How the air handling system is evolving from ICE to PEM fuel cells for efficiency and sustainability

Sunrise behind a highway

Sustainability in the transportation industry is a critical goal for Cummins Inc. We have been committed to leading the industry through the energy transition with Destination Zero – our strategy for reaching zero emissions. With a focus on reducing environmental impact through innovative technologies and practices, Cummins is leveraging its technological expertise, to lead the industry towards a greener, more sustainable path.

One critical avenue, to reducing emissions in the mobility and transportation industry involves transitioning from traditional internal combustion engines (ICE) to cutting-edge fuel cells (FCEVs). The software, electronics, turbochargers, and fuel systems components in these vehicles have improved to meet different technological requirements. The air handling system is another component whose role in this transition is worth exploring.

This article examines the evolution of ICE and FCEVs technology in the industry and explores the role of air handling architecture that is necessary in both these technologies to move the industry forward.

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How have internal combustion engines (ICE) evolved?

Internal combustion engines have been the backbone of automotive and industrial power for over a century. Burning fuel with air inside an engine creates power. The process involves drawing air and fuel into a combustion chamber, compressing and igniting the mixture to generate an explosion driving a piston. This movement is then translated into rotational force, powering everything from vehicles to generators with remarkable efficiency. The system depends on the interplay of air and fossil fuels like gasoline or diesel and now alternative fuels like biofuels, ammonia and hydrogen.

While ICE technology has advanced, including improvements in fuel efficiency, reductions in emissions and the adaptation to renewable fuels, the quest for cleaner energy sources requires exploring technologies like the proton-exchange membrane fuel cell (PEM FC).

How does the Proton Exchange Membrane Fuel Cell (PEM FC) work?

Like other fuel cells, a PEM FC generates power through electrochemical reactions. It begins when hydrogen gas is fed into the fuel cell on the anode side while oxygen is fed into the cathode. At the anode, hydrogen molecules are separated into protons and electrons. The positive and negative particles then travel two different paths.

The electrons travel to an external electric circuit before continuing to the cathode. The external circuit is where a flow of electricity is created. The positive particles pass through the membrane to the cathode. Once there, the protons reunite with the electrons and react with oxygen to produce the only clean biproducts, which are water and heat.

For commercial vehicles, PEM FCs offer the potential for long-range, heavy duty-cycle operations with fast refueling times, while maintaining the efficiency and reliability the transportation industry expects. Cummins and Accelera™ by Cummins – the zero-emissions business segment of Cummins is at the forefront of supplying and integrating zero-emissions technologies to decarbonize the world’s hardest working industries.

Cummins is actively working with Accelera™ on innovative technologies for transportation and heavy-duty operations. One of the principal areas of focus is adapting air handling technologies to support PEM FC power systems.

What is an air handling system and what does it do in commercial vehicles?

Air handling involves managing and controlling airflow within both ICE engines and fuel cell engines. It encompasses the intake of air, its compression and the exhaust of gases. In ICE, air handling is critical for ensuring that clean air is available for fuel combustion, optimizing performance and controlling emissions.

In fuel cell engines, air handling takes on a new dimension. The air handling system architecture and technology has evolved from low-pressure systems to high-pressure e-compressors and is now advancing towards e-turbos. These developments are driven by the need for efficient air supply to the fuel cell, ensuring increased power density and optimized system efficiency. In PEM FC, the air (Oxygen) pulls the proton through the PEM membrane which allows the electron to do work. So, the more air you move, the more electrons you get (electrons are the current), which results in more power.

From ICE TO PEM FC: The evolution of air handling

PEM FC technology has some unique characteristics in air handling compared to ICEs.

For example, air handling machines require high-speed electric motors since they cannot rely solely on waste energy from the exhaust. This shift has led to the development of high-pressure e-compressors and the transition to e-turbos, which aim to enhance system efficiency and performance.

Another significant difference is the need for an oil-free air supply in PEM FCs because hydrocarbons degrade fuel cell membranes. This contrasts with ICEs, where small amounts of oil contamination in the compressor are tolerable.

PEM FCs can use e-turbos to harness waste energy to reduce motor size and parasitic load, thereby improving fuel economy. The e-turbo's ability to push more air into the system directly increases the power density of the PEM FC - more air helps pull more protons through PEM which increase number of electrons available for current. This technology also enhances altitude capability, enabling air supply when the compressor power demand and energy recovery potential is at its highest.

Despite these differences, the fundamental applications of air handling architecture in a PEM FC remain unchanged. Cummins’ Components Business is leveraging its decades of manufacturing and supply chain experience in supporting the trucking and rail industry to design and support the transition to more sustainable transportation using PEM FCs.

How does Cummins support the transition to sustainability?

As we move closer to the future of energy and sustainable operations, Cummins is dedicated to developing a range of products that meet diverse requirements. Our focus on integrating advanced air handling technologies, such as e-turbos, in PEM FC systems is a testament to our commitment to innovation and environmental stewardship.

The evolution from ICE to PEM FC, particularly in air handling, exemplifies Cummins' ongoing journey towards a more sustainable future. By harnessing the power of PEM FCs and advancing air handling technologies, we are paving the way for cleaner, more efficient commercial vehicles. Cummins is working with Accelera on PEM FC technology for multiple applications to lower emissions and meet the demand for sustainable transportation solutions. For more information about BEVs and FCEVs, visit accelerzero.com.

