Hydrogen hybrid trucks join the carbon reduction race

Stepping up in the race to decarbonise New Zealand’s transport fleet, Southland-based heavy transport company H.W. Richardson (HWR) has partnered with Christchurch engineering company Fabrum to develop a hydrogen refuelling solution.

HWR put its first dual-fuel, hydrogen-diesel truck on the road last month and has plans to convert another nine.

The two companies have developed a working hydrogen refuelling unit that can produce hydrogen on site at their Allied fuel stations with the view of creating a network in the near future. They have been trialling dual-fuel hydrogen technology for their truck fleets since late 2021 with the view of enabling them to transition to low-carbon heavy transport in a sustainable manner and say dual-fuel technology diesel engines can replace up to 40 percent of the diesel with hydrogen – resulting in a 40 percent reduction in emissions – without power loss.

To build a network of hydrogen fuelling stations

HWR-owned Allied Petroleum will be utilised with its network of around 110 fuel stops across New Zealand, from Stewart Island to Karikari Peninsula.

“As one of New Zealand’s largest companies, HWR can action big change that impacts its emissions and provides a sustainability and decarbonisation blueprint for heavy transport,” says HWR Chief Executive Anthony Jones.

He says it is the first step of a potential revolution for the industry as HWR alone has 1,300 of the 45,000 New Zealand fleet.

It is cost-effective, as well with around $150,000 for the truck conversion which gave 40 percent renewable generation, while a 100 percent hydrogen truck could cost $1.2 million. He adds the company would convert 10 of its trucks into dual-fuel hydrogen trucks and would set up its first electrolyser in Gore.

The project

Anthony Jones says Fabrum is a key part of the company’s hydrogen project. He says the latest developments will help the heavy transport industry as a whole by removing barriers to accessing ready hydrogen fuel.

Fabrum Managing Director and co-founder Christopher Boyle says hydrogen is one of the most scalable and viable options to help the energy transition to a lower-carbon economy. “To leave the world a better place, we need to look to a new future with liquid hydrogen and we’ve developed the technology to make that future a reality. Our hydrogen fuel production technologies open new possibilities for sustainable long-distance transport, marine and aviation – and energy self-sufficiency, he says.

Anthony says the team made the decision 14 months ago to “jump boots and all” into dualfuel trucks with the view of converting another nine trucks this year, while a hydrogen fuelling station would be installed in Gore.

When in dual-fuel mode, about 40 percent of the truck’s energy is generated by hydrogen gas, in five tanks behind the cab, and 60 percent from diesel. It can also run on diesel only.

HWR’s plan is to build more refuelling stations over time and eventually shift from dual fuel-trucks to solely hydrogen-powered trucks.

The detail

If it is classed as a hybrid, most people think a battery is included but is this setup also a hybrid?

No battery involved. We are utilising dual-fuel technology where we retrofit a purpose-built hydrogen injector into the air intake of an existing diesel internal combustion engine. This mixes a precise dose of hydrogen and air together which is then combusted. Diesel injection remains the same.

How does it work-is it the flick of a switch in the cab?

We have a screen inside the cab. Our computer system reads the CANBUS of the truck and runs a protocol to assess when the engine is within optimal operating status to inject hydrogen. It then switches to dual-fuel mode. This screen is also used to revert to diesel-only mode.

CMB. TECH MODULARISED H2 STORAGE SYSTEM

EXHAUST AFTER TREATMENT EURO VI DPF & SCR

STANDARD FUEL TANKS (600 L + 740L)

500 HP, 2500 Nm ENGINE (STANDARD OEM)

H2 REFUELLING NOZZLE

ADBLUE TANK (78 L)