Current status and prospects of fuel cell electric vehicle industrialization in China

Abstract Hydrogen energy, valued for its cleanliness and efficiency, is increasingly recognized as the cornerstone of a sustainable society, particularly for addressing global climate change and driving the energy transition. Among its applications, fuel cell technology emerges as a pivotal pathway for clean energy adoption. Fuel cell electric vehicles (FCEVs) offer notable advantages over conventional internal combustion engine vehicles (ICEVs), including higher efficiency, zero carbon emissions, and reduced reliance on finite fossil fuels. However, the industrialization of FCEVs in China faces significant challenges. These include high capital expenditure (CAPEX), where the upfront cost of FCEVs for heavy-duty applications is 2–3 times greater than that of battery electric vehicles (BEVs) or ICEVs. Additional barriers comprise the elevated retail price of hydrogen, typically 60–70 CNY/kg, and the limited availability of hydrogen refueling stations (HRSs), with only 358 stations established nationwide. Consequently, the total cost of ownership (TCO) for FCEVs remains approximately 1.5 times higher than that of ICEVs and BEVs in heavy-duty applications. This review systematically examines the TCO of FCEVs across their lifecycle and proposes strategies to overcome these challenges. Reducing CAPEX can be achieved by minimizing the usage of Pt, enhancing fuel cell stack power density, and developing large-scale production and domestic manufacturing of key materials and components, complemented by efficient Pt recovery and recycling processes. Additionally, operational lifetime of fuel cells is extended by advanced system control strategies for the maintenance and service costs reduction. The review also provides a detailed analysis of the hydrogen supply chain, comparing the costs associated with different production and transportation methods. Achieving cost competitiveness in hydrogen supply requires innovations such as anti-poisoning hydrogen oxidation reaction catalysts, advancing renewable hydrogen production technologies, and selecting storage and transportation solutions tailored to specific applications. Lastly, optimizing investments in hydrogen refueling stations is vital for advancing hydrogen infrastructure development. Recommended strategies include increasing storage pressures in long-tube trailer tanks, reducing compressor costs, and promoting domestic production and mass manufacturing of HRS components. By addressing these challenges, this review offers actionable insights to accelerate the industrialization of FCEVs in China. Graphical Abstract This study highlights key strategies for reducing the total cost of ownership (TCO) of fuel cell vehicles, thereby facilitating their large-scale industrialization in China.