Authored by Alison Smyth, Lead Engineering Consultant

The global market for fuel cell electric vehicles (FCEVs) is expanding rapidly, with over 90,000 FCEVs on the road as of May 2024—a 14% increase since October 2023. Among these vehicles, buses account for 17%, highlighting the growing success of fuel cell technology in public transportation.

At the Center for Transportation and the Environment (CTE), we are proud to be at the forefront of the emerging fuel cell bus market in the U.S. With support from important initiatives such as the Federal Transit Administration’s (FTA) Low or No Emissions and Bus and Bus Facilities grant programs, CTE has partnered with transit agencies across the country to deploy fuel cell buses and the hydrogen infrastructure to fuel them.

Additionally, through the ARCHES Hydrogen Hub, a selected hub for the Department of Energy’s Regional Hydrogen Hub funding program, CTE will manage the deployment of more than 1,000 fuel cell electric buses (FCEBs) for 13 transit agencies in the coming years. This initiative integrates hydrogen fueling infrastructure with a growing fleet of zero-emission buses to ensure efficient operations and minimal environmental impact.

Transitioning to zero-emission fleets requires selecting the right technology to meet diverse operational needs. While battery-electric buses (BEBs) may be ideal for some routes, there are scenarios where FCEBs are a better fit — and others where a mixed fleet may provide the most efficient and flexible solution, optimizing performance across different route types and operational conditions.

Extended Range for Demanding Routes

FCEBs offer distinct advantages in range and fueling efficiency, making them ideal for demanding operational conditions. While BEBs perform well on shorter, urban routes with predictable charging opportunities, they may struggle in extreme weather or on long routes. While all vehicles are sensitive to temperature extremes, FCEBs are better equipped to handle extreme cold because they can recapture heat from the fuel cell to warm the cabin. This results in greater range and reliability in harsh conditions. Additionally, hydrogen fueling takes only a few minutes, enabling FCEBs to quickly return to service and maintain continuous operation without the downtime associated with charging.

In a rapidly evolving industry, agencies are prioritizing fleet diversification to enhance flexibility and resilience while addressing unique operational needs. A mixed fleet that includes both BEBs and FCEBs allows agencies to optimize their operations. FCEBs are able to step up where BEBs fall short by covering longer routes and supporting reliable service, ensuring environmental and performance goals are met through the complementary strengths of both technologies.

Scalable Infrastructure for Growing Fleets

While hydrogen fueling infrastructure can require significant upfront investment, it offers scalability as fleets grow. For large-scale deployments, a single hydrogen fueling station can support an expanding fleet without the need for additional infrastructure investments for each new bus. This contrasts with BEBs, where infrastructure is often deployed incrementally as the BEB fleet grows. The cumulative costs of installing chargers and electrical infrastructure can rise significantly as fleet sizes grow, particularly in urban areas where charging demand can require expensive utility upgrades and in some cases, entirely new substations. By installing large-scale hydrogen stations, transit agencies can minimize the number of infrastructure capital projects needed to grow their zero-emission bus (ZEB) fleet.

Operational Simplicity for Transit Agencies

FCEBs also offer operational simplicity, particularly for transit agencies already managing compressed natural gas (CNG) fleets. Fuel cell buses operate in much the same way as CNG buses, making them easier for agencies to incorporate into their existing operations. The introduction of BEBs adds an additional layer of complexity with route assignments and charge management, requiring advanced software systems and careful scheduling to ensure buses are sufficiently charged for their daily routes.

Policy and Economic Impact of FCEBs

The demand for low-carbon transportation fuels has spurred government actions and investments in hydrogen infrastructure and technological advancements.

In the U.S., the National Alternative Fuel Corridors Program and the Department of Energy’s Regional Hydrogen Hub Program were established to support building networks of hydrogen producers, consumers, and necessary infrastructure, such as fueling and charging stations. The newly released guidance of the Section 45V Tax Credit for Clean Hydrogen Production, while still flawed in some areas, provides certainty that will be vital in scaling hydrogen and supporting the deployment of FCEBs across the country. These programs provide critical resources for transit agencies and the private sector to adopt cleaner, hydrogen-powered alternatives.

FCEVs are not only good for the environment, but also for our economy. The deployment of FCEVs of all classes directly supports American OEMs and manufacturing, which will create jobs and promote technological innovation. As the market for FCEBs grows, so too does the demand for hydrogen infrastructure, creating new opportunities for American businesses and strengthening the US economy.

Through the combined efforts of government programs, industry innovation, and transit agency leadership, the widespread adoption of FCEBs will reduce emissions, improve air quality, and create jobs. At CTE, we are proud to contribute to this movement by providing expert guidance on fleet electrification, hydrogen infrastructure, and the integration of zero-emission technologies. We are committed to helping transit agencies successfully navigate this transition, ensuring that they have the tools, strategies, and support needed to build a sustainable and efficient zero-emission future.