Why Hyzon Motors Is More Than Just a Truck Company

Reimagining the Company Identity

Hyzon Motors, based in Bolingbrook, Illinois, prides itself on being far more than a manufacturer of trucks. With a focus on sustainability, the company describes itself as a “clean technology” organization. According to Chief Operating Officer Dr. Bappaditya Banerjee, “We are a clean technology company that makes it possible to provide emissions-free power to some of the most difficult applications out there. It just so happens we are starting with Class 8 and refuse trucks.”

Launch of the 200-kW Single-Stack Fuel Cell

Hyzon recently began production of its groundbreaking 200-kilowatt single-stack fuel cell systems, which are tailored for heavy-duty hydrogen-powered trucks. These systems represent a significant leap forward compared to the company’s earlier 110-kilowatt assemblies.

Image Credit: Hyzon Motors

Key advantages of the new 200-kW single-stack system include:

• A design that is 30% lighter than combining two 110-kW fuel cells.
• Reduced production costs by 25%.
• Compact size fit for placement under a truck hood.

Chief Operating Officer Banerjee explained the strategic aim clearly: to enhance engine power without drastically increasing the size of the fuel cell system.

Proprietary Hybrid Bi-Polar Plate Technology

Hyzon’s advancements are rooted in unique engineering solutions. One of its standout innovations is its proprietary hybrid bi-polar plate technology. Unlike conventional fuel cell stacks, which are either metal or carbon-based, Hyzon’s hybrid solution combines the strengths of both materials.

Features of the bi-polar plates technology include:

• A carbon-based cathode, offering greater corrosion resistance.
• A metal-based anode, enabling rigidity, strength, and manufacturing ease.
• Compact, durable designs that allow for space-efficient stacks.

According to Vice President of Global Engineering Ravi Desai, integrating this technology with a Membrane Electrode Assembly and a compact balance of plant enables the system’s fitment under the truck’s hood, a critical challenge for heavy-duty vehicles.

Applications and Impressive Range

Hyzon’s advancements are bringing hydrogen-powered heavy-duty vehicles closer to parity with their diesel counterparts, particularly in terms of range and practicality.

Class 8 Trucks

• Achieve 350 miles on a full tank of hydrogen fuel.
• Refuel in just 15 to 20 minutes with a 350-bar fast-fill dispenser.

Refuse Collection Trucks

• Handle up to 1,200 trash bin lifts and a 125-mile range on a full tank.
• Reported increased fuel efficiency of up to 300% compared to traditional diesel models.
• Some trials demonstrated potential for more than 1,500 cart lifts on one fill.

Solving Key Challenges

Despite its technological success, widespread adoption of hydrogen-fueled vehicles in the U.S. faces two substantial hurdles. The first is the scarcity of hydrogen fueling stations, which are largely limited to California. The second is the high cost of hydrogen fuel.

Promising steps are being taken to address these issues:

• The Biden administration allocated $7 billion for the development of regional hydrogen hubs to expand refueling infrastructure.
• The Inflation Reduction Act offers the 45V hydrogen production tax credit, which aims to make hydrogen production economically viable and scalable in the U.S. However, companies are still awaiting final regulatory guidance before receiving these credits.

Collaboration for Better Infrastructure

Hyzon explicitly welcomes competition within the hydrogen ecosystem, emphasizing that a collaborative approach among industry players will help normalize hydrogen as part of the larger energy infrastructure.

“We are proud to partner with Mt. Diablo Resource Recovery in pioneering the use of hydrogen fuel cell technology for heavy-duty waste management,” said Hyzon CEO Parker Meeks after a recent successful trial of their refuse collection truck in California. These trials revealed the viability of hydrogen as a zero-emission alternative to diesel for demanding operations, aligning with California’s Advanced Clean Fleet regulations.

A Future Fueling Heavy-Duty Industries

Hyzon is also advancing its trial programs for both Class 8 trucks and refuse collection vehicles, aiming to conduct over 30 fleet trials by February 2025. With such pilot programs, the company continues to refine its technology, ensuring real-world performance matches its design ambitions.

Practical Potential and Looking Forward

Hyzon’s hydrogen fuel cell innovations highlight the progress being made to make sustainable heavy-duty transportation a reality. For industries like waste management, freight transport, and beyond, these advancements showcase how zero-emission vehicles can perform demanding tasks without compromising efficiency or practicality.

The challenges of infrastructure and cost remain, but ongoing efforts at both the private and governmental levels indicate that solutions are on the horizon. Hydrogen fuel cell technology is poised to complement existing energy strategies, especially in sectors where electrification is less feasible. Beyond individual companies, the success of such technology lies in a networked effort, from building adequate fueling stations to perfecting production methods.

For now, hydrogen-powered vehicles like Hyzon’s are proving the possibilities of clean energy solutions in tough applications. While its widespread adoption may be a few years away, the groundwork laid today is setting the stage for a cleaner and more sustainable future across industries.