Analysis and Optimization of Operating Parameters for PEMFC Stack Performance and Vehicle Hydrogen Consumption in Heavy-Duty Trucks

This study investigates the performance and hydrogen consumption of a 120 kW PEM fuel cell stack in a SANY heavy-duty truck under high-load operating conditions. A stack model was developed based on first-generation Toyota Mirai single-cell data and verified for applicability to the target vehicle. The effects of operating parameters—including temperature, hydrogen and air partial pressures, and membrane water activity—on stack ECOP, power, efficiency, and vehicle hydrogen consumption under the C-WTVC driving cycle were analyzed. Multi-objective optimization using NSGA-II identified parameter combinations that improved overall stack performance. Results show that key operational parameters significantly influence both stack and vehicle-level performance. After optimization, the stack exhibited enhanced power and efficiency, and the truck’s equivalent hydrogen consumption decreased to 2.227 kg, which is lower than both the unoptimized and reference conditions.