Fuel Cell Technology for Emission-Free Rail Mobility

The rail industry faces the pressing task of significantly reducing emissions and actively transitioning to alternative propulsion technologies. Especially on non-electrified routes, in urban shunting operations, or in applications with high energy demands, hydrogen is emerging as an increasingly important energy carrier. Proton Exchange Membrane (PEM) fuel cell systems offer an emission-free, quiet, and scalable solution in this context.

PEM fuel cells convert hydrogen into electrical energy through an electrochemical process, without CO₂ emissions, particulate matter, or nitrogen oxides. They are suitable for powering mainline and shunting locomotives, track maintenance equipment, and onboard power systems. Thanks to their modular design, these systems can be flexibly integrated into both new and existing vehicle concepts—either as the sole energy source or as part of a hybrid propulsion architecture.

PEM Fuel Cells in Rail Applications

PEM fuel cell technology is characterized by high power density and dynamic load response, making it ideal for the variable performance demands of rail operations. Key features include:

• Operating temperature of 60–80 °C for rapid system startup and high responsiveness
• High power density
• Dynamic load adaptation – suitable for start-stop operation and variable load profiles
• Scalability – from single units to modular multi-stack systems in the megawatt range

Operation requires ultra-pure hydrogen (99.999%). The only by-products are water and small amounts of heat—clear advantages for use in emission-sensitive or noise-restricted environments.

System Integration in Rail Applications: Components and Requirements

A fuel cell system for rail is far more than just the stack. It is a complex integration of multiple technical subsystems that must be individually tailored to the specific vehicle type and application:

• Hydrogen storage: High-pressure tanks, pressure regulation, and valve technology compliant with rail standards
• Air supply: Compressors, filters, and control units to ensure reliable oxygen supply
• Cooling and thermal management: Precise thermal control for efficient and long-lasting operation
• Power electronics: Converters for integration into vehicle power grids or onboard systems
• Safety and diagnostics systems: Monitoring for hydrogen leakage, pressure, and temperature – including redundancies and compliance with railway safety standards

Integration poses high demands on space, weight, certification, and system compatibility – especially in retrofitting existing vehicles. Zeppelin Power Systems collaborates with partners from industry and research to develop practical, rail-ready solutions.

Research, Development, and Pilot Projects in Rail

Zeppelin Power Systems is actively engaged in the advancement and real-world testing of fuel cell technology for the railway sector. Key areas of focus include:

• Reliability and lifespan: Testing under real-world operating conditions and optimization of maintenance intervals
• System efficiency: Analysis and optimization of system interaction with other energy and propulsion technologies, including energy management strategies
• Cost and scalability: Development of modular platforms for economically viable implementation in small and large fleet applications
• Safety and standards compliance: Ongoing development of digital monitoring, diagnostic, and protection systems in line with railway-specific regulations