Greenhouse Gas Emissions from Fuel Cell Heavy-Duty Vehicles in China: A Cradle-to-Gate Analysis

<div>Considered as one of the most promising technology pathways for the transport sector to realize the target of “carbon neutral,” fuel cell vehicles have been seriously discussed in terms of its potential for alleviating environmental burden. Focused on cradle-to-gate (CtG) stage, this article evaluates the environmental impacts of fuel cell heavy-duty vehicles of three size classes and three driving ranges to find the critical components and manufacturing processes in the energy context of China. The findings show that the greenhouse gas (GHG) emissions of the investigated fuel cell heavy-duty vehicle range from 47 ton CO<sub>2-eq</sub> to 162 ton CO<sub>2-eq</sub>, with the fuel cell system and hydrogen storage system collectively contributing to 37%–56% of the total. Notably, as the driving range increases, the proportion of GHG emissions stemming from fuel cell-related components also rises. Within the fuel cell system, the catalyst layer and bipolar plate are identified as the components with the most significant impacts, accounting for 62.9% and 32.7%, respectively, of the total GHG emissions from a fuel cell stack. The fundamental materials constituting these components namely, platinum, titanium, and carbon black are thus of considerable significance in the emission profile of the fuel cell stack. For the hydrogen storage system, carbon fiber-reinforced polymer (CFRP) layer stands out as the most important component, constituting 98% of the total GHG emissions. It is suggested that GHG emissions from fuel cell systems and hydrogen storage systems can be effectively curtailed by implementing strategies such as grid decarbonization, reducing Pt loading in catalysts, and enhancing fuel cell power density. Additionally, the potential for GHG emissions reduction in fuel cell heavy-duty vehicles can be reinforced through the adoption of lightweight materials and the integration of low-carbon alternatives into the glider components.</div>