| Ian Porter
reports on the secret life of hydrogen cars.
We could
be headed for a dangerous future on the roads. In our cities the main roads
will be almost permanently wet, from, say, 7am to perhaps 7pm, even when
the Bureau of Meteorology sees not a cloud in the sky.
Global warming, right? Not in this
case.
Imagine a future where we're all
driving cars that don't pump out noxious gases from the tail pipe. Rather,
imagine we're all driving hydrogen-powered cars that emit only water vapour.
Then imagine a traffic jam. There will be a mist hanging in the air on
many days, making it
difficult to see very far ahead.
Cars ahead will be pumping out more
droplets of water, adding to the visibility problems. There will be puddles
accumulating on the road and in the gutters.
Drivers will have to get used to
longer braking distances as a matter of course.
And insurance costs could rise because
there could be more crashes in slippery conditions. This dramatic change
in our driving world may evolve as we move away from oil as the fuel for
our vehicles to hydrogen. Welcome to the flipside of fuel cell-powered
electric vehicles.
If the car companies are right, we
will soon be driving cars and trucks that use no petrol, electric vehicles
that consume only hydrogen gas and produce power in the form of electricity.
The only byproduct will be water vapour.
It is not clear yet how much water
will be produced, but a petrol-powered car emits several tonnes of carbon
dioxide in a normal year's usage, as well as water vapour.
At present, the carbon dioxide and
water vapour produced by internal combustion engines are emitted at high
temperature and drift away into the atmosphere.
Water vapour from fuel cell cars,
emitted at much lower temperatures - around 75 degrees - will be suspended
in the atmosphere in larger droplets and will more readily condense and
fall to the ground as water.
It's a problem that has already caught
the attention of senior research engineer Sae-Hoon Kim at the Hyundai-Kia
Eco-Technology Research Institute in Korea.
"It is possible the roads will be
wet all the time because, with a fuel cell car, when the water vapour comes
out it condenses. Many companies are looking at the exhaust system," he
said.
But that's not all they are looking
at when it comes to electric vehicles powered by hydrogen fuel cells.
Many rivals are also looking closely
at what Kia and its parent company, Hyundai, are doing because the two
Korean companies - often dismissed as low-cost, low-technology manufacturers
in the past - have recently emerged as leaders in fuel cell and electric
vehicle
design.
Earlier this month the companies
stunned their European opposition at the annual Michelin Bibendum Challenge
for alternative energy vehicles, which was conducted in Shanghai.
"This is hot news," Mr Kim said.
"We entered a hydrogen fuel cell vehicle purely made with Kia technology
and we won first prize for all items that were tested."
The 13 vehicles from eight different
companies were measured on a series of criteria including noise, pollutants,
fuel efficiency and carbon dioxide emissions.
The converted sport utility vehicle
entered by Kia/Hyundai was the only fuel cell vehicle to be rated an "A"
in each of the four categories.
An A-Class Mercedes-Benz entered
by Daimler was next best with three "A"s and a "B" for noise. Other entrants
included General Motors, Ford, Nissan and and VW's Chinese partner Shanghai
Automotive Industry, some of which entered purpose-built vehicles as
opposed to converted production
models.
"You can see . . . our technology
is very superior to others. Only we need a little bit more design or better
packaging because we are using general commercial vehicles, not real fuel
cell vehicles," Mr Kim said.
The Kia achievement in the Bibendum
Challenge cannot be over-estimated. Kia only started looking at electric
cars and hydrogen fuel cells in 2000, years after industry leaders such
as GM, Toyota and Honda started work on electric cars.
(Mr Kim makes the point that a hydrogen
fuel cell-powered electric vehicle is a hybrid, just as the Prius is a
hybrid, in that it carries a power source other than batteries.)
The company's first fuel cell vehicle
used bought-in hydrogen fuel cells producing the equivalent of 75 kW, which
is about the power most other manufacturers are working with. It took 40
seconds to get the fuel cell cycle going, but it wouldn't start in below
freezing
temperatures.
Kia did not make its own hydrogen
fuel cell until 2005, when it built its second-generation vehicle. That
cell took only five seconds to fire up and could be started at minus 15
degrees, but at that temperature it took five minutes before you could
drive away.
"Our target is to develop technologies
which can reduce that to 30 seconds," Mr Kim said.
