drives the motor and the car. There is no emission except for water vapour. The car runs smoothly and silently because there is no mechanical engine or moving part. It is truly a Carbon free car if the Hydrogen is generated from a renewable energy source such as solar or wind. It is ideal for houses with roof top solar panels. However, one has to install a water purifier, an electrolyser, a compressor and a compressed tank for Hydrogen storage. If the Hydrogen is generated by steam reforming of Natural gas, then it will have a Carbon footprint and cannot be classified as carbon free car. Generation of Hydrogen using roof top solar panel, electrolysis and compression is possible by individual households but it involves still some risk due to the explosive nature of Hydrogen. A centralized Hydrogen dispensing is still a safer method.  Toyota Mirai Fuel cell car is a new model introduced by Toyota motor Co of Japan. It too has certain additional features such as a power generator for a remote households or camp.

2.The third alternative is to eliminate fuel as well as the engine completely; instead supply power to the motor from a storage battery. Here there is no emission or noise because there is no engine or moving parts similar to Fuel cell car. However, the battery is heavy and occupies a large space and it requires frequent charging from an external power source. The power often comes from the main power grid which carries the power generated from a power station which invariably uses fossil fuel. Though there is no Carbon emission from the electric car it still has Carbon footprint. However, if the power is generated from a renewable energy source such as solar and wind then it can be classified as Carbon free car. It is ideal for houses with roof top solar panels. However, it should be connected to the power grid in parallel. Alternatively, it can be connected to a storage battery if there is no grid.

The Lithium ion battery pack in Tesla Roadster weighs 990 pounds, stores 56 kWh of electric energy, and delivers up to 215 kW of electric power. Tesla battery packs have the highest energy density in the industry. To achieve this energy density, Tesla starts with thousands of best-in-class Lithium-ion cells and assembles them into a liquid-cooled battery pack, wrapped in a strong metal enclosure. The battery is optimized for performance, safety, longevity, and cost. The cells used in a Roadster employ an ideal chemistry for electric vehicles

Nickel Metal Hydride (NiMH) batteries are commonly used in hybrid cars. However, a 56 kWh NiMH battery pack would weigh over twice as much as the Roadster battery. Instead, Tesla uses Li-ion battery cells which dramatically decrease the weight of the Roadster pack and improve acceleration, handling, and range.

With Lithium-ion chemistry, there is no need to drain the battery before recharging – there is no “memory effect”. Roadster owners simply “top-off” each night

Each of the above cars have their own advantages and disadvantages. However, Fuel cell cars have certain advantages over Electric cars in spite of the advancement in battery technology primarily due to the weight of the battery and frequency and time required to charge the battery. Fuel cell car has a capacity to store Hydrogen fuel as well as to generate power onsite and this advantage will go a long way to make fuel cell cars truly carbon free not only for transportation but also for stationery power generation in remote locations.

A large scale deployment of renewable energy generation such as solar and wind around the world can deliver a Car that is truly carbon free. However fossil fuel power generation will continue for years to come as the new technologies are developed to generate power using fossil fuel without emitting Carbon emission such as Carbon recycling. The real winner of the car race will depend upon how a Carbon emission free power generation technology will emerge in the future. Whatever may the power technology Fuel cell be here to stay and if a cheap alternative catalyst is developed for Fuel cell then the race will be well and truly on.(Ref : BMW,Honda,Toyota and Tesla Roadster websites)


Bioethanol has successfully substituted Gasoline as a fuel for cars both in the form of blends with Gasoline or individually as an Anhydrous Ethanol. This  successful demonstration by Brazil opens up new generation of cars called flex-fuel cars that allow usage of various blends of Ethanol and Gasoline.Bioethanol can also be used to generate Hydrogen on site by steam reformation so that even Fuel cell cars such as Honda FCX can be felled by Bioethanol.This makes Bioethanol unique as an alternative fuel for transportation. It also facilitates on site electricity generation using Fuel cell, replacing diesel engines.

