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Developing the Infrastructure for Hydrogen-Powered Heavy-Duty Vehicles

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Reviewed by Lexie CornerDec 10 2024

The Southwest Research Institute has announced a joint industrial project (JIP) to support the development of infrastructure and fueling technologies for hydrogen-powered heavy-duty vehicles.

Southwest Research Institute is home to several hydrogen-energy-related initiatives, including the H₂-ICE consortium, which completed the construction of a hydrogen internal combustion engine-powered heavy-duty vehicle (pictured left), and an on-site liquid hydrogen storage tank capable of holding up to 17,000 gallons of liquid hydrogen. These capabilities will aid the H₂HD Refuel JIP’s efforts. Image Credit: Southwest Research Institute

SwRI’s H₂HD REFUEL (Hydrogen Heavy Duty Refueling Equipment and Facilities Utilization Evaluation Laboratory) JIP is designed to support the adoption of hydrogen fuel in heavy-duty vehicles. By advancing hydrogen refueling station (HRS) technologies, SwRI aims to assist the mobility industry in meeting its decarbonization and zero-emissions targets.

Over the next four years, SwRI researchers will conduct hands-on experiments, system modeling, and theoretical studies to improve existing HRS equipment and methods while exploring potential replacements.

There are less than sixty hydrogen refueling stations in the U.S., but only one or two currently exist that can meet the specific needs of heavy-duty hydrogen-powered vehicles. Many light-duty hydrogen stations face significant technical challenges, including supply chain issues, mechanical failures, and lack of infrastructure. Considering the multimillion-dollar investment per station, these issues reflect a significant technology gap that industry and government must bridge before building additional heavy-duty refueling stations.

Dr. Thomas E. Briggs, Jr., Institute Engineer, Powertrain Engineering Division, Southwest Research Institute

The H₂HD REFUEL JIP brings together hydrogen vehicle manufacturers, original equipment manufacturers (OEMs), and refueling station operators to develop reliable and compatible HRS solutions.

The initiative will address various technical challenges, including determining the optimal onboard hydrogen storage method—liquid, H70 gas, or cryo-compression—and evaluating the performance of refueling station flow components. It will also examine hydrogen losses in cryogenic systems due to boil-off and other inefficiencies.

Connecting industry stakeholders is vital to developing compatible and reliable hydrogen refueling technologies and associated infrastructure. H₂HD REFUEL’s comprehensive approach will ensure that the industry can meet the growing demand for heavy-duty hydrogen vehicles efficiently and safely. This JIP is another example of how SwRI is leading the way when it comes to hydrogen energy research.

Angel Wileman, Manager, Southwest Research Institute

H₂HD REFUEL members will have access to SwRI-led cutting-edge research and hydrogen storage system models. Members can also engage in interactive workshops and bi-annual meetings to network and share expertise, as well as get vital economic and performance insights into various hydrogen storage systems.

Hydrogen Internal Combustion Engine (H2-ICE) Consortium

Hydrogen Internal Combustion Engine (H₂-ICE) Consortium. Video Credit: Southwest Research Institute

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Southwest Research Institute

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Dr.M.Velliangiri says:

February 5, 2025 at 1:55 AM

The current landscape of hydrogen refueling infrastructure in the United States reveals a significant technology gap, particularly in supporting heavy-duty hydrogen-powered vehicles. While there are fewer than sixty hydrogen refueling stations nationwide, only one or two are capable of meeting the specific needs of heavy-duty vehicles. This disparity highlights the pressing need for targeted advancements in both technology and infrastructure.

Challenges Facing Light-Duty Hydrogen Stations:

Supply Chain Issues: The production, transportation, and storage of hydrogen involve complex supply chains that are susceptible to disruptions. These issues can lead to inconsistent fuel availability and increased operational costs.

Mechanical Failures: Existing stations often face technical difficulties, including pump malfunctions, compressor breakdowns, and issues with cooling systems necessary for high-pressure refueling. Such mechanical failures can reduce station reliability and user confidence.

Lack of Infrastructure: The limited number of stations, especially in rural or less-populated areas, restricts the viability of hydrogen-powered vehicles. This scarcity creates a "chicken-and-egg" problem where vehicle adoption is hindered by infrastructure gaps, and infrastructure investment is stymied by low vehicle demand.

Challenges Specific to Heavy-Duty Refueling Stations:

Higher Capacity Requirements: Heavy-duty vehicles require significantly larger quantities of hydrogen and faster refueling times. Existing stations are not equipped to handle such demands, necessitating specialized equipment and larger storage facilities.

Technical Complexity: The high-pressure systems and advanced cooling technologies needed for heavy-duty refueling are more complex and costly to implement and maintain.

Regulatory and Safety Concerns: Heavy-duty hydrogen stations must adhere to stricter safety regulations due to the larger volumes of hydrogen handled, adding layers of complexity to the design and operational processes.

Bridging the Technology Gap:

Public-Private Partnerships: Collaboration between government entities and private companies can accelerate the development of advanced refueling technologies and the expansion of infrastructure. Incentives, grants, and subsidies can reduce financial barriers.

Standardization and Innovation: Developing standardized equipment and protocols for hydrogen refueling can reduce costs and improve reliability. Investment in R&D to innovate more robust and efficient refueling technologies is crucial.

Integrated Supply Chains: Strengthening the hydrogen supply chain through localized production, improved distribution networks, and strategic partnerships can mitigate supply disruptions and reduce costs.

Pilot Projects and Demonstrations: Launching pilot projects focused on heavy-duty refueling can provide valuable data, demonstrate feasibility, and build confidence among stakeholders.

Regulatory Support and Safety Frameworks: Streamlining regulatory processes and establishing comprehensive safety standards can facilitate the deployment of new refueling stations without compromising safety.

Considering the multimillion-dollar investment required for each station, addressing these challenges is critical. Strategic planning, technological innovation, and coordinated efforts between industry and government are essential to bridge the current technology gap and pave the way for a robust hydrogen refueling infrastructure that supports both light-duty and heavy-duty vehicles.

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