Why use a fuel cell instead of a gas tank?

Use a hydrogen fuel cell instead of a gasoline tank when you need zero tailpipe emissions, higher drivetrain efficiency, quiet operation, and fast refueling with long range—provided hydrogen supply and service are available. In motorsport and off-road, the term “fuel cell” can also mean a safer, crash-resistant fuel bladder that replaces a conventional metal gas tank.

Two meanings of “fuel cell”

In everyday automotive news, “fuel cell” usually refers to a hydrogen fuel cell that generates electricity for an electric motor. In racing and some specialty vehicles, a “fuel cell” can also mean a safety fuel tank—a flexible, puncture-resistant bladder that contains gasoline or other fuel more safely than a standard tank. This article explains both, with most focus on hydrogen fuel cells versus gasoline tanks powering internal-combustion engines.

How a hydrogen fuel cell powertrain works

A hydrogen fuel cell vehicle (FCEV) stores hydrogen gas onboard, then converts it to electricity through an electrochemical reaction to drive electric motors. There’s no combustion and no tailpipe CO₂; the only exhaust is water vapor, plus heat.

1. Hydrogen is stored in high-pressure carbon-fiber tanks (typically up to 700 bar/10,000 psi).
2. In the fuel cell stack, hydrogen reacts with oxygen from the air across a membrane, producing electricity, water, and heat.
3. A power electronics system conditions electricity to drive the traction motor and charge a small buffer battery.
4. Regenerative braking captures energy back into the battery, improving efficiency.

This setup makes an FCEV an electric vehicle with rapid refueling, combining some benefits of EVs with the convenience of liquid-fuel pit stops—if hydrogen is accessible.

Key reasons to choose a hydrogen fuel cell over a gasoline tank

Several attributes make hydrogen fuel cells attractive compared with gasoline tanks feeding internal combustion engines (ICEs), especially in use cases where emissions and uptime matter.

• Zero tailpipe emissions: FCEVs emit water vapor at the tailpipe, eliminating local NOx, CO, PM, and CO₂. Lifecycle emissions depend on how hydrogen is produced.
• Higher drivetrain efficiency: Tank-to-wheel efficiency for FCEVs is commonly ~50–60% at the stack and roughly 40–50% at the vehicle level, versus ~20–30% for modern gasoline ICEs.
• Fast refueling with long range: Typical light-duty FCEVs refuel in about 3–5 minutes and can achieve 300–400 miles per fill, reducing downtime compared with many battery-electric vehicles (BEVs) in certain duty cycles.
• Quiet, smooth performance: Like other EVs, FCEVs deliver quiet operation and instant torque, enhancing drivability in cities and around sensitive sites.
• Cold-weather capability: Modern stacks can operate in subfreezing conditions with appropriate thermal management, without the fast-charge performance loss common in BEVs in very cold climates.
• Energy diversification: Hydrogen can be produced from multiple sources (natural gas with carbon capture, water electrolysis using renewable or nuclear power, biomass), aiding energy security and grid balancing.
• Heavy-duty potential: For long-haul trucking, buses, rail, and some maritime uses where payload, uptime, and quick refueling matter, hydrogen can outperform gasoline or diesel on emissions and match duty-cycle needs better than today’s batteries in some routes.
• Lower local pollution: Eliminating combustion at the vehicle reduces urban air pollution exposure compared with gasoline ICE fleets.

In short, fuel cells offer the cleanliness and driving feel of electric propulsion with refueling times familiar to liquid fuels—particularly compelling where charging time or battery mass is a constraint.

Trade-offs and limitations

Fuel cells are not a universal upgrade over gas tanks; they come with infrastructure, cost, and efficiency challenges—especially for light-duty consumer use in many regions today.

• Hydrogen source matters: Most hydrogen is still made from natural gas (steam methane reforming), which has significant lifecycle emissions unless paired with effective carbon capture. “Green” hydrogen via electrolysis is growing but remains limited and often expensive.
• Infrastructure scarcity: Outside a few regions (e.g., parts of California, Japan, South Korea, and select European corridors), public hydrogen refueling is sparse or unavailable. Retail networks in California have faced reliability issues and closures in 2023–2024.
• Cost per mile: Retail hydrogen has often been substantially more expensive per mile than gasoline or electricity for BEVs, though costs can drop with scale, long-term contracts, and policy support.
• Efficiency vs. BEVs: While more efficient than gasoline ICEs, FCEVs are less efficient than battery EVs well-to-wheel, especially when hydrogen is made from electricity (electrolysis, compression, distribution, conversion losses).
• Storage complexity: 700-bar tanks add cost, weight, and packaging constraints; hydrogen’s low volumetric energy density requires robust tanks and station equipment.
• Durability and maintenance: Modern light-duty stacks typically achieve around 5,000–8,000 hours before major service, with higher-hour targets for heavy-duty applications; maintenance ecosystems are still maturing.
• Station reliability and uptime: Dispenser failures, hydrogen supply interruptions, and maintenance have been recurring issues in early retail networks, affecting daily usability.
• Safety and standards: High-pressure systems demand rigorous design, testing, and training. Safety is strong under standards (e.g., SAE J2579, J2601; ISO norms), but public familiarity and service capacities vary.

