Is hydrogen the future for trucks?

A Glimpse into Hydrogen Trucks: The Future of Long-Haul Transportation?

Hydrogen is emerging as a game-changer in the energy landscape for zero-emission long-haul trucking. Two primary avenues are being explored: hydrogen fuel cell engines and new hydrogen internal combustion engines. While hydrogen may not be the best fit for every duty cycle, hydrogen fuel cell tractors stand as the most promising zero-emission candidates for replacing diesel engines in the future of heavy-duty long-haul trucks.

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In December, the North American Council For Freight Efficiency (NACFE) evaluated an array of alternative fuel technologies for heavy-duty trucks, including hydrogen. Here are the key findings from that report, which remain relevant today:

• Hydrogen fuel cell trucks are beginning real-world trials, with adoption driven by larger regional or national goals.
• Battery-electric trucks should serve as the benchmark for comparing hydrogen fuel cell electric vehicles (HFCEVs), rather than internal combustion engines.
• Fleets should tailor HFCEV specifications for their specific roles, expecting longer trade cycles compared to diesel trucks.
• The future growth of HFCEVs hinges more on hydrogen production and distribution than the vehicles or fueling stations themselves.
• Autonomous hydrogen fuel cell trucks could operate around the clock, enhancing returns on investment in hydrogen technology.

NACFE predicted that state and federal regulations would accelerate hydrogen adoption, and indeed, there has been significant progress in recent years.

NACFE's 2020 report also highlighted crucial issues to consider for hydrogen's viability as a commercial vehicle fuel:

• The hydrogen economy cannot rely solely on long-haul trucking to reach the scale needed for cost reductions.
• Standardization across tank, fuel system, fuel cell, battery, cable, and connector designs is essential for achieving volume cost reductions.
• The rate of innovation, investment, regulation, and awareness of hydrogen as a truck fuel is increasing.
• The oil industry's move towards zero-emission markets, including hydrogen, is significant.
• Infrastructure investments and regulatory efforts are crucial to hydrogen's development as a fuel for medium- and heavy-duty trucks.
• Hydrogen combustion engines offer near-zero emissions, longer ranges, faster refueling times, and lower weight compared to battery-electric trucks.
• Green hydrogen production projects are on the rise with substantial funding allocated to hydrogen freight initiatives.

Industry Voices on Hydrogen

"Most countries have committed to decarbonize, and the consensus is that hydrogen is vital for a low-carbon grid. Thus, low-carbon hydrogen will inevitably be available." — Alan Mace, Product Applications Manager, Ballard Power Systems

"In the move towards a zero-emissions freight future, the long-term choices boil down to battery-electric and hydrogen fuel cell." — Rick Mihelic, NACFE Director of Emerging Technologies

"Hydrogen technology is advancing faster than expected. We plan to test a hydrogen truck this year." — Rob Reich, Executive Vice President, Chief Administrative Officer, Schneider

Key Insights

Hydrogen could play a significant role in the future of long-haul freight transportation, especially when combined with battery-electric vehicles for shorter distances. The major takeaways from the report are:

1. Hydrogen freight is essential for achieving a zero-emission future in freight transportation.
2. Substantial funding is being directed towards building a hydrogen economy, including long-haul freight transport.
3. The cost of hydrogen—production, transportation, storage, and dispensing—needs tax credits and subsidies to compete with diesel.
4. Monitoring retail hydrogen prices is crucial, perhaps even more than focusing solely on production costs.
5. Hydrogen and electricity are interconnected; ample electricity is necessary for hydrogen production.
6. Hydrogen is increasingly factored into federal, state, and local zero-emission transportation plans and regulations.
7. Purpose-built hydrogen trucks optimized for specific roles may not be valuable in secondary markets, affecting their resale value.
8. Hydrogen costs decrease with larger hydrogen plants requiring multi-industry demand, trucking alone will not suffice.
9. Using hydrogen to create renewable diesel may delay zero-emission technology adoption.
10. Not all answers need to be apparent initially; hydrogen supply and market demand will co-evolve.
11. Hydrogen and electricity supply are inherently robust, with various production methods creating competitive pricing and supply stability.