Substitution of Gasoline by  Bioethanol has several advantages over other alternative fuels. The biggest advantage with Bioethanol is, it is renewable and it allows reduction of greenhouse gases from the atmosphere and will be eligible for Carbon credit. It can be produced by both developing  as well as developed countries using  locally available agriculture produces such as cane sugar, corn, tapioca, sorghum etc. Hydrogen generated from Bioethanol is also free from Sulfur compounds normally associated with natural gas, making it an ideal fuel for Fuel cell application in cars, as well as for power generation using SOFC (solid oxide Fuel cell) or PAFC (Phosphoric acid Fuel cell).The resulting high purity Hydrogen 99.99% can be used as fuel for all type of transportation including Fuel cell Buses, scooters and even boats.

The stoichiometric reaction of steam reformation in presence of catalyst can be represented by the following chemical reaction:

C2H5OH + 3 H2O———- 6H2 + 2 CO2

The Ethanol and water mixture is preheated and the vaporized mixture is fed into a catalytic reactor. The resulting Hydrogen is contaminated with carbon monoxide. This gas mixture is separated using membrane such as Palladium to get Hydrogen with less than 50ppm CO as contaminant. Such purity is acceptable by Fuel cell such as SOFC as well as PAFC.In future a small micro-reactor for on-board reformation may be possible making Fuel cell cars with onboard liquid fuel storage.

Commercial reformers consumes about 0.88 lits of Biothanol of 96% purity to generate 1 Nm3 of Hydrogen with 60% conversion. This translates to $ 5.90 per Kg of Hydrogen. Fuel cell cars offer a mileage of 240 from 1 kg Hydrogen costing only $5.90. For on site power generation 1 kg Hydrogen generates as much as 15Kw electricity and 20Kw heat .Onsite Hydrogen generation with steam reformation also facilitates using SOFC and PAFC for high temperature power generation applications. They are ideal for CHP (combined heat and power) applications for 24×7 operations like hospitals, hotels and super markets. These fuel cells are silent in operation without any emissions except water vapor.

Governments should encourage Bioethanol production and distribution for both transportation and power generation. There is a fear that Ethanol could be diverted for potable purposes illegally depriving Governments of potential reveneues.But this can be solved by denaturing Bioethanol and making it unsuitable for potable purposes. Denaturants such Pyridine has no effect on steam reformation and number of denaturants are available. Such policies will allow the transition from fossil fuels to Hydrogen or Bioethanol.This is a simple and straight forward step any Government can take irrespective of the size or type of nation. But it requires political will, determination and leadership. Developing countries need not wait for big greenhouse emitters such as US, China and India to make a decision on their Carbon emissions but start introducing Bioethanol as fuel locally.

Hydrogen is the cleanest source of energy that can power your homes and fuel your cars. It can potentially substitute diesel and petrol or coal and clean up our environment. Hydrogen has been manufactured industrially for the past several decades and transported across thousand of kilometers by pipelines in Europe. The science and technology of Hydrogen is well known but its application to generate power and fuel a car is relatively new. The gasoline internal combustion engines that drive our gasoline cars can be modified to suit Hydrogen fuel. But the physical and chemical properties of Hydrogen gas created a necessity to alter existing gasoline engines for commercialization. But such conversion has been painfully slow for couple of reasons. There is a stiff resistance from gasoline cars to switch over to Hydrogen because they have a well established infrastructure to manufacture gasoline cars and to supply gasoline through well established distribution network. But Hydrogen cars lack both of them. Even if the cars can be modified for Hydrogen, there are no sales or distribution network for the fuel Hydrogen, similar to Gasoline. Even consumers need to be educated that Hydrogen is safe, environmentally friendly and we need not depend on import of oil and so on. It is a blessing in disguise that Hydrogen can be generated by each home, business and industries for their captive use from their tap water. Recently Hydrogen fuelled scooters have been introduced in the market. There are number of advertisements in the media too; that you can fit a Hydrogen generator at your car that will reduce your gasoline bills substantially and also cut your emissions.But these Electrolyzers can generate only water gas and not a pure Hydrogen. Yet such simple devices can help reduce your petrol bills to an extend .If things are so simple why are we still struggling with high crude oil prices and increasing electricity bills? Let us examine this in detail. Water (H2O) can be split into Hydrogen (H2) and Oxygen (O2) by simply passing an electric current through water using a battery. The water disassociate as follows: 2    H2o———   2 H2+ )2 Stochiometrically, it means 36 lits of water will generate 4 Kgs of Hydrogen and 32 kgs of Oygygen.The current PEM (Proton exchange membrane) Fuel cell car (Honda FCX clarity) can drive 100 miles with just 0.105 kgs of Hydrogen from 5000 psi Hydrogen tank. Similarly 4kgs of hydrogen can generate about 100 kws of electricity using PEM Fuel cell, based on a conservative estimate; but 4Kgs of gasoline can generate only 15 kW electricity. The gasoline engine offers only 100km mileage from 13 kgs (16lits) of gasoline. In other words, 0.105 kgs of Hydrogen at 5000 psi gives the same mileage as 16 lits of Gasoline.  This is the amazing power of water, yet to be unleashed! The tap water is suitable to generate Hydrogen by adding a little amount of potash lye to improve the electrical conductivity. An Alkaline water electrolyzer can be attached to the water tank to generate required amount of Hydrogen based on the above calculation. The resulting Hydrogen has to be compressed to a required level. The power consumption to electrolyze water will be about 75-80 kwhrs per Kg of Hydrogen generated at 5000 psi.Therefore 4Kgs of Hydrogen will need a power of 300kwhrs costing about $30 for a total mileage of 3800 miles. You will need a small reverse osmosis unit to be attached to your water tap so that the water is de-ionized so that there is no precipitation in the Electrolyzer or reduction in the efficiency of electrolysis. Recently, Suzuki Bargeman introduced Hydrogen Fuel cell scooter which claims to offer a mileage of 200km from 12 lits Hydrogen (carbon composite material) tank at an higher pressure of 10,000psi.The future of Hydrogen car is very promising and finally the world can hope to get rid of smoke and noise from our roads and cities.

