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The use of reciprocating internal combustion engines (ICE) dominates the sector of the on-road transportation, both for passengers and freight. CO2 reduction is the present technological driver, considering the major worldwide greenhouse reduction targets committed by most governments in the western world. In the near future (2020) these targets will require a significant reduction with respect to today’s goals, reinforcing the importance of reducing fuel consumption. In ICEs more than one third of the fuel energy used is rejected into the environment as thermal waste through exhaust gases. Therefore, a greater fuel economy could be achieved if this energy is recovered and converted into useful mechanical or electrical power on board. For long haul vehicles, which run for hundreds of thousands of miles per year at relatively steady conditions, this recovery appears especially worthy of attention.

The use of reciprocating internal combustion engines (ICE) dominates the sector of the in-the-road transportation sector, both for light and heavy duties. CO2 reduction is the technological driver, considering the severe worldwide greenhouse commitments. In ICE more than one third of the fuel energy used is rejected to the environment as thermal waste through the exhaust gases. Therefore, a greater fuel economy could be achieved, recovering this energy and converting it into useful electric power on board. Financial benefits will be produced in terms of fuel cost which will rebound similar benefits in terms of CO2 emitted. For long hauling vehicles, which run for thousands of miles, frequently at fixed engine operating conditions, this recovery appears very worthy of attention. In this activity, an ORC-based power unit was designed, built and tested fed by a heavy duty diesel engine, so contributing to the huge efforts on going in that specific sector.

Alternative vehicle powertrains (hybrid, hydrogen, electric) are among the most interesting solutions for environmental problems afflicting urban areas. Electric and hybrid vehicles are now slowly taking place in the automotive sector, but on a Tank To Wheels (TTW) basis, the most effective alternative powertrain is surely represented by Fuel Cell Electric Vehicles (FCEV): those fuelled by hydrogen seem to be the ones closest to market. The design of a FCEV however, is not straightforward and involves several issues (fuel cell sizing, hydrogen storage, components efficiency, sizes and weights). Basing on these considerations, the Authors present a software procedure for the optimal design of the components of a passenger FCHEV (Fuel Cell Hybrid Electric Vehicle).