Development and multi-scenario analysis of a hybrid fuel cell vehicle tool, considering energy, economic and environmental perspectives

This paper presents the development and application of a numerical simulation tool designed to evaluate the performance of hybrid fuel cell–battery powertrains across various transportation sectors. Implemented in MATLAB using Simulink and AppDesigner, the model allows for flexible configuration and detailed performance analysis under customizable driving conditions. The tool integrates modules for power demand estimation, energy source sizing and dynamic performance simulation, including a control strategy based on a state-machine approach to manage the fuel cell output and battery state of charge. Three case studies are analyzed, forklift, heavy-duty truck, and ship, each tested in different scenarios, such as single-source and hybrid configurations, using different sizing strategies and energy ratios. The main results concern: a 40% reduction in installed battery capacity for the forklift versus a full-battery design, a reduction in the truck’s hydrogen consumption from 4.11 kg (loaded) to 1.81 kg (unloaded) under the same powertrain sizing, and a system cost reduction of over €700,000 for the hybrid ship compared to a full fuel cell configuration, while maintaining similar CO2 savings per mission (approximately 1380 kg). The findings highlight the advantages of hybridization in improving system flexibility, reducing fuel consumption, and maintaining stable fuel cell operation, especially under variable load conditions. This simulation framework offers a valuable tool for supporting zero-emission vehicle designs and guiding the transition toward sustainable mobility solutions.