These constraints mean that, for many private motorists today, a gasoline tank or a BEV battery remains simpler—unless they live near reliable hydrogen stations and prioritize zero tailpipe emissions with fast refueling.

When a fuel cell makes sense, and when a gas tank still does

Choosing between technologies depends on route length, downtime tolerance, local infrastructure, and emissions goals.

Fuel cells make sense for…

Hydrogen power tends to shine where quick refueling, long range, and high utilization are critical, and where hydrogen supply is secured through fleet depots or contracts.

• High-uptime fleets: Transit buses, regional delivery, drayage, and long-haul routes with depot hydrogen.
• Corridors with fueling: Specific regions in Japan, South Korea, Germany, and limited California corridors.
• Environments sensitive to emissions/noise: Ports, tunnels, warehouses (fuel-cell forklifts are already widespread), and near hospitals/campuses.
• Cold climates: Where fast charging is challenging and operational downtime is costly.
• Heavy-duty applications: Trucks, rail, and some maritime use cases where battery mass or charge time is impractical.

In these contexts, fuel cells can deliver EV-like driving with operational patterns closer to diesel fleets, while slashing local emissions.

A gasoline tank (or alternatives) still wins when…

Conventional fuel or batteries often outperform fuel cells where infrastructure is thin or where cost and efficiency dominate.

• Infrastructure is absent: Most regions lack public hydrogen; gasoline is ubiquitous and BEV charging is expanding fast.
• Lowest operating cost is key: BEVs generally have the lowest energy cost per mile and highest efficiency where charging is available; gasoline remains cost-effective in many areas lacking hydrogen or robust charging.
• Light-duty personal cars: For typical commuters, a BEV or efficient gasoline hybrid is usually cheaper and simpler than an FCEV today.
• Remote service concerns: Limited FCEV dealer/service networks can hinder uptime for individuals.
• Long-term ownership: Residual values and stack replacement costs are clearer for gasoline and BEVs than for early FCEVs.

If you don’t have reliable hydrogen access—or you prioritize cost above rapid refueling—gasoline or battery-electric options are likely better today.

What about motorsport and off-road “fuel cells” (safety bladders)?

In racing and some off-road builds, “fuel cell” refers to a safety fuel tank—a reinforced, flexible bladder inside a protective shell that holds gasoline or other liquid fuel. These are used instead of standard metal tanks to reduce fire risk and fuel spillage in crashes.

• Puncture resistance: Multi-layer elastomer/Kevlar construction resists rupture better than thin metal tanks.
• Anti-slosh and foam baffling: Reduces fuel movement, stabilizing the vehicle and limiting vapor space that can ignite.
• Rollover and check valves: Prevents fuel escape if lines are severed or the vehicle flips.
• Standards compliance: Meets FIA FT3/FT5 and SFI specs often required by sanctioning bodies.
• Serviceability: Cells can be inspected and replaced on defined service intervals for safety assurance.

Here, choosing a “fuel cell” over a standard gas tank is about safety and compliance—not about hydrogen or emissions.

Current landscape in 2025

Hydrogen mobility is evolving quickly, but availability remains uneven. Light-duty FCEVs are mostly confined to regions with public hydrogen and OEM support, while heavy-duty pilots are expanding on freight corridors with depot fueling.

• Light-duty vehicles: Toyota Mirai and Hyundai Nexo remain the primary FCEVs on U.S. roads, largely in California; Honda launched the CR‑V e:FCEV (a plug-in fuel-cell hybrid) in limited leases. Consumer stations in California have faced reliability and supply challenges since 2023, with some closures; outside California, retail hydrogen access in the U.S. is minimal.
• Heavy-duty pilots: Hyundai XCIENT Fuel Cell trucks, Toyota fuel-cell Class 8 programs (with PACCAR partners), Nikola’s FCEV deployments, and European efforts (Daimler GenH2, Volvo/Cellcentric) are scaling along select corridors.
• Policy and funding: The U.S. DOE’s regional Hydrogen Hubs (announced 2023) and European/Japanese programs are financing production and corridor infrastructure; impact on retail availability will take time.
• Hydrogen costs: Green hydrogen via electrolysis is growing as electrolyzer costs trend down, but delivered retail prices for mobility in many places remain high relative to gasoline and grid electricity.
• Station standards and reliability: SAE J2601 fueling protocols and improved compressors/chillers are maturing, but uptime and supply chain resilience are still focal points for 2025 deployments.

