The 5,000 Hydrogen Vehicle Challenge

Hydrogen Technology and Zero Emission Vehicles: An Overview

Hydrogen

production methods

There are three methods of hydrogen production: grey, blue, and green. The differences between these methods don’t refer to differences in the hydrogen itself, but rather the differences in the methods used to produce it and the amount of carbon released in it’s production.

MOST COMMON TECHNIQUE
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Grey hydrogen

Grey hydrogen is made using natural gas, splitting the natural gas into its core elements, namely hydrogen and carbon dioxide. In doing this, it produces hydrogen, but alongside the hydrogen it also releases carbon dioxide, which is a key greenhouse gas culpable for climate change.

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Blue Hydrogen

Blue hydrogen is made in the same way as grey hydrogen – by splitting natural gas – but using carbon capture, utilization, and storage (CCUS) techniques to capture and store the emitted carbon emissions, thus making it net-zero.

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green hydrogen

Green hydrogen is made where there are no carbon emissions. Most commonly it is produced through electrolysis, a process where electricity is used to split water (H2O) into hydrogen and oxygen, the only byproducts of this kind of hydrogen production process. True green hydrogen also uses renewable sources as the energy source for electrolysis, ensuring no greenhouse gas emissions during the production of this kind of hydrogen.

Elements of

hydrogen value chain

Efficient hydrogen deployment relies on seamless integration of production, storage, transportation, refueling, and vehicle usage, with technology and infrastructure tailored for each stage.

Challenges in the development of the

hydrogen economy

Scaling the hydrogen economy requires addressing key factors in production, infrastructure, transportation, and water sourcing to ensure efficiency, safety, and sustainability.

Technology maturity and decarbonization pathway certainty

Adoption of low-carbon hydrogen depends on both technology maturity and sector alignment, with faster progress in established industries like ammonia and refining, while sectors like shipping face greater uncertainty and complexity.

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Alberta is advancing Canada’s hydrogen

transportation sector

From vehicle refueling to aviation, Alberta is leading Canada’s shift towards zero-emission transportation solutions across industries.

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Vehicle refueling

Alberta is a key player in expanding Canada’s hydrogen refueling networks, alongside B.C., Québec, and Ontario. HTEC operates five stations in B.C., Alberta supports its first station for light and heavy-duty vehicles. New stations, including Air Products’ planned site along the Calgary-Edmonton corridor, are further strengthening Alberta’s hydrogen infrastructure.

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Trains

Pilot projects like CPKC’s hydrogen locomotive testing, or Québec’s Alstom Coradia iLint demonstrate the potential for hydrogen-powered trains, reducing diesel use. With refueling infrastructure already installed, rail companies in Alberta and B.C. are converting locomotives to run on hydrogen, supporting the transition to low-emission rail transport.

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Airport Operations

Alberta is at the forefront of integrating hydrogen into airport operations, with Edmonton International Airport converting its fleet vehicles to hydrogen. Additionally, DeHavilland and ZeroAvia are collaborating on hydrogen-powered aircraft, including Dash 8 planes, supporting aviation advancements.

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Ports

Canadian ports are trialing hydrogen in port operations. Vancouver’s hydrogen projects and Montreal’s hydrogen-powered equipment pilots demonstrate the drive to decarbonize port activities

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Trucking and Freight

Alberta is at the forefront of Canada's hydrogen trucking initiatives, spearheading projects like the AZETEC fuel cell truck trials and Transport Canada’s Zero Emission Truck Testbed pilot. Additionally, dual fuel technologies are being developed in the region by companies such as Hydra, DTI, and IFS.

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Urban Transit

Canadian cities like Edmonton and Winnipeg are leading hydrogen bus pilots, where fuel cell and dual fuel buses deliver consistent range year-round, with additional bus trials and conversions planned in multiple cities.

Reasons why Alberta is leading in

hydrogen manufacturing and innovation

With strong production capacity, government support, and industry expertise, Alberta is positioned as a leader in hydrogen manufacturing and innovation, paving the way for continued growth and global competitiveness in the sector.

Hydrogen Technology in the Transportation Sector

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Fuel Cell Electric Vehicles (FCEVs)

FCEV technology is the most commercially mature hydrogen propulsion technology with on-going pilots in Alberta, and globally across various vehicle classes.

FCEV technology overview

  • Most fuel cell trucks are considered load followers, where most of the power to the electric motor is provided by a large fuel cell stack, supplemented by a smaller battery providing extra electricity if needed.
  • The propulsion system, powered by a fuel cell system and electric motor, generates electricity using hydrogen stored in pressurized tanks in the vehicle.
  • Compressed hydrogen in the pressurized tanks can be stored at 350 or 700-bar, with 700-barpressurized tanks providing higher driving range due to higher volumetric density per liter of hydrogen system storage.
  • FCEVs have a small battery relative to battery electric trucks and primarily rely on these batteries to smooth fuel cell power fluctuations absorbing and releasing electricity as needed rather than powering the vehicle.
  • Hydrogen fuel cell trucks are considered zero- emissions vehicles with water vapour(H20) as the only byproduct released from their tailpipes.

Opportunities

  • Similar fueling time, range, hauling capabilities and performance to internal combustion engine vehicles making FCEV technologies preferential for long-haul trucking compared to battery electric technologies.
  • High energy efficiency from fuel cell technology resulting in significantly lower fuel consumption compared to a comparable conventional internal combustion engine.
  • Considered zero-emission technology, as a result this technology falls within government’s ZEV sales mandate.
  • Applicable for various provincial and federal grants and incentives like iMHZEV which can reduce capital and operating costs for FCEV trucks and buses improving TCO.
  • Wide variety of models available particularly in Class 8 truck and bus categories.