Conclusive Thoughts

Hydrogen as a fuel for freight transport is still in its developmental stages. NACFE identified four primary conclusions regarding hydrogen's role in commercial transportation:

• Both hydrogen and battery-electric technologies are crucial for a zero-emission freight future, with BEVs being more economical for short distances and hydrogen more viable for long hauls.
• Hydrogen fuel cell tractors are crucial for zero-emission heavy-duty, long-distance operations. Significant cost reductions across the board are necessary for economic viability.
• Alternative fuels like renewable natural gas and renewable diesel will aid the transition towards zero-emission goals while hydrogen and battery-electric infrastructure scales up.
• The industry needs consensus on whether long-haul hydrogen fuel cell tractors and hydrogen transport will rely on gaseous or liquid hydrogen, affecting infrastructure and market penetration.

This condensed, online version of the report offers critical insights. For more detailed text and figures, download the full report.

Vehicle manufacturers and commercial fleets are channeling investments into hydrogen-powered trucks to counteract climate emissions and other pollutants from heavy-duty vehicles. However, several barriers exist in making hydrogen trucks a practical zero-emissions solution.

This piece aims to clarify common inquiries about the potential benefits and challenges associated with hydrogen-powered trucks.

An Introduction to Hydrogen in Heavy-Duty Vehicles

Heavy-duty trucks and buses are disproportionately responsible for vehicular pollution on roads and highways. Comprising merely 10% of vehicles on U.S. roads, Class 2b-8 trucks and buses account for over one-quarter of global warming emissions, about half of nitrogen oxides (NOx) emissions, and more than half of all fine particulate matter (PM2.5) from on-road vehicles.

Reducing pollution from these vehicles is crucial for a sustainable and equitable transportation system. While Battery-Electric Vehicles (BEVs) are the most widely adopted zero-emission vehicle technology today, hydrogen-powered trucks are also gaining traction in global transportation electrification.

This explainer aims to provide decision-makers, researchers, and the public with a better understanding of the state of heavy-duty hydrogen vehicle technologies and economics, as well as key considerations around the benefits and challenges of hydrogen vehicles and their fueling infrastructures.

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Are Fuel-Cell Electric Trucks Truly Zero-Emission?

The answer is yes, but the degree of zero-emissions depends on the hydrogen production process.

Today’s zero-emission trucks and buses include Battery-Electric Vehicles (BEVs) and Fuel-Cell Electric Vehicles (FCEVs). In the global shift towards zero-emission trucks and buses, understanding these technologies is paramount to leveraging their strengths while minimizing potential drawbacks.

Like BEVs, FCEVs produce no tailpipe emissions. However, the life-cycle emissions of the fuels they use—electricity and hydrogen—must be assessed for a complete understanding of their environmental impact. Thus, as the electricity grid becomes greener, so too can FCEVs, provided their hydrogen fuel comes from renewable sources.

This explainer delves into upstream impacts of FCEV trucks and examines research on their potential to create a more sustainable freight system.

How Do Hydrogen Fuel-Cell Trucks Operate?

FCEVs can be considered electric vehicles with onboard power plants. These trucks have fuel cells that convert hydrogen stored in high-pressure tanks into electricity. Unlike BEVs, which store energy directly in batteries, FCEVs use smaller batteries, relying on their fuel cells for longer driving ranges.

For instance, a long-haul BEV tractor truck's battery might exceed 1 megawatt and offer several hundred miles of range per charge. Conversely, a comparable FCEV would utilize a smaller battery, relying on hydrogen fuel cells for continuous power over extended ranges, necessitating hydrogen refueling less frequently.

