Today, leading commercial vehicle manufacturers are actively working to expand their range of eco-friendly models. While battery-electric propulsion systems remain the optimal solution for zero emissions in light delivery vehicles, the situation is more complex for medium- and heavy-duty trucks. These multi-ton electric vehicles, especially long-haul trucks that cover hundreds of kilometers daily, require large batteries, making the solution expensive. Additionally, the charging infrastructure, particularly with stations capable of delivering the required power levels, including the so-called megawatt stations, is still in its early stages of development.
This is where hydrogen-powered engines come in as an excellent alternative. Specifically, internal combustion engines (ICE) running on hydrogen, as opposed to electric ones powered by hydrogen fuel cells, which are more expensive in comparison.
It’s worth noting that hydrogen ICEs offer several key advantages over fuel cells. They are less expensive, simpler in design, and more reliable due to their commonality with time-tested diesel and gas engines. That’s why hydrogen ICEs require much less time and resources to organize production.
First Serial Production in Europe
MAN Truck & Bus is set to become the first European manufacturer of hydrogen-powered trucks. The focus is on the new heavy-duty hTGX model, with 200 units slated for delivery to customers in Germany, the Netherlands, and Norway as early as 2025. These 6×2 and 6×4 tractors will be capable of traveling up to 600 km as part of road trains. To achieve this range, they will require 56 kg of hydrogen stored in tanks at a pressure of 700 bar. These vehicles are designed to handle heavy loads, functioning as timber trucks, in construction, and with tank semi-trailers. Notably, the hTGX model has minimal CO2 emissions—only 1 gram per tonne-kilometer—allowing these vehicles to be classified as zero-emission, i.e., environmentally friendly.
As for the engine of this new model, the H45 is based on the well-known and reliable MAN D38 turbodiesel, with a displacement of 15.2 liters. In its hydrogen version, the engine delivers 520 hp and a maximum torque of 2,500 Nm, within the range of 900 to 1,300 rpm.
It’s worth mentioning that MAN started working on hydrogen internal combustion engines back in 1992. Four years later, the company introduced its first experimental city bus model, the SL202. Over the next three years, this bus transported tens of thousands of passengers on various routes, covering a total of 42,000 km.
In 1997, MAN began developing a new hydrogen engine, which was completed in 2004. This engine was based on the H 2866 UH natural gas engine. An electromagnetic valve controlled the supply of an air-hydrogen mixture at a pressure of 10 bar. Interestingly, the ignition required significantly less energy. The power unit generated 272 hp, and the city bus had a declared range of 300 km.
Innovations from Overseas
In the US market, Cummins, a leading American manufacturer of truck power units, has made significant strides in developing hydrogen internal combustion engines. Recently introduced, the 15-liter Cummins X15H engine is built on the new X-series platform. This engine features a Double-Overhead-Camshaft, which enhances the combustion process and reduces friction, and utilizes direct fuel injection. About 80% of its components are shared with serial diesel engines. The hydrogen engine will be available in versions ranging from 405 to 537 hp, with a maximum torque of up to 2,600 Nm.
The Cummins X15H is currently undergoing intensive testing. Additionally, the first vehicles set to feature this power unit have been announced. A recent letter of intent between Cummins and Terex Advancer outlines plans to install these engines in the Commander family of concrete mixer trucks. It’s worth noting that Terex Advancer is a leading manufacturer of front-discharge mixers in the USA.
Another noteworthy development from Cummins is the B6.7H hydrogen engine, designed for lighter trucks with a gross weight of 10 to 26 tons. With a 6.7-liter displacement, it produces 290 hp and a maximum torque of 1,200 Nm. Unlike the X15H, its older brother, the B6.7H has already been installed in a vehicle. It was showcased at the IAA Transportation 2022 international exhibition in Hanover. The project was based on a production Mercedes-Benz Atego truck with a slightly redesigned front. The H2-ICE concept truck was developed by the Cummins team at the Gross-Gerau plant in Germany, in collaboration with automotive specialists at EDAG Group.
The H2-ICE truck features two tanks that store 40 kg of hydrogen each, under a pressure of 700 bar, along with an additional reserve tank of 10 kg. This setup provides a range of 500 km, which is sufficient for this truck class. Refueling with gaseous hydrogen takes just 10 minutes.
Notably, Cummins has partnered with NPROXX, the largest manufacturer of hydrogen storage and transport tanks, to supply these tanks. Made from composite materials reinforced with carbon fiber, the tanks offer an optimal balance of strength and weight.
From Excavators to Delivery Vans
Hydrogen-powered internal combustion engines are making their way into light delivery vans. Recently, a hydrogen engine was installed in a Mercedes-Benz Sprinter —and what’s most interesting is that it was done not by the three-point star automaker but by the British company JCB. This hydrogen-powered engine, originally developed for construction equipment, has now found a new home under the hood of a van.
The engine is based on a 4.8-liter diesel unit, producing 74 hp. It features a special cylinder head and unique pistons designed for efficient combustion of the hydrogen-air mixture. Hydrogen is stored in cylinders at a pressure of 350 bar, located at the rear of the vehicle. This isn’t the first vehicle to receive a JCB hydrogen unit; a similar engine was previously installed in a 7.5-ton Mercedes-Benz Atego truck.
JCB stands out as the first manufacturer in its sector to focus on hydrogen internal combustion engines for specialized equipment. The company invested around £100 million into this program, resulting in approximately 150 engines that have been actively tested in backhoe loaders and telescopic handlers since 2020. Additionally, in 2022, JCB introduced the first mobile hydrogen refueller of its kind.
In conclusion, trucks with hydrogen internal combustion engines offer a viable alternative to electric vehicles, including fuel cell-powered ones. To effectively promote this promising type of transport in the market, it is crucial to develop the necessary infrastructure, including an extensive network of refueling stations.