Hydrogen fuel cell propulsion is key in supporting UK Net Zero transport policies, as demonstrated by the Automotive Council roadmaps. Fuel-cell Commercial Vehicle Generation 2.0 (FCVGen2.0) is a Ford-led industrial research project that pilots the introduction of Fuel Cell Hybrid Electric Vehicles (FCHEV) to the Light Commercial Vehicle (LCV) sector, aiming to advance the UK capability for fuel-cell powertrain development and vehicle integration, and to validate the business case with a joined-up approach between OEM, energy company, supply chain, and fleet operator. Building on the success of the ARMD FCVGen1.0 project, which delivered the first Ford Transit FCHEV vehicle in Europe, this project aims to design, develop, and build a fleet of 9 fuel-cell Transits, that will benefit from the latest advances in fuel-cell supply chain technology. 8 of the vehicles will be piloted by strategic fleet operators and customers for six months, gathering subjective and objective feedback to assess their suitability for wider deployment. The fleet trial data will be used to inform a Total Cost of Ownership (TCO) analysis tailored to the specific segment, and to provide insights into the required attributes of a possible future product and hydrogen infrastructure. Even with the current high pace of advancement in battery technology, it is unlikely in coming years, that Battery Electric Vehicles (BEV) will fulfil those LCV use-cases that require high daily energy, range, payload or have limited opportunities for charging. FCHEV is a zero-emissions alternative that can address this gap. Competitor FCHEVs have not demonstrated the anticipated benefits in range and payload that can be achieved with a fuel-cell powertrain. This project aims to employ a high-power fuel cell stack, in conjunction with significant hydrogen storage capability to achieve a vehicle specification that is a direct replacement for the equivalent diesel or gasoline LCV. The cost and packaging of the hydrogen storage system is critical in delivering the attributes required of a commercial vehicle, such as payload and loading space. The project will include a dedicated workstream on hydrogen storage, aiming to design and develop state of the art hydrogen pressure vessel(s), optimising for capacity, cost, and weight. The pressure vessel(s) will be built in the UK, and the design potentially adapted for volume manufacturing. A separate workstream will examine efficient and viable recycling methodologies at end of life, for the high value carbon composites used for pressure vessel reinforcement, and possibilities to re-introduce into the supply chain.

This £2.44m 2.5-year project, led by ULEMCo, will deliver an operational prototype zero emission ambulance, for Yorkshire Ambulance Service (YAS) based on taking the current TRL3 level feasibility study for use of a fuel cell range extension (FC Rx) power module on a OEM EV, along with light-weighting, base vehicle modifications and innovative power electronics to a TRL5 level demonstration vehicle, that will also be applicable to additional customer partner, Ocado for their refrigerated vans. The demonstration prototype will be certified for use under CEN1789 so that it can be field tested around the Sheffield area, where the hydrogen will be sourced at publicly available stations. ULEMCo with their sub-contractor Revolve Technologies (RT) will develop and integrate a FC Rx power module and hydrogen system kit, to be fitted onto the modified base EV; Lyra Electronics (LE) will apply innovative solutions for DC/DC conversion and power solutions for the on-board equipment; Ocado will share learning on light-weighting such that YAS can procure appropriate changes from their box supplier; all partners targeting the demonstration of a ZEV that has a range of up to 300 miles, top speed over 70 mph; with GVW that allows for 800 kg payload and a box body fitted with the appropriate equipment (currently 1350kg), within the constraints of the cargo dimensions. The key objectives alongside the specific opportunity for a world first in a hydrogen FCEV of this size (>5 tonnes van) will be the application of innovative approaches to deliver the weight, vehicle performance and range requirements of the two applications and the creation of a stand-alone FC Rx module and system control kit, which can be applied to other similar vehicle applications. In phase 1 all the partners will focus on the innovation needed at a system level to deliver weight reduction, modifications of the base vehicle, optimisation of the fuel cell characteristics and incorporation of the onboard equipment electronics to deliver the speed and range targets of the application. Having developed the detailed engineering design and build programme for the vehicle and the body, it then moves on to a physical build phase involving procurement, build, integration and test of the FC module with the vehicle, in parallel to the work to build the body and transfer learning of such to Ocado's box supplier. The final phase includes completion of single vehicle type approval, and ambulance certification with testing by YAS.

This 24-month project will trial a range of vehicles and associated duty cycles with hydrogen dual-fuel technology (H2ICED®), in order to provide evidence of the carbon reduction and air quality improvement of this world leading unique approach. The project is led by ULEMCo, the technology provider in partnership with vehicle operators The London Fire Brigade (LFB), Wiles Greenworld (WG), Aberdeen City Council (ACC), Westminster City Council (WCC), Veolia, Ocado & the Yorkshire Ambulance Service (YAS) that will provide the vehicles, the fleet operations experience and their fleet management systems to support data gathering. The project provides value for money by incorporating a range of vehicles, duties and operators who will all get hands on experience of the benefits of the dual fuel technology including LFB(2 vans), WG(2 vans), ACC(2 RCV & 1 road sweeper), Ocado(1 chassis cab) and YAS(1 patient transport ambulance), that will largely make use of the existing hydrogen refuelling stations (HRS), with a temporary facility being installed for WCC. It aims to show between 40-70% reduction in tailpipe C02e is possible by displacing diesel, alongside improving real world air quality relative to the MY16 standards, & WtW of 5%-60% depending on the source of H2.