Analytical Approach to Predict Hydrogen Consumption of a Lightweight PEM Fuel Cell Vehicle Muhammad Rizuwan b. Mustaffa Faculty of Mechanical Engineering Universiti Teknologi MARA (UiTM) Shah Alam, Malaysia rizuwan.mustaffa@yahoo.com Wan Ahmad Najmi B. Wan Mohamed, Rahim B. Atan Faculty of Mechanical Engineering Universiti Teknologi MARA (UiTM) Shah Alam, Malaysia Abstract - This paper reports the methodology to predict the hydrogen consumption for fuel cell vehicle (FCV). Preliminary studies has been conducted to predict fuel consumption of fuel cell vehicle for Shell Eco Marathon competition. In the design process, the starting point is to evaluate the actual performance of the fuel cell stack before applied to the model of vehicle power demand. Both experimental and numerical method has been conducted. Predictions are based on two inputs which is vehicle speed and hill slope. The relationship between power demand and hydrogen consumption are presented and discussed. Finally, driving simulation was performed under aggressive and passive driving conditions and the mileage for every kWh of fuel energy was evaluated. Under average speed of 35 km/h speed and zero slope, the specific range was calculated at 958.2 km/kWh. Keywords; Shell Eco Marathon; Hydrogen consumption; PEM fuel cell; fuel cell vehicles. I. INTRODUCTION Research trend in automotive sector has changed to more reliable sources because of environmental issue and uncertainty of fuel price [1]. Both issues became more critical in recent years. Motor vehicle or ICE contributed at least 70-75 percent to air pollution in Malaysia and this percentage is expected to increase [2]. Thus, the hazardous and sound emissions created by the ICE have catalyzed much effort by research institutions to find better solution on aforementioned issue. Huge usage of ICE increases the oil price globally. Malaysia, which is one of oil producers, has recorded a petrol price increase (RON 97) from 2004 to 2011 about 76 percent and the highest increase is about 91 percent in 2008 [3]. With this example, plus the implementation of stringent environmental rules in certain region has forced rapid fuel cell development due to its capability to overcome this problems. Nowadays, fuel cell has become major topic in research development growth especially in automotive application. It converts the chemical energy into electric energy. By releasing water and heat as by product, the device is considered as zero emission devices with silent operation because of less involvement of mechanical part. Recommended as a high efficiency system, configuration with battery and ultra capacitor compensates for the existing shortcomings [4] [5]. Research in fuel cell development, performances and hybridization for vehicles application has been taken actively by many institution especially automotive makers [6] [7]. The categories of fuel cell vehicle developed is not limited, therefore many sector are involved including public transportation [8, 9] military [10], and also recreation [11, 12]. Shell Eco Marathon are among the event that promotes the fuel cell technology. This competition challenges the student to design and develop the vehicle a vehicle that is able to produce long driving range with less fuel consumption. Energy source were divided based on the type; petrol, gasoline, diesel, fatty acid methyl ester (FAME), ethanol E100, hydrogen, solar, and battery. In this competition, a vehicle must complete 11.2 km driving within 23 minutes to obtain a valid result [13]. Hydrogen consumption becomes the most important parameter in order to become a fuel efficient vehicle. The physical development measurement systems of hydrogen consumption are presented in [14] and [15]. However, the physical development costs a lot of money and requires huge space. Constraint by that issue, the authors proposed a numerical method to predict hydrogen consumption based on actual fuel cell stack data. By this method, a series of case study can be conducted quickly. Thus, the designer can plan the driving method during the competition. In this paper, laboratory test has been conducted to study and analyze fuel consumption for fuel cell vehicle. Section 2 briefly describes the step of process involved in this work. In section 3 detail numerical study for fuel cell and hydrogen consumption prediction is outlined where the equations involved and calculation method are explained. Section 4 presents laboratory test performances of fuel cell stack and graphical analysis of fuel consumption prediction. Result are 2012 IEEE International Conference on Control System, Computing and Engineering, 23 - 25 Nov. 2012, Penang, Malaysia 978-1-4673-3141-8©2012 IEEE