As technology advances and challenges are overcome, hydrogen fuel cells for heavy-duty applications will become more prevalent, making the path to decarbonization for the waste industry even more viable.
By Kelli McConahey
Viability of hydrogen fuel cells and fuel cell technology have been prevalent topics in recent years, especially with federal mandates pushing toward zero emissions and emissions reduction regulations from the California Air Resources Board (CARB). Heavy-duty sectors, including over-the-road trucking and public transportation, have been gaining traction for hydrogen fuel cells, demonstrating their potential as an alternative power source that could have a far-reaching positive effect on reducing the country鈥檚 carbon footprint.
Hydrogen power also offers a promising future for the waste and recycling industry. In many ways, hydrogen fuel cell-powered garbage trucks represent an ideal application to test the technology鈥檚 viability for widespread use. Across the U.S., refuse collection routes provide a myriad of operational test cases: varying landscapes, unpredictable weather, a range of payloads and waste types ranging from industrial waste to organics, recyclables, yard waste, and more. A particularly compelling benefit of hydrogen adoption is the opportunity for haulers to produce their own power source, generating hydrogen through waste-to-energy processes, such as gasification or anaerobic digestion, creating a circular economy.
Beyond proving the performance of hydrogen fuel cell technology in heavy duty applications, there are numerous advantages that can be realized by adopting hydrogen power for waste management operations.
Images courtesy of New Way and Recology.
Operational Efficiency
Hydrogen-powered refuse collection vehicles offer performance on par with, or in some cases superior to, traditional diesel internal combustion engine (ICE) trucks. Refueling a hydrogen fuel cell truck takes about the same time as refueling a diesel truck, roughly 12 to 15 minutes, which is significantly quicker than charging electric trucks. For comparison, a Level 3 DC (direct current) fast charger can take four to eight hours to charge a heavy-duty battery electric vehicle (BEV) to 80 percent from empty, according to the Department of Energy.
In trials with North America鈥檚 first hydrogen fuel cell-powered electric refuse collection vehicle (HFCEV)1 route performance data showed that the truck achieved three times better fuel efficiency over comparable diesel trucks. It also completed routes of exceeding 120 miles, lifted more than 1,300 containers, and hauled nearly 30 tons of payload, all on a single hydrogen fuel fill. This outperforms the standard statistics published on battery electric refuse collection trucks.
Refuse collection presents an ideal application to showcase the viability of hydrogen fuel cell technology across the environmental services industry. Integrating the performance and functionality of an automated side loader body and the consistent and regenerative power of a hydrogen fuel cell drivetrain offers a lighter-weight refuse vehicle with more payload, compared to battery electric alone, and similar range and performance as diesel and CNG (compressed natural gas) trucks.
Heavy-Duty Clean Energy
Hydrogen fuel cells offer more than just high performance. They work collaboratively with electric power. Hydrogen fuel cells generate electricity to power the electric power take-off (PTO) and, like other hybrid vehicles, HFCEVs use battery power only when necessary. Because these trucks do not rely solely on battery power, it helps to minimize battery size and weight.
Hydrogen fuel cell-powered electric vehicles (HFCEVs) also use regenerative braking to recapture energy during deceleration, providing extra power during short accelerations and balancing power delivery from the fuel cells. The combination of hydrogen fuel cells and electric power means fewer batteries, less space claim on the chassis frame and body and less overall vehicle weight, creating the ability to handle larger payloads while maintaining zero tailpipe emissions.
Weight savings, range capabilities, and zero emissions are three of the top advantages that make transitioning refuse collection fleets to hydrogen attractive, especially for states with Clean Fuel Standards like California, Washington, and Oregon. 鈥淗ydrogen fuel cell technology presents a transformative opportunity for the waste and recycling industry鈥攄elivering the power and range needed for heavy-duty collection while eliminating emissions,鈥� said Salvatore M. Coniglio, Chief Executive Officer of Recology, a San Francisco-based resource recovery company. 鈥淥ur trials with hydrogen-powered refuse trucks have shown promising results, supporting their reliability and potential for widespread adoption across diverse operating conditions. As we advance sustainable solutions, hydrogen offers a practical and scalable path to decarbonizing waste collection without compromising performance.鈥�
Another key advantage is the potential for hydrogen to be produced locally through waste-to-energy processes such as gasification or anaerobic digestion, creating a circular, zero-emissions ecosystem that benefits haulers and the environment.
Other Environmental and Economic Benefits
Emitting only water vapor as a byproduct, hydrogen fuel cells offer a zero-emission power source, contributing to cleaner air, a healthier environment, and a reduced carbon footprint. This is a significant contrast to traditional diesel ICE vehicles or hydrogen ICE vehicles. Hydrogen fuel cell vehicles produce no emissions. In comparison, hydrogen combustion engines do produce emissions, including nitrogen oxides, and have been shown to be less efficient than fuel cells.
