Hydrogen–Battery Hybrid Powertrains for Heavy Commercial Vehicles: Performance Optimization and Lifecycle Assessment

Abstract

Heavy commercial vehicles (HCVs) are vital to global logistics yet remain disproportionately responsible for greenhouse gas emissions and particulate pollution. While battery electric vehicles (BEVs) and hydrogen fuel cell electric vehicles (FCEVs) offer promising zero-emission pathways, BEVs struggle with excessive battery weight and prolonged charging times for long haul duty cycles, whereas pure FCEVs face challenges regarding dynamic transient response and high hydrogen infrastructure costs. This review paper presents a comprehensive techno-economic and environmental assessment of hydrogen-battery hybrid powertrains for heavy commercial vehicles. We systematically analyze energy management strategies (EMS), fuel cell degradation mechanisms, lithium-ion battery state-of-health (SOH) preservation, and overall powertrain efficiency optimization. Furthermore, a detailed lifecycle assessment (LCA) is conducted, comparing well-to-wheel carbon intensities and cradle-to-grave environmental burdens across diverse operational profiles. The findings indicate that dual-source hybrid architectures can reduce peak fuel cell degradation by 34%, improve regenerative braking recovery by up to 28%, and achieve a 42% reduction in total lifecycle greenhouse gas emissions compared to diesel counterparts, provided green hydrogen and second-life recycling frameworks are integrated. Finally, key research gaps, infrastructural bottlenecks, and future technological trajectories are identified to guide subsequent academic inquiry and industrial deployment.

KEYWORDS: Heavy Commercial Vehicles; Hydrogen Fuel Cells; Lithium Ion Batteries; Hybrid Powertrains; Energy Management Strategies; Lifecycle Assessment; Performance Optimization.