This article provides an overview on Hydrogen cars and how we can generate renewable hydrogen to fuel these cars. There are two well-known brands of Hydrogen based cars already in the market, BMW7 and Honda FCX Clarity models.

BMW7 works on Hydrogen Internal Combustion engine fuelled by Liquid Hydrogen. It is a 6 Liters V12 engine with 191Kw capacity and 390 N of torque. It offers 100km from 50 Liters of Liquid Hydrogen with a density of about 70-80gms/lit and offers 100kms from Gasoline of 16.7 liters. It has a capacity of 170 liters for liquid Hydrogen storage at the rear end of the car. It can run both on Hydrogen as well as on Gasoline. Liquid hydrogen has a better power density but liquefaction is a cryogenic technology and consumes power for liquefaction. The storage tank also is of special construction because Liquid Hydrogen is stored at -253C.

Honda FCX Clarity car is fuel cell car fuelled by compressed Hydrogen gas. It offers 100kms for 3.5 lits of Hydrogen (at 5000 psi pressure with density at 30gms/lit.). It has Hydrogen storage of 3.92kgs kgs with a total mileage of 240miles. Increasing Hydrogen storage gas pressure up to 10000psi, the Hydrogen power density is considerably increased making it comparable with liquid Hydrogen. Moreover fuel cell car is silent while driving because there is no combustion engine.
BMW is able to use their existing conventional internal combustion engine with slight changes suitable for Hydrogen so that they can use their existing infrastructure. But Honda FCX uses proton exchange membrane Fuel cell. It is an electrochemical device that converts Hydrogen into electricity which runs the motor for transmission of power. It is similar to an electric car in which power is stored in batteries and used to drive the motor for transmission. The only difference is the power is generated in Fuel cell car as and when hydrogen is supplied whereas in Electric cars, power is drawn from stored energy from the battery.

We can inject pure Hydrogen along with Gasoline, CNG or LPG to assist the combustion to save fuel consumption up to 30% and to reduce harmful emissions. The conventional gasoline cars can be fitted with water electrolyzer to generate Hydrogen using the car battery. The electrolyzer currently sold in the market is quite different. They generate ‘water gases’ and not pure Hydrogen. They electrolyze water using pulsating DC current which essentially breaks down water into Hydrogen and oxygen molecules. The complete mixture of Hydrogen, Oxygen and undissociated water molecules are injected into fuel manifold of the car. The hydrogen will assist in the process of combustion to certain extend and help save the fuel consumption of gasoline.

Renewable Hydrogen is a potential source for fuelling automobiles. One can use solar panels and simple tap water to generate hydrogen gas and store them under high pressure in cylinders. We will be releasing an eBook in the near future to design a suitable Renewable Hydrogen system and install them at homes and businesses for power generation as well as to fuel two-stroke engines such as scooters and bikes. Initially the book will offer DIY kits to design and install power generation for homes and businesses up to 10Kw capacity electricity generation. We will be conducting trials on two-stroke engines using renewable Hydrogen to get approvals from proper transport authorities for safety and usage on Indian roads.