The Impact of Hydrogen Production on FCEV Pollution

Hydrogen FCEV trucks emit only water from their tailpipes, but hydrogen fuel production can entail substantial life-cycle greenhouse gas emissions and air pollution, depending on the production method. Most hydrogen is currently produced from natural gas, incurring significant climate and air quality concerns.

For hydrogen FCEVs to be environmentally beneficial, hydrogen must be produced using renewable energy sources, such as wind or solar power. Yet, the US Department of Energy reports that only 1% of hydrogen in the country is made through electrolysis powered by renewables. The bulk still comes from natural gas.

Implications of Hydrogen Trucks on Local Communities

Current hydrogen production processes emit various pollutants posing serious health risks to both humans and ecosystems. Nearly all hydrogen today is derived from natural gas through steam reformation, leading to emissions that include particulate matter (PM2.5) and nitrogen oxides (NOx).

Although hydrogen fuel-cell trucks might reduce tailpipe pollution in urban areas, increased demand for hydrogen could elevate pollution levels near production facilities. Some manufacturers are even developing vehicles that combust hydrogen rather than converting it to electricity, potentially exacerbating air quality issues.

The Challenges of Hydrogen Combustion Technologies

Hydrogen combustion engines, while eliminating tailpipe carbon dioxide emissions, still produce considerable levels of pollutants such as nitrogen oxides. Studies indicate that hydrogen combustion engines might emit more fine particulate matter than gasoline engines, undermining their environmental benefits.

Moreover, hydrogen combustion is less efficient than using fuel cells, making these engines expensive to operate. Their fuel efficiencies are estimated to be lower than current diesel engines, limiting their commercial appeal.

Economic Hurdles in Fuel Costs for Hydrogen Trucks

Hydrogen-powered heavy-duty vehicles incur higher operational costs due to the steep price of hydrogen fuel. For example, California retail hydrogen prices hit about $30/kg in 2022, with projections suggesting prices will hover between $8/kg and $10/kg even with federal incentives.

Even with subsidies, green hydrogen must fall significantly in price to compete economically with BEVs. Enhanced production efficiencies may lower costs, but hydrogen derived from natural gas will always be subject to fossil fuel market volatilities.

Efficiency Comparison of Fuel-Cell Trucks

Transitioning to zero-emission vehicles requires consideration of overall fuel and energy efficiency. BEVs hold an advantage by storing energy directly in batteries, bypassing the significant efficiency losses that occur in converting electricity to hydrogen and back.

Studies have shown that BEV trucks can travel much farther than FCEVs using the same amount of renewable energy, partly due to hydrogen production's inherent inefficiencies.

Availability of Hydrogen Trucks and Buses Today

Currently, over 100 battery-electric heavy-duty trucks are available in the market, but hydrogen fuel-cell options are limited. The primary commercial FCEVs available in the U.S. are transit buses based in California.

Demonstration projects in Californian ports aim to assess the viability of hydrogen fuel-cell trucks for drayage applications, targeting communities disproportionately impacted by air pollution.

Economic Viability of Large-Scale FCEV Deployment

Commercial deployment of hydrogen trucks will likely be niche, focusing on applications where BEVs are impractical due to higher costs and technical challenges. For instance, FCEVs could be ideal for freight routes covering significant distances that BEVs currently struggle to accommodate.

While various studies present mixed forecasts for FCEV adoption, many agree that BEVs will dominate the market sooner, especially given the current and projected costs of hydrogen fuel.

Fueling Infrastructure: Hydrogen vs. BEVs

Fueling infrastructure for both hydrogen and BEVs requires considerable investment. Hydrogen stations, costing significantly more to build than BEV stations, entail challenges and opportunities related to their construction, cost, and technology.

Companies like Nikola claim that their hydrogen trucks can refuel in just 20 minutes for up to 500 miles, while BEVs continue to improve their range and charging speeds. However, hydrogen's economic viability and scalability are contingent upon reducing fuel prices and ensuring minimal leaks to maintain its environmental benefits.

This is a condensed, online version of the report. For more detailed text and figures, download the full report.

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