Hydrogen fuel cells also operate quietly, reducing noise pollution. They require minimal space claim on the refuse vehicle鈥攁bout the same space requirement and placement as CNG systems鈥攚hich makes them suitable for urban and residential applications where limited space and noise concerns can be constraints.
In areas where natural disasters and power disruptions can present challenges for haulers, such as along the West Coast, hydrogen fuel cells offer resilience by providing reliable power during electrical grid outages. Local hydrogen production, powered by renewable sources like solid waste, solar, and wind, enables refuse collection fleets to continue their operations even when traditional power sources are unavailable.
Additionally, producing hydrogen locally can reduce energy costs, minimize environmental impacts, foster local job creation, and contribute to stabilizing and sustaining local economies.
Streamlining Adoption
Integrating hydrogen fuel cells into refuse vehicles shares similarities with diesel, CNG and battery electric power systems. Fleets with existing CNG vehicles and infrastructure can integrate hydrogen-powered refuse trucks with minimal adjustments to fuel system mounting, weight distribution, and refueling infrastructure. A hydrogen fuel cell electric refuse vehicle is like a hybrid between CNG and BEV integration, with a similar weight distribution as diesel and CNG. The hydraulic pump integration uses an electric PTO, much like a BEV, but the power source comes from fuel cells, similar to how CNG tanks operate. The fuel cells and support structure can be integrated into the body to gain a more desirable weight distribution, just as CNG systems are built today. Fuel cells are also similar in size to ICE vehicles and are packaged similarly, which allows more frame space on the chassis to be used for mounting hydraulic tanks, cylinders and other body components.
When it comes to introducing these technologies into hauler operations, manufacturers can draw off experiences with high-pressure CNG systems and combine it with knowledge of high-voltage EV systems. HFCEVs have both high-pressure gas and high-voltage systems that make up the powertrain.
Hydrogen Adoption Challenges
While HFCEV refuse trucks have the potential to revolutionize hauler operations and the industry by delivering clean, sustainable, efficient power, and performance, there are several challenges to address. One major hurdle is the cost associated with hydrogen fuel production, storage, and distribution. The infrastructure needed to support hydrogen fueling鈥攕uch as stations and transportation systems鈥攊s expensive due to the complexities of storage, compression, and dispensing technology. However, as technology advances and the availability of hydrogen fuel increases, costs are expected to decrease, improving the economic viability. Coniglio added, 鈥淪caling hydrogen fuel cell adoptions comes with challenges鈥攆rom infrastructure development to production timelines and cost. However, as technology advances and demand grow, we expect to see costs decrease, making hydrogen an even more attractive alternative for waste collection fleets. Investing in clean fuel infrastructure today will set the foundation for a more sustainable tomorrow.鈥�
The variability of hydrogen production can also present challenges. Whether it is green, gray, or blue hydrogen, each production process has different methods and costs. Green hydrogen, the cleanest of the three, is produced using renewable energy and electrolysis but is also more expensive to produce than the traditional method鈥攗sing natural gas鈥攖o produce gray hydrogen. Blue hydrogen is also produced using natural gas but features a carbon capture component, making it a cleaner process compared to gray hydrogen.
Though cost and production may be prohibitive currently, a 2023 report from Bloomberg says a tipping point is near. By 2030, the cost of producing green hydrogen in a new plant could be nearly 20 percent less than an existing gray hydrogen plant.
Misconceptions about the safety of hydrogen also persist, with concerns about flammability and explosion risks in particular. However, most haulers already have proper safety protocols and training in place for operating and servicing CNG vehicles, which are similar to those needed for hydrogen-powered refuse vehicles. And as electric vehicles become more widespread, training required for high-voltage systems in BEV trucks provides a foundation for safely running HFCEVs.
The Drive Forward
The training and work instructions for hydrogen fuel cell electric vehicles are very similar to CNG and other electric vehicles that may already exist in a hauler鈥檚 fleet. Because of this, introducing hydrogen to the fleet might not be as challenging as initially thought. As technology advances and challenges are overcome, hydrogen fuel cells for heavy-duty applications will become more prevalent, making the path to decarbonization for the waste industry even more viable. In the coming months and years, more new entrants in hydrogen fuel cell technology, increased hydrogen fuel production, and expanding clean energy policies will also drive down costs and enable wider adoption of hydrogen fuel cells. The industry, its associations, suppliers, and haulers can be poised to drive it forward. | WA
Kelli McConahey is Director of Marketing for McLaughlin Family Companies, which owns New Way Trucks. She has been working in the waste industry for more than 12 years and leads the brand and marketing strategy for all McLaughlin Family Companies businesses and programs. Kelli can be reached at (712) 634-0089 or email [email protected].
Contributing to this article, from New Way Trucks, were Eric Evans, Chief Product Officer, Tyler White, Product Manager, and Marc de Smidt, Director of Engineering.
Note
The hydrogen fuel cell electric refuse collection vehicle was developed in collaboration between New Way Trucks and Hyzon..