Fuel cell vehicles (FCVs) modeling: from subsystems optimization to lifecycle environmental and cost impact evaluation, preliminary design and performance comparison

The transition toward sustainable and low-carbon mobility represents a key strategy for addressing global challenges related to climate change and environmental degradation. In recent years, increasingly stringent environmental regulations and policy frameworks have accelerated the decarbonization of the transportation sector, promoting cleaner and more efficient propulsion systems. Within this context, this thesis investigates Proton-Exchange Membrane Fuel Cell (PEMFC) technology as a promising solution for achieving zero-emission mobility. In particular, PEMFC-based Fuel Cell Vehicles (FCVs) are analyzed due to their high efficiency, scalability, and ability to deliver competitive performance while eliminating direct pollutant and greenhouse gas (GHG) emissions. The study begins with an overview of the global and anthropogenic drivers of climate change, highlighting the role of the transportation sector in enabling a sustainable transition. Hydrogen is introduced as a versatile energy carrier, with analysis of its production pathways, storage technologies, and carbon footprint. The work then explores the fundamentals of FCs, retracing their evolution and classification, with specific attention to PEMFCs, describing their electrochemical mechanisms, thermodynamic principles, and performance dependence on key operating parameters. The research further investigates the Balance of Plant (BoP) components in FCVs. Within a collaboration with FPT Motorenforschung AG under the PNRR MOST project, a lumped-parameter model of a PEMFC thermal management circuit was developed and optimized, providing performance improvements and insights for future applications. Map-based models for FCVs, Battery Electric Vehicles (BEVs), Hydrogen Internal Combustion Engine Vehicles (H2ICEVs), and H2ICEV hybrid configurations were developed to evaluate the effects of ambient conditions, vehicle mass, and passenger load on energy consumption and efficiency. Life Cycle Assessment (LCA) of both GHG and non-GHG emissions and Total Cost of Ownership (TCO) analyses across EU27 countries highlight the potential of FCVs in balancing performance, sustainability, and economic viability, and demonstrate the scalability of hydrogen technologies in road and maritime transport.