The net: heavy-duty and fleet-depot use is advancing, while consumer FCEVs remain niche, closely tied to local station reliability and pricing.

Bottom line

Choose a hydrogen fuel cell over a gasoline tank when you need zero tailpipe emissions, fast refueling, and electric-drive performance—especially in fleet or heavy-duty operations with secured hydrogen supply. For most private drivers without reliable hydrogen access, a gasoline tank (or a battery-electric vehicle) is still simpler and cheaper today. In motorsports, a “fuel cell” means a safer fuel bladder that replaces a standard gas tank to reduce fire risk. As hydrogen production decarbonizes and fueling networks mature, fuel cells will make more sense for specific high-uptime and long-range segments, while BEVs and efficient gasoline hybrids continue to dominate most personal transport.

What are the advantages of using fuel cells?

Fuel cells offer advantages including high energy efficiency, low or zero emissions (with hydrogen fuel cells releasing only water), quiet operation, high reliability and scalability, and the ability to provide continuous power without recharging. They also have potential for lower operational costs, can be very durable, and contribute to energy security by reducing dependence on fossil fuels. 
Environmental Advantages 

• Reduced Emissions: Hydrogen fuel cells produce only water and heat, and no carbon dioxide or other harmful pollutants, which helps address climate change and improve air quality.
• Cleaner Operation: They are more environmentally friendly than internal combustion engines and do not generate smog or other air pollutants that cause health problems.

Efficiency and Performance

• High Efficiency: Opens in new tabFuel cells directly convert chemical energy to electrical energy, avoiding the mechanical losses of combustion engines, resulting in higher energy efficiency. 
• Continuous Power: Opens in new tabUnlike batteries, fuel cells are not limited by their initial charge and can provide power continuously as long as fuel is supplied. 

Operational Advantages

• Quiet Operation: Fuel cell systems have few or no moving parts, making them significantly quieter than conventional generators and engines. 
• Reliability and Durability: They are reliable, have a long lifespan, and require less maintenance, positioning them as a dependable, long-term energy solution. 
• Scalability: Fuel cell systems can be scaled to meet a wide range of power needs, from small electronic devices to large power plants. 

Fuel and Energy Security

• Fuel Versatility: Opens in new tabFuel cells can use various fuels, including hydrogen, which offers high energy density by weight. 
• Energy Security: Opens in new tabBy enabling the use of renewable hydrogen, fuel cells can reduce reliance on traditional fossil fuels and enhance energy security. 

What is the disadvantage of a fuel cell?

Disadvantages of Fuel Cells
This power may well be greater than that acquired from hydrogen alone while being extra expensive. Moreover, this removal usually necessitates fossil energy usage, undermining hydrogen’s environmental efficiency in the apparent lack of Carbon capture and storage.

Are fuel cells street legal?

No, aftermarket or custom-installed fuel cells are generally not street legal because they are not approved or certified by the Department of Transportation (DOT) or state regulatory bodies like the California Air Resources Board (CARB), and are considered unsafe for public roads. These fuel cells, often used in racing, are not designed or approved for the safety and environmental standards required for vehicles on public highways.
 
Why fuel cells are not street legal:

• Lack of DOT Approval: The primary reason is that these fuel cells have not been approved by the Department of Transportation for on-highway use. 
• Environmental Regulations: In states like California, alternative fuel systems must be evaluated and certified by the California Air Resources Board (CARB) to be legal for road use. 
• Safety Concerns: Fuel cells are not designed to meet the safety standards required for public roads, and a vehicle with one installed would likely not pass a visual inspection. 

What is a fuel cell? 

• It is important to note that the term “fuel cell” in the context of vehicle modification refers to a specialized racing fuel cell that holds fuel, similar to a fuel tank, but designed to be more resistant to impact than a standard fuel tank. It is not a system that generates power like a hydrogen fuel cell power plant.

Is a fuel cell better than a fuel tank?

A Fuel Cell is specially designed and built for racing use. Fuel cells are more impact resistant than a fuel tank. They can be made of steel, aluminum, or high-strength plastic. They are also “Universal” fit, meaning you will need to fabricate a mounting location.