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Fuel Cell Hybrid PowerPack for Rail Applications

Periodic Reporting for period 2 - FCH2RAIL (Fuel Cell Hybrid PowerPack for Rail Applications)

Reporting period: 2022-01-01 to 2022-12-31

Half of the railway lines in the European Union are electrified and already enable local emission-free rail transport. Diesel-powered trains are used on the remaining sections of the lines. Across Europe, more and more railway lines are being electrified, i.e. equipped with overhead lines. A very expensive and long-term project that always depends on the local geographical conditions.

In the EU-funded project FCH2RAIL (Fuel Cell Hybrid Power Pack for Rail Applications), the consortium is developing and testing a new type of train prototype. At the heart of the project is a hybrid, bi-modal drive system that combines the advantages of electrical power supply from the overhead line with a hybrid power pack consisting of fuel cells and batteries. This leads to more sustainable and energy-efficient rail transport. It shall be shown that this type of bi-mode power pack is a competitive and environmentally friendly alternative to diesel power.
In WP1 - Generic FC Train Requirement Specifications and Concept the relevant use cases for hybrid bi-mode vehicles have been analysed. During RP2 WP1 has completed the deliverable D1.1 that analyses the use cases of the actual services in Spain, Portugal, Slovakia and Germany to derive the working parameters and requirements. Additionally, 2 further deliverables related with the Hydrogen Refuelling Station have been released to study the characteristics of the HRS itself, and to define the boundary conditions for the areas where the HRS will be installed. WP1 has been completed during RP2.

WP2 - FC powered Train Demonstrator, Architecture and Concept focuses on the integration of the Fuel Cell Hybrid Powerpack (FCHPP) in the demonstrator train. During RP2 the integration study of the FCHPP in the demonstrator train has been completed, ending with the Train Design Freeze of all the electro-mechanical interfaces needed for the integration in the Train Demonstrator. Deliverable D2.3 gathers all the details about the integration, including the layout of components, mechanical and electrical drawings. WP2 has been completed during RP2.

WP 3 – FC Hybrid Powerpack Development is advancing in the definition of the modular and scalable FCHPP. During RP2 the components of the FCHPP have been manufactured and tested at the supplier’s facilities. One set of FCHPP components was sent to CNH2 and integrated in the stationary test bench. The second set of components was sent to CAF for the integration in the train demonstrator. Deliverables D3.2 D3.3 D3.4 and D3.5 are documenting the successful tests of the different components. WP3 has been completed during RP2.

The objective for WP4 - Implementation and Test of FCHPP is to test the FCHPP in a laboratory environment, before installing it in the Train Demonstrator. In RP2 it started with the installation and commissioning of the FCHPP components separately, to finally have the commissioning of the complete FCHPP. Once the test bench and test plan were developed the tests with different load collectives have been performed. By the end of September, the test bench was dismounted and the FCHPP components were sent to CAF for the installation on the train. A video showing the operation of the test bench was produced: https://youtu.be/mC7EGb9VA7w.

WP5 - Demonstrator Integration, Testing and Homologation focused on the physical integration of the FCHPP in the demonstrator train and on the development of the Hydrogen Refuelling Station (HRS). Starting in January 2022 the equipment necessary to fit one FCHPP onto the train has been delivered. From March 2022 the Energy Storage System from CAF PA, the Fuel Cells from TME and the Fuel Cell Cooling Systems were installed. Static tests were completed in July, followed by testing and validating the PowerPack in dynamic low-speed conditions on a closed track. This is documented in a video: https://youtu.be/bFBR6nhyEVI. The integration of the second PowerPack was completed end of 2022, in parallel the implementation of the HRS was started by CNH2.

The WP6 -Demonstration of the competitiveness main objective is to demonstrate that the proposed FCHPP generic solution provides benefits in terms of operational performance and costs compared to the current state-of-the-art diesel propulsion. This involves making the FCHPP performance comparable to the diesel propulsion in several areas. In RP2 a new objective related with the optimization of the refuelling process using refuelling simulations and data of the service experience phase of the mobile HRS has been included. The set of KPI and the method to quantify them have been defined and the innovative AC subsystems have been modelled (HyPAC, Absorption AC).

WP7 - Normative Framework develops the fundamental basis of a normative framework for the use of hydrogen technology in different kinds of railway applications. In RP2 the deliverable D7.1 Gaps in regulatory framework has been published. It gathers a list of gaps in railway and hydrogen regulations which is the basis for preparation of proposals to modify the normative framework and the future networking activities.

WP8 -Dissemination, Communication, Exploitation focuses on communication, dissemination and exploitation activities. In RP2 this included an update of the PDER, support of the creation of video footage, flyer, poster and project brochure and updates of the project website www.fch2rail.eu. A highlight was the live presentation "FCH2RAIL insights: Demonstration of the Fuel Cell Hybrid PowerPack" on InnoTrans2022, one of the world’s leading trade fairs for transport technology.

WP9 – Project Management describes the safety management for the complete FCH2Rail project and establishes the safety processes. During RP2, the safety concept has been reviewed together with the European Hydrogen Safety Panel (EHSP), and the D9.4 Hazard Log has been updated with a more advanced status of the hazards following the start of the track test of the train demonstrator.
FCH2RAIL project will effectively contribute to the European Green Deal and in particular to the decarbonisation of European rail transport by providing alternative fuel cell based power sources for the application in multiple units, mainline and shunting locomotives.

FCH2RAIL project aims at having an impact in the following areas:

Cost reduction:
1. Strengthening the European hydrogen supply chain.
2. Proposed Modular/scalable solutions are reducing cost of the fuel cell hybrid traction systems.
3. Multipurpose FCHPPs facilitates a higher market penetration compared to specific solutions for single markets. Valid for any use case (multiple unit, mainline and shunting locomotive) but also for refurbishment.
4. Bi-Mode trains are providing a service not provided by conventional diesel trains or pure fuel cell hybrid trains.
5. Holistic energy management and reuse of waste energy through innovative on-board subsystems is improving energy efficiency and reducing TCO of trains on non-electrified lines. (Absorption HVAC and HyPAC system).
6. Aligning the standardization worlds of rail and hydrogen sector.

Increase Technology Awareness
7. Homologation of the TRL7 train demonstrator in new EU member states (Spain and Portugal). Hence it extends the market for the FCH trains.
8. Dissemination activities are considered to increase the awareness level of this technology by all the relevant stakeholders.
FCH2RAIL: Civia Train Demonstrator
FCH2RAIL: Structure of Fuel Cell Hybrid PowerPack FCHPP
FCH2RAIL: Civia Train Demonstrator travelling in hybrid mode