Hydrogen can be safely handled as long as we take appropriate safety measures as we normally do while handling petroleum products like gasoline or butane gas. It may look like a daunting task to fuel a car with Hydrogen gas but in reality, all necessary equipment and systems are commercially available including High pressure Carbon fiber tanks fully tested and approved.

Water makes up 71% of the planet earth and it is the most potential energy source of the future. Water is a product of combustion between Hydrogen and Oxygen, two most abundantly available elements and   vital for life on earth. The bondage between Hydrogen and Oxygen is so strong that it requires a certain amount of energy to separate them. Separation of Hydrogen and Oxygen using the process of Electrolysis is a well-known technology. Separation of water by high temperature using Thermolysis has also been studied.  In both the processes the separation of Hydrogen and Oxygen after decomposition is a key step because of the strong affinity between the two elements. Hydrogen has to be separated in a pure form without any trace of Oxygen. Currently most of Hydrogen is generated commercially by steam reforming natural gas because of its easy availability as piped gas in many developed countries. Moreover steam reforming is a well established commercial technology that has been used for decades in chemical process industries. The hydrogen resulting from steam reforming is acceptable for combusting in Hydrogen internal combustion engines but not pure enough for a Fuel cell car. Any trace of impurity from natural gas such as Sulfur or Mercaptans can potentially poison the catalyst used in fuel cell which is very expensive. Hydrogen with purity less than 99.99% is not recommended for Fuel cell applications.

Currently there are few issues to be addressed before Hydrogen becoming a commercial fuel. The energy required to separate Hydrogen from water by commercial electrolysis is about 6Kws (kilowatts) to generate 1 m3 (cubic meter) of Hydrogen. Two key factors for electrolysis are purity of water and  direct current source. Water of certain purity is a critical part for Hydrogen generation. Deionized water with electrical conductivity less than 0.10 micro Siemens/cm is required. Normal drinking water conductivity is less than 100micro Siemens/cm. The potable water can be deionized with reverse osmosis system to get necessary quality. In fact both high purity water and direct current are not commercially available. A renewable energy sources such as solar or wind that generates direct current can be used for electrolysis. This will drop batteries and rectifier that we normally use in renewable energy systems. The generated Hydrogen can be stored in cylinders under high pressure. The stored hydrogen is the stored energy that can be used as and when required.  We can use the stored Hydrogen to generate electricity to meet our power requirement whether it is a home or business or industry. The major advantage with this system is that we can generate power when we need and we don’t have to depend on the grid power. We can also export surplus power to the grid. In fact all DC appliances can be connected with DC power from Fuel cell and operated to improve the efficiency. Such a system is ideal for remote locations without any grid supply such as remote villages or islands.

The same stored Hydrogen can also be used as fuel for a car whether it is a combustion engine or a Fuel cell car. Hydrogen can be compressed and stored under high pressure. Alternatively, Hydrogen can be stored using metal hydrides in smaller volumes. Honda introduced the first fuel cell car in the market in 1999. Since then they have made considerable improvements. Honda FCX Clarity, sedan offers a mileage of 270 miles for a single cylinder of Hydrogen at 5000 psi pressure. They are introducing a latest model with Hydrogen pressure at 10,000 psi which will considerably improve the mileage further. Unlike Hybrid cars, Fuel cell cars run silently and experts who have test-driven the car are very much impressed with the performance. Similarly Ford introduced Hydrogen combustion engine 6.8 liters V-10 engine to power E-450 Hydrogen shuttle bus. Ford modified their Gasoline engine to suit Hydrogen fuel.

Substituting Gasoline with Hydrogen is no longer a theory but a commercial reality. More and more research is being undertaken to improve the performance. Currently the cost of Hydrogen cars and Hydrogen fuel is expensive, due to lack of infrastructures to manufacture such cars or to distribute Hydrogen. However these cars will soon replace gasoline cars. Similarly homes and business can generate their own electricity for their daily use using stored Hydrogen. Water will become the fuel of the future and Hydrogen will clean up the air that has been heavily polluted by fossil fuels for decades.

%d bloggers like this: