Periodic Reporting for period 3 - FCH2RAIL (Fuel Cell Hybrid PowerPack for Rail Applications)
Reporting period: 2023-01-01 to 2023-12-31
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 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 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 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. WP3 has been completed during RP2.
The objective for WP4 was to test the FCHPP in a laboratory environment. In RP2 it started with the installation and commissioning of the FCHPP components on a test bench. Once the test bench and test plan were developed the tests with different load collectives have been performed. A video showing the operation of the test bench was produced: https://youtu.be/mC7EGb9VA7w. The WP4 has been completed in RP3.
WP5 is focused on the physical integration of the FCHPP in the demonstrator train, on the development of the Hydrogen Refuelling Station (HRS) and the demonstration and authorisation of the Hydrogen Train. The integration of the second PowerPack was completed end of 2022; in parallel the implementation of the HRS was started by CNH2. Train demonstration with the first dynamic testing in the national Spanish railway network on the line from Huesca to Canfranc in the Pyrenees was achieved mid of 2023. This also marks the first H2 train in the Spanish railway network. Further testing campaigns in the lines Torralba to Soria and Zaragoza to Teruel marked the TRL7 authorisation of the Demonstrator train for Spain, completing a major objective of the project. Also in the second half of RP3 the hydrogen refueling station developed by the project partners under the lead of CNH2 could be finalised an is now used to refill the demonstrator train during the testing campaigns.
The WP6 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 RP3 data from the demonstration and testing campaigns as well as from the refueling with the HRS developped in the project has been analysed and the methodologies to derive the required KPIs from the measured and simulated train runs has been refined. First results of the HVAC related measures to reduce overall energy consumption have been evaluated and presented on the International Railway Symposium Aachen in November 2023.
WP7 develops the fundamental basis of a normative framework for the use of hydrogen technology in different kinds of railway applications. In RP3 the analysis of regulatory gaps complementary to the initial one in RP2 has been carried out based on the experience with the demonstrator train eventually resulting in the D7.4 Complementary gaps in analysis framework which has been finished for the submission end of RP3.
WP8: In RP3 the comunication and dissemination activities were focused on the "First H2 Train in the Spanisch railway network", the TRL7 authorisation and the ongoing testing campaign. A LinkedIn account was created and together with the project website www.fch2rail.eu the achievements of the project have been comunicated on a more frequent basis. Several workshops have been organised and attended, and project results have been presented on conferences such as the International Railway Symposium Aachen, Rail Live 2023 and the EU H2 Research Days.
WP9 describes the safety management for the complete FCH2Rail project and establishes the safety processes. During RP3, the safety concept has been further developed and implemented and a more advanced status of the hazards following the tests of the train demonstrator and the comissioning of the H2 refueling station developed in the project has been provided.
WP2 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. WP3 has been completed during RP2.
The objective for WP4 was to test the FCHPP in a laboratory environment. In RP2 it started with the installation and commissioning of the FCHPP components on a test bench. Once the test bench and test plan were developed the tests with different load collectives have been performed. A video showing the operation of the test bench was produced: https://youtu.be/mC7EGb9VA7w. The WP4 has been completed in RP3.
WP5 is focused on the physical integration of the FCHPP in the demonstrator train, on the development of the Hydrogen Refuelling Station (HRS) and the demonstration and authorisation of the Hydrogen Train. The integration of the second PowerPack was completed end of 2022; in parallel the implementation of the HRS was started by CNH2. Train demonstration with the first dynamic testing in the national Spanish railway network on the line from Huesca to Canfranc in the Pyrenees was achieved mid of 2023. This also marks the first H2 train in the Spanish railway network. Further testing campaigns in the lines Torralba to Soria and Zaragoza to Teruel marked the TRL7 authorisation of the Demonstrator train for Spain, completing a major objective of the project. Also in the second half of RP3 the hydrogen refueling station developed by the project partners under the lead of CNH2 could be finalised an is now used to refill the demonstrator train during the testing campaigns.
The WP6 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 RP3 data from the demonstration and testing campaigns as well as from the refueling with the HRS developped in the project has been analysed and the methodologies to derive the required KPIs from the measured and simulated train runs has been refined. First results of the HVAC related measures to reduce overall energy consumption have been evaluated and presented on the International Railway Symposium Aachen in November 2023.
WP7 develops the fundamental basis of a normative framework for the use of hydrogen technology in different kinds of railway applications. In RP3 the analysis of regulatory gaps complementary to the initial one in RP2 has been carried out based on the experience with the demonstrator train eventually resulting in the D7.4 Complementary gaps in analysis framework which has been finished for the submission end of RP3.
WP8: In RP3 the comunication and dissemination activities were focused on the "First H2 Train in the Spanisch railway network", the TRL7 authorisation and the ongoing testing campaign. A LinkedIn account was created and together with the project website www.fch2rail.eu the achievements of the project have been comunicated on a more frequent basis. Several workshops have been organised and attended, and project results have been presented on conferences such as the International Railway Symposium Aachen, Rail Live 2023 and the EU H2 Research Days.
WP9 describes the safety management for the complete FCH2Rail project and establishes the safety processes. During RP3, the safety concept has been further developed and implemented and a more advanced status of the hazards following the tests of the train demonstrator and the comissioning of the H2 refueling station developed in the project has been provided.
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 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.