The global push towards decarbonisation has spurred significant advancements in clean transportation, particularly for heavy goods vehicles (HGVs). Among the emerging solutions, hydrogen power stands out due to its potential for zero emissions and high energy density, making it an attractive alternative to diesel.
In recent years, development in hydrogen-powered HGVs has gained momentum, with both hydrogen internal combustion engine (ICE) and fuel cell technologies presenting distinct pathways for the future of heavy-duty transport.
HGVs, given their operational demands—long distances, heavy loads, and extensive duty cycles—face unique challenges in transitioning to greener energy sources. Battery-electric vehicles (EVs) can struggle to meet these demands due to range limitations and lengthy charging times, especially when compared to conventional diesel trucks. Hydrogen, on the other hand, offers fast refuelling times and extended driving ranges, making it well-suited to the logistics sector.
Project ICEBreaker’s hydrogen fuel cell prototype. Image: Intelligent Energy
Major automotive and energy companies, including Hyundai, Daimler, and Toyota, have recognised hydrogen’s potential and invested heavily in developing hydrogen-powered HGVs. This surge in innovation is largely driven by the global push for carbon-neutral economies, with governments and industry stakeholders aligning to support the hydrogen economy.
Most of the advancements in hydrogen-powered HGVs have centred around fuel cell technology. In a hydrogen fuel cell vehicle (FCV), hydrogen stored in tanks is combined with oxygen from the air in a fuel cell stack, generating electricity to power the vehicle’s electric motor. The only by-product of this process is water, making FCVs a zero-emission alternative to diesel.
One of the main benefits of fuel cell technology is its suitability for long-haul transport. FCVs offer similar refuelling times to diesel trucks and can achieve ranges that outpace battery-electric HGVs, making them ideal for long-distance freight operations. Additionally, hydrogen fuel cells are generally lighter than the large battery packs required for electric trucks, allowing FCVs to carry heavier payloads.
As Andy Marsh, CEO of Plug Power, a major player in hydrogen fuel cell technology, has noted, “Hydrogen fuel cells are a game-changer for long-haul trucking. They provide the range and efficiency needed without the extended downtime required for battery charging.”
While fuel cell technology leads in terms of zero emissions, hydrogen internal combustion engines (ICEs) offer another promising solution for heavy transport. Hydrogen ICE vehicles function similarly to traditional petrol or diesel engines but run on hydrogen instead of fossil fuels. This approach allows manufacturers to adapt existing ICE technology, which could lower costs and accelerate the transition to cleaner energy.
Hydrogen ICEs, however, are not entirely emission-free. Although they do not produce carbon dioxide, they can emit small amounts of nitrogen oxides (NOx), a by-product of high-temperature combustion. Despite this, NOx emissions from hydrogen ICEs are significantly lower than those from diesel engines, and after-treatment systems can further reduce these emissions.
One key advantage of hydrogen ICEs is their compatibility with existing infrastructure, which could ease the industry’s transition to hydrogen. Leading companies such as Cummins and MAN are actively developing hydrogen ICE prototypes. According to Cummins‘ Vice President Thad Ewald, “Hydrogen ICE provides a cost-effective and faster-to-market solution, especially as fuel cell infrastructure is still maturing.”
Hyundai’s XCIENT fuel cell truck. Image: Hyundai
The development of hydrogen-powered HGVs has seen a flurry of activity in recent years. Hyundai’s XCIENT Fuel Cell truck is already operational in Switzerland, with plans to expand into other European markets. This vehicle offers a range of around 400 km and can be refuelled in under 20 minutes, showcasing hydrogen’s practicality in heavy-duty transport.
In the UK, Project ICEBreaker has made headlines as a pioneering initiative to develop hydrogen-powered HGVs. This government-backed consortium that includes Viritech, HORIBA MIRA and Intelligent Energy, recently unveiled a fully configured hydrogen fuel cell HGV, which represents a significant milestone in the UK’s efforts to decarbonise road freight.
The project aims to demonstrate the commercial viability of hydrogen-powered HGVs and support the development of a national hydrogen refuelling infrastructure. The consortium, which includes major industry players and academic institutions, is working to ensure that hydrogen-powered trucks become a practical reality for UK logistics in the near future.
Timothy Lyons, Viritech’s CEO said: “In less than 12 months, our combined experience has enabled us to jointly develop an engineering process to design, plan and integrate the operation of a hydrogen drivetrain for commercial vehicles.
“We’re confident that this project will deliver important insights that will be of great use to the industry as it embraces hydrogen to tackle forthcoming emissions regulations.”
Daimler Trucks, a global leader in commercial vehicle manufacturing, has also made strides with its GenH2 truck, designed for long-distance operations. Powered by hydrogen fuel cells, the GenH2 is expected to offer a range of 1,000 km on a single refuelling, making it one of the most advanced hydrogen-powered HGVs currently in development.
The debate between fuel cell and hydrogen ICE technologies focuses on efficiency, emissions, and infrastructure requirements:
- Efficiency: Hydrogen fuel cells tend to be more efficient than internal combustion engines, as they convert hydrogen directly into electricity without the energy losses associated with combustion.
- Emissions: Fuel cells are zero-emission, producing only water vapour as a by-product. Hydrogen ICEs, while significantly cleaner than diesel engines, still generate small amounts of NOx, which means they do not meet the same environmental standards as fuel cells.
- Infrastructure: Hydrogen ICE vehicles have the advantage of using much of the existing refuelling infrastructure, while fuel cells require specialised hydrogen refuelling stations. However, with significant investment underway, the hydrogen refuelling network is expected to expand in the coming years.
The future of hydrogen-powered HGVs looks increasingly promising. While hydrogen fuel cells are seen as the ultimate solution for zero-emission transport, hydrogen ICE technology provides a practical, cost-effective stepping stone. The rapid development of both technologies, coupled with the construction of hydrogen refuelling infrastructure, is critical to the widespread adoption of hydrogen-powered trucks.
The ongoing work of projects like ICEBreaker and advancements by major manufacturers signal a bright future for hydrogen-powered HGVs. With governments and industry stakeholders committed to achieving net-zero emissions, hydrogen has the potential to revolutionise heavy transport, paving the way for a cleaner, more sustainable logistics industry.
Author: Mark Salisbury, Editor, Fleetpoint