Technology constraints

  • Fuel cells require high purity(minimum of 99.97%) grade hydrogen to operate efficiently to prevent fuel cell degradation thus increasing cost and limiting supply. Hydrogen production methods have a significant effect on purity levels, with green hydrogen production being the purest but generally the most expensive production method.
  • Fuel cell trucks are largely in piloting phases so operators are learning how they will perform under various conditions.

Adoption barriers

  • Capital costs can be 2-3x the cost of an equivalent diesel vehicle.
  • Robust fueling network required to maintain operations.
  • Low supply of fuel cell grade hydrogen and high cost associated with accessible supply.
  • Limited supply availability of MHDV vehicles.
  • Safety concerns and myths on hydrogen as a fuel.
  • Cost of producing, storing, and distributing low-carbon fuel cell grade hydrogen is significantly higher than diesel leading to high operating costs for truck and bus owners.

Hydrogen Internal Combustion Engine(HICE) vehicles

Hydrogen combustion engines are currently being prototyped and have the potential to be used in heavy-duty applications which have severe duty cycles requiring large energy demands and long operational hours.

Dual fuel technology overview

  • Hydrogen combustion engines require a combustion process like spark-ignition or compression ignition engines to generate power in the vehicle.
  • Hydrogen is stored in high pressure tanks on a truck and is fed into the combustion chamber where it is mixed with oxygen and ignited.
  • The pressure from the ignition moves the engine pistons, driving the crankshaft, and creating a rotating motion.

Opportunities

  • As combustion engines become more efficient at higher loads, HICE has potential to be used in heavy-duty applications which require large energy demands and long operational hours, like mining trucks and other off-road heavy-duty applications.
  • No CO2is produced while operating a hydrogen combustion engine.
  • Engines operate very similar to internal combustion engines not requiring significant upskilling from mechanics.
  • Existing supply chains are already in place for key inputs required for HICE engines and servicing.
  • Hydrogen engines are more tolerant to impurities than a fuel cell and can operate on lower grade hydrogen (98%purity) compared to FCEV (99.97% purity) increasing likelihood of securing supply at a lower cost.

Technology constraints

  • •Emit nitrogen oxides (NOx) from the tailpipe which may require aftertreatment technologies such as Exhaust Gas Recirculation (EGR) or Selective Catalytic Reduction (SCR) to reduce emissions.
  • In general, less efficient than FCEV because of energy lost during the combustion process, however, efficiency improves under certain heavy-duty applications.

Adoption barriers

  • Robust fueling infrastructure required to maintain operations.
  • High R&D cost required to develop HICE engines.
  • No commercial models currently available to pilot.
  • Regulated zero-emission technology in the European Union, however, it is unclear whether the United States and Canada will follow suit.

Hydrogen dual fuel vehicles

Hydrogen dual fuel technology can be an important bridge technology allowing diesel truck and bus operators to reduce emissions while maintaining existing assets and operations.

Dual fuel technology overview

  • Existing internal combustion trucks or buses can be retrofitted by dual fuel companies*adding components like hydrogen storage tanks, hardware to deliver hydrogen into an engine cylinder, and control software, hardware, and sensors to monitor and regulate fuel injection, combustion, and performance.
  • Dual fuel technology specifics often vary based on the retrofitter’s proprietary technology.

Opportunities

  • Truck retrofits are lower cost relative to FCEVs and can be installed immediately as existing assets can be retrofitted rather than replaced.
  • Retrofitted vehicles can have a GHG emission reduction of up to 80% while maintaining high uptime and having a minimal impact on operations.
  • Considered a bridge technology creating a demand for hydrogen while FCEV technology matures.
  • Lower grade of hydrogen is required to operate dual fuel trucks compared to FCEV trucks.

Technology constraints

  • Retrofitting is only available for diesel powered trucks and buses.
  • While dual fuel reduces GHG emissions, it is not considered a zero-emission technology and can still produce common diesel pollutants like NOx, particulate matter, carbon monoxide, etc.

Adoption barriers

  • Extensive fueling network is required for dual fuel vehicles to operate on hydrogen.
  • Retrofit kits may risk voiding some OEM warranties
  • Dealerships and OEMs may be hesitant to service vehicles which have been retrofitted.
  • Technology does not qualify as zero-emission.
SIDE BY SIDE COMPARISON
hydrogen propulsion technology
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OPERATIONAL
CONsiderations when
TRANSITIONING TO HYDROGEN TRUCKS
01
Vehicle Age

Older diesel vehicles emit a larger share of total greenhouse gas and criteria air pollutants with impact on public health.

Why is this important?
- Modern diesel trucks have made significant improvements in reducing their emissions; however, older diesel trucks still disproportionately contribute a significant amount of emission in the road-transportation sector affecting both the environment, air quality, and public health
- In a study conducted in New York City, pre- 2007 diesel engines contributed 64-83%of tailpipe emissions while only making up a total share of 6-10% of the fleet.

02
Vehicle routes

Trucks should travel long and predictable routes.

Why is this important?
- FCEV scan refuel in 10 – 20 minutes allowing a truck to make a quick fuel stop on along route.
- Due to the lack of infrastructure in the province, potential candidates for hydrogen vehicles should travel on predictable routes where a fueling station is identified.

03
Hauling load

Trucks should be required to haul heavy payloads.

Why is this important?
- Fuel cell electric trucks (FCET) can haul similar payloads to diesel from a gross vehicle weight perspective, although certain design features of FCET’s may lower payload capacities.
- Hydrogen’s energy density is nearly three times diesel and gasoline. In a fuel cell, one kilogram of hydrogen contains nearly the same amount of energy as one gallon of diesel allowing hydrogen vehicles to haul comparable payloads to their diesel/gasoline counterparts.

allocating trucking technologies to different responsibilities
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Fueling Infrastructure

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