Design and risk assessment of integrated H2 fuel cell systems for rail transportation

Hydrogen-powered train technology is a promising solution for decarbonising non-electrified railway lines that currently rely on diesel. This study focuses on the development and evaluation of integrated on-board energy systems for hydrogen production and utilization in railway applications. The system combines an on-board reactor with a high-temperature proton exchange membrane fuel cell (HT-PEMFC) to efficiently generate electricity from alternative fuels such as methanol, ethanol, glycerol and ammonia. Process simulations in AspenPlus® assess the energy balance, heat integration and self-sustainability under real operating conditions on the Brescia-Edolo railway line. In addition, a quantitative risk analysis (QRA) using empirical models and PHAST evaluates the hazards associated with the storage and handling of these fuels. Results showed that ethanol has the lowest risk (10 −6 yr −1 ) while ammonia the lowest volume (21 m 3 ). The final ranking of the different solutions strongly depends on the production source (fossil or renewable). • Feasibility and risk evaluation of hydrogen-based on-board rail energy systems. • Alcohol reforming and ammonia cracking evaluated for hydrogen fuel cell trains. • Energy and storage systems sized for 10 h autonomy on the Brescia–Edolo line. • Ethanol shows the lowest risk index (10 −6 yr −1 ) while ammonia provides the most compact storage (21 m 3 ).