Cummins Components Business Unit

Components Business Unit

Cummins Custompaks are being used for water management as Thailand struggles with its water crisis

CustomPak on site

Water crisis

Sixty Cummins Inc. CustomPaks are in service in Thailand as part of a critical water management plan aimed at easing the country’s water crisis – a crisis that has caused enormous economic and social damage and stirred conflict among communities.

Over the past several decades, Thailand has continually faced water problems caused by severe drought. Water reserves in dams and reservoirs are insufficient while water resources are often contaminated with toxins caused by urban communities and the industrial and agricultural sectors.

Severe flooding is a threat, too, at a time when the realities of climate change are hanging over the country.

As a result, the allocation of precious water resources, which must be shared among various stakeholders including new and existing industry, large and small agriculture, and cities and villages has become a flashpoint.

Kittithanapat Engineering Co. (KTP), has been involved in the water management system since 1996, working closely with authorities such as the Royal Irrigation Department, Department of Water Resources, Bangkok Metropolitan Authority and others.

CustomPaks on site

600 hp CustomPaks

To help KTP meet its often urgent requirements, Cummins DKSH (Thailand) has recently supplied 60 Australian-built CustomPaks – 45 powered by Cummins’ X15 engine rated at 600 hp, and 15 powered by the QSL9 rated at 325 hp. These fully self-contained powerpacks are emissions certified to Tier 3.

The CustomPaks are coupled to hydraulically-driven, large-volume submersible water pumps sourced by KTP from US company Moving Water Industries (MWI); KTP is the exclusive distributor in Thailand for these MWI Hydroflo pumps.

Prior to Cummins’ involvement, KTP was using another diesel engine brand but service support wasn’t up to the standard required.

Long-serving KTP engineer Kittisak Thanasoot says Cummins DKSH’s reputation for technical and aftersales support along with the reliability of the Cummins product were a key reason behind KTP’s decision to specify the CustomPaks for the Royal Irrigation Department.

The ability of Cummins DKSH to respond to short delivery times was also important.

“Supplying large quantities of high horsepower diesel engines for emergency situations such as flash flooding can be a challenge for KTP,” says Kittisak Thanasoot.

“Responding to the needs of the government agencies to manage such problems in a timely manner and with least impact on communities, KTP has found the answer in our partnership with Cummins DKSH.”

Power, pride and passion

Parked semi truck

The switch back to Cummins power has been beneficial for iconic New Zealand company Uhlenberg Haulage. It's all about whole-of-life costs.

Uhlenberg Haulage is closing in on 60 years in business, having been founded in 1966 by Mike and Carol Uhlenberg.

Based in Eltham, Taranaki, in New Zealand’s North Island, the operation is today owned and operated by their sons Chris, Daryl and Tony Uhlenberg.

Describing the Uhlenbergs as “old school family truckies”, Daryl talks about the company’s time-honored journey with a definite tone of pride, especially the work of his parents in laying the foundations for what is today an iconic fleet in its own right.

Cummins Inc. made its debut in the Uhlenberg fleet in 1971 with an NH250 powering a second-hand Kenworth K923 used in logging. A second Kenworth, a new W924 with a Cummins NTC335, followed soon after hauling an LPG tanker.

The Uhlenberg operation today comprises 40 prime movers and a variety of trailing gear to cater for the myriad of a jobs the fleet is involved in.

A number of Peterbilts feature in the fleet although Kenworth is now the brand of choice with six new units to be delivered over the next 12 months to cater for business growth.

Cummins’ X15 Euro 5 engine rated at 550 or 600 hp is the preferred power specification, with 18 red engines currently in the fleet.

Uhlenberg family in front of truck

Whole-of-life support

“The switch to Cummins has been a very good experience for us. We have nothing but praise for the Cummins organization,” says Daryl.

“The whole-of-life picture is the key thing for us and we’ve got that nailed with the support we get from Cummins – parts availability, scheduled maintenance, life expectancy and in-frame rebuilds.

“So the red engines turn up, we run them to life, which is 900,000 to 1.2 million kilometers, and then Cummins does an in-frame overhaul in a timely manner. If there’s an issue, parts and support are close by.

“The support we get from Cummins Palmerston North is fantastic, second to none.”

Daryl recently looked under a Kenworth that was in the workshop for a service and was surprised to see no oil leaking from the one-million-kilometer X15. “I remember when I was a fitter we had to wear a raincoat when working under a truck,” he jokes.

Fuel agnostic

Acknowledging that the push to decarbonize is now “very real”, Daryl likes the idea of Cummins’ fuel agnostic concept where one base internal combustion engine, optimized to run on diesel, can also be customized to run on ultra-low and zero-carbon fuels like renewable natural gas and hydrogen.

“My father was a pioneer of linehaul trucking in New Zealand and he always embraced new technology. He was never scared of it,” he says.

“I tend to be a little more cautious but I can see where a 500 hp natural gas or hydrogen engine would work for us in short haul applications,” he admits. “We’re certainly willing to look closely at these alternative fuel technologies when suitable infrastructure is in place.”

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