Fuel Cell System Modeling: Powering the Future of Hybrid Locomotives

Transitioning from Diesel to Hydrogen Locomotive Power: Modeling the Future of Rail Transport

Can a fuel cell-powered locomotive haul freight as reliably as diesel while significantly reducing emissions?

 

As the transportation sector accelerates toward net-zero goals, hydrogen fuel cells are emerging as a clean alternative to conventional diesel locomotives. In fact, the hydrogen fuel cell train market is projected to generate $653.6 billion in cumulative revenue by 2038, with unit sales growing at a compound annual growth rate (CAGR) exceeding 100%, clearly signaling global momentum.

Yet, designing an efficient and reliable hybrid fuel cell-battery system for rail applications is no easy task.

This is where GT-SUITE plays a critical role. It offers a unified simulation platform to model, analyze, and optimize the dynamic interaction between fuel cells, batteries, cooling systems, and traction power demands under realistic operating conditions.

Customer Spotlight: Wabtec Corporation

Wabtec Corporation, a respected leader in the global locomotive industry, presented their innovative fuel cell powertrain work at Gamma Technologies’ technical conference. This blog summarizes their study to help you better understand the modeling objective, fuel cell-battery control strategy, and key insights gained using GT-SUITE. To access the complete presentation, click here.

Optimizing the Power Split Between Fuel Cells and Batteries in Hybrid Locomotives

The primary objective of this simulation study was to optimize the power split between the PEM (Proton Exchange Membrane) fuel cell system and the traction battery to fulfil the power demand of the locomotive’s traction motor under realistic route conditions.

The traction battery acts as a secondary energy source, supporting peak load requirements and supplying power during low-demand phases.

A 1D simulation model of the hybrid locomotive powertrain was developed in GT-SUITE to simulate power distribution and energy flow across a representative rail route.

Simulation Framework for Hybrid Hydrogen Locomotives

The GT-SUITE model integrates multiple physical domains in a single simulation environment.

Key Inputs:

1. Throttle and dynamic braking data for selected routes
2. Ambient conditions (pressure and temperature) for each route
3. Battery specifications, including charge/discharge limits
4. Empirical model of fuel cell stack performance and control logic

Simulation Configuration:

• Route data: 5 rail routes selected based on typical duty cycles
• Power profiles: Time-dependent notch profiles for both throttling and dynamic braking
• Weather conditions: Summer and winter ambient profiles
• Fuel Cell Module Variants: 3 configurations delivering net power comparable to a diesel locomotive
• Battery Pack Options: 3 configurations plus one baseline case without a battery

 

Simulations for Route-Based Hydrogen Powertrain Performance

The following configurations were studied for a single route simulation:

• Fuel Cell Power Rating as a percentage of diesel engine equivalent: 80%, 100%, 120%
• Battery Power Rating as a percentage of diesel engine equivalent: 0%, 1.5%, 3%, and 6%

Simulation Outputs and KPIs

The model provided detailed insights into:

1. 1. Total hydrogen consumed
   2. Power supplied by the battery
   3. Power loss in the battery system
   4. Power generated by the fuel cell
   5. Power recovered through regenerative braking
   6. Power delivered to the traction motor
   7. Power loss at the traction motor

Key Insights from Fuel Cell Locomotive Modeling

• Increasing battery capacity helps shift the fuel cell’s operating region toward higher efficiency, improving route-specific hydrogen consumption.
• Power deficits decrease with larger battery configurations, as expected.
• A careful trade-off between fuel cell sizing and battery cost (initial and operational) can help determine optimal hybrid configurations.
• GT-SUITE enables estimation of fuel economy, power deficits, and component interactions, offering an efficient way to right-size the hybrid powertrain.
• The simulation framework is scalable to multiple routes and environmental conditions, making it highly adaptable for feasibility studies.

Why Use GT-SUITE for Hydrogen Train and Rail Electrification Projects?

GT-SUITE provides a holistic modeling platform for virtual prototyping and optimization of fuel cell-electric locomotives. Its capabilities include:

• Electrochemical modeling of hydrogen PEM fuel cells
• Battery system dynamics, including thermal and aging effects
• Mechanical and thermal subsystem modeling, such as cooling circuits and lubrication systems
• Full system-level simulation of train powertrains, including control strategies and energy management

This allows engineers to virtually test fuel cell vs battery performance and make informed design decisions before committing to physical prototypes.

Conclusion: Advancing Clean Rail Transportation with Simulation

Simulation accelerates innovation. With GT-SUITE, engineers can explore the full design space of hybrid hydrogen locomotives, optimizing component sizes, control logic, and energy flow management. This empowers rail operators to confidently pursue clean transportation technologies and reduce reliance on fossil fuels. Learn how simulation supports cleaner rail strategies in our blog “How to Model Fuel Reformers with Simulation“, and watch the “GT Webinar – Fuel Cell Fault Simulation and Detection for OBD Using Real-Time Digital Twins” to see how digital twins enable predictive maintenance and regulatory compliance or contact us to see how Gamma Technologies can support your fuel cell development goals.