Toyota’s Fuel-Cell Conversion Kit Can Replace Diesel in U.S., EU

Toyota announces its heavy-duty hydrogen-fuel-cell powertrain kit has received approval from the California Air Resources Board, opening the door for owners of Class 8 heavy trucks to replace diesel engines with zero-emission powertrains.

The heavy-truck industry is transitioning away from diesel and toward zero-emissions alternatives including hydrogen.

The kit is made up of fuel cell stacks, battery packs, electric motors, a transmission and hydrogen fuel tanks. Toyota worked with a team at Kenworth to develop the kit using the FCEV powertrain. The companies built 10 Kenworth T680s with the hydrogen powertrain installed.

"We believe hydrogen will play a significant role in the emissions reduction of heavy-duty transport while not sacrificing the distance, power or fueling times needed to keep these fleet and individual operators running," says Chris Rovik, executive program manager in Toyota Motor North America's advanced mobility division.

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As part of its CARB certification, the trucks were put into service with customers for practical field development and data collection. They were deployed to carry cargo between the Ports of Los Angeles and Long Beach, for example. Shell Oil provided refueling support for the program.

CARB is driving the elimination of diesel in California, and several states plan to follow suit. Under a CARB proposal, expected to become law in California, new big rigs and other trucks will have to be zero-emissions in 2040.

Under the proposal, manufacturers couldn’t sell new medium- or heavy-duty trucks fueled by diesel or gasoline that operate in California, instead turning to electric models powered by batteries or fuel cells. In addition, large trucking companies would have to gradually convert their existing fleets to zero-emission vehicles, buying more over time until all are zero-emissions by 2042.

"Fuel-cell technology is scalable, and we believe it will take an increasingly visible and important role in our collective fight to reduce and eliminate carbon as we move towards a hydrogen society," Rovik says.

Toyota’s hydrogen fuel-cell modules are also being integrated into heavy-duty trucks made by Hyliko for the European market. 

Trucks account for 72% of cargo movements in the U.S., and 77% in Europe. The industry generally views hydrogen fuel cells as a better substitute for diesel than batteries. The lower mass of hydrogen systems allows for heavier payloads, while the fast refueling of hydrogen is essential for heavy commercial transport.

Hydrogen fuel-cell powertrains have been around for decades, but scaling the technology has always been thwarted by lack of refueling infrastructure. Additionally, most hydrogen is actually produced from fossil fuels, negating the benefits of running vehicles on hydrogen.

The landscape is changing, though. The Inflation Reduction Act signed into law last year includes $8 billion for a program to establish six to 10 regional “hydrogen hubs” around the U.S.

Hydrogen Impact

Heavy trucks are being considered for conversion from diesel to hydrogen fuel for several reasons:

Overall, the conversion to hydrogen fuel for heavy trucks is a promising solution for reducing emissions and improving the sustainability of transportation.