Hydrogen Trucks Are Here—But What Will It Take To Fuel Them? – Hydrogen Fuel News

Southwest Research Institute’s H2HD REFUEL Project Aims to Solve Hydrogen Refueling Delays

The Southwest Research Institute (SwRI) has launched an ambitious project aimed at tackling the challenges in hydrogen refueling technologies for heavy-duty vehicles. Known as the Hydrogen Heavy Duty Refueling Equipment and Facilities Utilization Evaluation Laboratory (H2HD REFUEL), this joint industry project (JIP) is designed to strengthen hydrogen infrastructure while empowering the transition to zero-emission heavy-duty vehicles.

Bridging the Technology Gap in Hydrogen Refueling Stations

Hydrogen refueling stations (HRS) face significant hurdles, particularly for the heavy-duty trucking sector. Currently, the U.S. has fewer than 60 hydrogen refueling stations, with only a few configured to accommodate the unique needs of heavy-duty vehicles. This scarcity, combined with the high cost of building and maintaining such facilities and persistent technical issues, has slowed the move to hydrogen-powered freight transport.

SwRI seeks to address these challenges through an integrated approach that combines hands-on experiments, system modeling, and theoretical research. The four-year H2HD REFUEL project will focus on resolving technical bottlenecks, connecting key industry stakeholders, and evaluating alternative solutions to ensure safe, reliable, and cost-effective hydrogen refueling for heavy-duty vehicles. By advancing HRS technologies, the project aims to bridge the gap between existing infrastructure capabilities and the growing demand for hydrogen-powered freight systems.

Key areas of research include:

• Evaluating onboard hydrogen storage methods, including liquid hydrogen, H70 high-pressure gas, and cryo-compressed storage.
• Testing and comparing the performance of refueling station flow components under various conditions.
• Investigating hydrogen losses in cryogenic systems caused by boil-off and inefficiencies.

Advancements in Hydrogen Engine Technologies for Trucks

Hydrogen adoption in trucking largely revolves around two core technologies—internal combustion hydrogen engines (H2-ICE) and hydrogen fuel cell engines. Both offer distinct advantages and potential applications within the heavy-duty vehicle sector.

Internal Combustion Hydrogen Engines (H2-ICE)

• Operates using hydrogen as a fuel source within a modified traditional combustion engine.
• Produces minimal tailpipe emissions, with water vapor as the primary byproduct.
• Retains many components of standard internal combustion engines, making it easier to adapt for fleet operations.
• Offers the potential for faster market entry due to lower overhaul costs and established manufacturing systems.
• Compatible with existing vehicle designs, reducing the need for completely new infrastructure.

Fuel Cell Engines

• Utilizes hydrogen and oxygen to generate electricity through an electrochemical process.
• Powers electric motors, achieving higher energy efficiency compared to combustion engines.
• Emits only water vapor, aligning with zero-emissions goals.
• Provides a quieter, smoother driving experience and requires less maintenance than traditional engines.
• Ideal for long-haul applications due to an excellent range-to-weight ratio.

Why Are These Advancements Crucial?

Hydrogen-based trucking has the potential to reshape the heavy-duty transportation sector in several key ways:

1. Decarbonization of Freight
   Heavy-duty vehicles account for a significant proportion of greenhouse gas emissions in the transportation sector. Hydrogen technology—whether through H2-ICE or fuel cells—offers a pathway to drastically reduce emissions.

2. Energy Security
   Hydrogen, as a versatile energy carrier, can be produced from various renewable sources, reducing reliance on fossil fuels and enhancing energy independence.

3. Economic Growth in Clean Energy
   Expanding hydrogen infrastructure and technologies can drive employment in clean energy sectors while fostering innovation.

4. Global Competitiveness
   Nations investing in hydrogen technology are positioning themselves as leaders in the evolving clean transportation industry. The U.S., through initiatives like SwRI’s H2HD REFUEL, can build a sustainable hydrogen economy and maintain its competitive edge.

Transforming Hydrogen Fuel Trucking Infrastructure

A well-developed hydrogen trucking infrastructure could transform freight transport by enabling wide adoption of zero-emission vehicles. Here’s how this technology could drive change:

• Streamlined Refueling
  The work by SwRI and stakeholders aims to improve the reliability and efficiency of hydrogen refueling stations. Compatible systems designed to meet the high-flow demands of heavy-duty vehicles will make refueling quicker and more practical.

• Fleet Integration
  Developments in H2-ICE and fuel cell engines will allow fleet operators to transition to hydrogen vehicles with minimal disruption. Hydrogen’s high energy potential and rapid refueling capabilities make it an attractive alternative to battery-electric vehicles for long-haul operations.

• Global Sustainability Goals
  Countries focusing on carbon reduction targets, including those outlined by the U.S. Environmental Protection Agency, could benefit from hydrogen tech advancements by cutting emissions from heavy-duty freight transport.

The Road Ahead

While technical barriers continue to challenge the widescale adoption of hydrogen vehicles, projects like H2HD REFUEL bring us closer to a sustainable transportation future. The insights gained from this project can immediately influence hydrogen station designs, improve vehicle compatibility, and boost the network necessary for hydrogen trucks.

For practical application, fleet managers can begin integrating hydrogen solutions into operations, especially in routes supported by early-stage refueling infrastructure. Over time, as research progresses and costs drop, hydrogen fuel offers a scalable way to decarbonize trucking alongside broader clean energy initiatives. With collaboration between industries, governments, and researchers, hydrogen technology can move from experimental to mainstream, enabling heavy-duty transport to become cleaner, more efficient, and ready for the challenges of tomorrow.