Another impedient is that the life-cycle
of a fuel cell is about 1500 hours, which Mr Kim said was equivalent to
about three years' driving.
"Our target is to make this 5000
hours and we are quite near."
Kia revealed its third-generation
fuel cell vehicle earlier this year and the performance expected from this
machine will approach that of a vehicle with a conventional engine.
The second-generation fuel cell car
had a Kia-made 80 kW stack when we drove it recently.
Everything in the cabin looks quite
normal, except the dial to the left of the speedo now bears the initials
''SOC'' (State of Charge) and measures the charge in the battery.
Move the gear lever to D as you would
in any automatic, let the brake off and press the accelerator.
The vehicle starts moving but there
is no mechanical commotion to signal its progress. It is eerily quiet in
the cabin and, for pedestrians, eerily quiet outside. All they can hear
is some tyre noise as the tyre treads move over the tarmac.
But, there is something else missing:
strong acceleration. Electric motors are supposed to have lots of torque
low down in the rev range, and on other electric cars this gives a satisfying
push in the back when you tread on the accelerator.
But the Sportage has a distinctly
leisurely attitude to acceleration.
It's no Morris Minor, but it was
a bit of a let-down. We were not alone in feeling this way.
''We all feel like it lacks torque,''
said Mr Kim. ''That's why we changed the motor and the fuel cell in the
third-generation car.''
Kia has raised the power of the fuel
cell to 100 kW, but not just by adding more cells and making the fuel cell
stack bigger.
Companies have to balance the power
they want from a fuel cell with the actual physical size of the stack.
To increase power output, you just
add more single-layer cells to the stack, but that makes it more difficult
to build into the vehicle. This balance between power output and the size
of the cell is referred to as the power density of the cell.
At present, Kia's fuel cells have
a power density of about 1200 watts for each litre of space, but the company
is about to make a big step forward.
In its third-generation technology,
Kia has developed a stack that dispenses with the graphite normally used
as spacers between the cells.
"Graphite is very thick so you cannot
makes the stacks smaller. Now, we use metal, which is thin so we can make
a very small stack."
"The power is 100 kW but the power
density will go up to about 1900 watts in a stack about half the size,"
Mr Kim said.
This is a tremendous advance and
has helped Kia produce a compact chassis for its third-generation vehicle,
revealed at the Seoul motor show.
Mr Kim expects the third-generation
vehicle to match the performance of a petrol-engined car with a driving
range of 600 kilometres and a maximum speed of 170 km/h.
Mr Kim is also confident the improved
power density of the new stack will be complemented by a further improvement
in the efficiency of the fuel cell.
"Our second-generation fuel cell
was 48 per cent efficient and we have 53 per cent with the new one. Our
target is 60 per cent and that is not that far (away)," he said.
In terms of fuel consumed, it costs
US6.2 cents (A7.2) a kilometre to drive a fuel cell vehicle and about A15.8
cents for a petrol-engined car at current oil prices.
"In the future, we think it will
only cost A3.6 cents for a fuel-cell vehicle."
Kia already has fleets of hydrogen-powered
electric vehicles under test with the US Department of Environment and
with the Korean Government.
However there is no refuelling infrastructure
installed anywhere.
"We never know when we will produce
fuel-cell vehicles because we need hydrogen stations. The technology is
there but there are no refuelling stations."
Mr Kim said Kia's target was to complete
its development of all major components so that production could start
by 2012.
"After 2012, we'll be ready. Any
time someone else produces, we will be ready to go into the market."
As for the looming problem of permanently
wet roads, Mr Kim said some companies were already considering not having
an exhaust pipe, and just condensing the water vapour and collecting the
water on board, for disposal later.
However, Mr Kim has another solution,
and it's one he hopes will make him a rich man: "I have already made a
patent. First, I mix the exhaust with ambient air.''
Mixing ambient air with the water
vapour before it leaves the tail pipe will reduce the humidity of the gas
and lessen the propensity of the vapour to condense, he explains.
"It's just an idea. It doesn't help
me a lot now but, in the future, maybe."
And that is about the only "maybe"
to be found in the Kia hydrogen fuel cell program. The rest of it is all
definitely full steam ahead.
Ian Porter travelled to Korea as
a guest of Kia Motors Corporation. |