Heavy-Duty Fuel Cell Electric Vehicles Update

by Mark Luth

Hydrogen-Powered Heavy-Duty Trucks Carrying Forward

The global economy is carried by the supply chain, logistics, and heavy-duty vehicles. Finding ways to decarbonize this critical sector is key to reducing global emissions and is an excellent application for hydrogen fuel cells. Since our last blog post on these hydrogen-powered commercial vehicles, fuel cell electric trucks have continued to make significant progress as several companies have announced new developments in this key market sector.

Heavy-Duty Deployment Partnerships

Recently, FCHEA member Air Products announced a partnership with fellow FCHEA member Cummins to begin transitioning its global delivery fleet to fuel cell electric vehicles. In this project, announced in July 2021, the partners will be able to directly promote the technology in operation, with more than 2,000 trucks eventually intended to be converted within the Air Products’ fleet.

A Cummins Heavy-Duty Fuel Cell Prototype Truck (Source: Cummins)

FCHEA members Nikola and Bosch announced a partnership in September 2021 that expands on their previous work in the heavy duty sector. The companies will manufacture and integrate heavy-duty fuel cells of Bosch’s design into Nikola’s truck models at Nikola facilities in Arizona and Germany. The initial production of the modules will begin in 2023 with the Tre heavy-duty electric vehicle.

The Nikola Tre Fuel-Cell Electric Truck. (Source: Nikola Corporation)

Symbio, a joint venture between FCHEA members Faurecia and Michelin, announced plans to bring its light-duty fuel cell system to medium and heavy-duty spaces in the near future. The company will use its experience to partner with manufacturers looking to integrate fuel cells into existing truck architectures.

FCHEA members Hexagon Purus and Ballard Power Systems are collaborating on Class 6 and 7 fuel cell electric trucks that are planned for deployment in the second quarter of 2022. The companies plan to debut the vehicles in Los Angeles, California, to provide zero-emission logistics solutions that comply with the stringent local air quality regulations.

Bringing Heavy-Duty Hydrogen to Switzerland

FCHEA member Hyundai debuted its mass-produced heavy-duty fuel cell electric truck, the XCIENT, in October 2020 within a partnership in Switzerland. As part of this effort, 46 commercial vehicles were put in service by July 2021, less than a year after beginning deployment. The fleet passed one million kilometers driven in those 11 months in service to more than 25 Swiss companies, with 140 vehicles planned for active operation by the end of this year. The success of the XCIENT in Switzerland has further established the commercial viability of fuel cell heavy-duty vehicles. In addition, Hyundai received funding for 2022 deployment tests in New Zealand in March 2021, and in July 2021 announced a partnership to bring 30 trucks to the United States for fleet operations in California beginning in 2023.

Hyundai XCIENT in Switzerland (Source: Hyundai)

Toyota and Port of Los Angeles and Long Beach

As detailed previously in our blog, in the United States, FCHEA member Toyota has been working on a heavy-duty fuel cell electric truck pilot project at the Ports of Los Angeles and Long Beach in California. Working alongside truck manufacturer Kenmore, the companies deployed five heavy-duty vehicles in June 2021, with five more planned to deploy soon, where the vehicles provide zero-emissions solutions for drayage runs and local cargo hauling.

The Toyota-Kenmore Fuel Cell Trucks at the fueling station in the Port of Los Angeles (Source: Port of Los Angeles and Long Beach)

South African Mining Trucks Converting to Hydrogen

In October 2021, global mining company and FCHEA member Anglo American announced a new partnership with Seattle-based creative engineering firm First Mode to develop a 290-ton demonstration hydrogen mine haul truck in South Africa at Anglo American’s Mogalakwena mine. The mine haul truck will be the world’s first of its size to run fully on hydrogen, which will be produced on-site through wind and solar power. The companies aim to continue the development of green hydrogen production systems at several open cut sites to convert all diesel-powered ultra-class mine haul trucks at those sites to green hydrogen power.

The 290-ton Komatsu mine haul truck being converted to hydrogen at Anglo American’s Mogalakwena mine in South Africa. (Source: Anglo American)

Global Production Grows

Production of heavy-duty fuel cell vehicles is ramping up around the world. FCHEA member Nuvera has received certification for its heavy-duty fuel cell module in China, paving the way for eventual mass deployments both in China and globally. The company now produces fuel cell modules designed for vehicle integration across a range of power requirements. Hyzon Motors opened its new Dutch production facility in March 2021, and joined a pledge with a number of manufacturers and truck operators, including FCHEA members Toyota, Hyundai, Honda, Ballard, Michelin, and BMW Group, to deploy 100,000 heavy-duty fuel cell vehicles in Europe by 2030. Daimler Truck, recently separated from Mercedes-Benz to pursue separate technical approaches to decarbonization, received a license from the German government to proceed with public road testing of its GenH2 truck.

Heavy-duty fuel cell electric trucks are already proving hydrogen’s strengths in global logistics operations. Decarbonizing this critical industry, while keeping familiar parameters of range and refueling time, is a key role for fuel cells to play now and moving forward.