Komatsu and General Motors have announced that they will design, co-develop, and validate a hydrogen fuel-cell power module for an electric-drive version of Komatsu’s 930E, one of the world’s best-selling ultra-class haul trucks. They intend to test the first Hydrotec-powered prototype in the mid-2020s at Komatsu’s Arizona Proving Grounds research and development facility. The vehicle will be powered by Hydrotec power cubes, each containing more than 300 hydrogen fuel cells and providing 77 kW, with a total system power of over 2 MW.
“At GM, we believe fuel cells can play an integral role in a zero-emissions future, helping to electrify heavier-duty applications beyond passenger vehicles,” said Charlie Freese, Executive Director of GM’s Global Hydrotec Business. “Mining trucks are among the largest, most capable vehicles used in any industry, and we believe hydrogen fuel cells are best suited to deliver zero emissions propulsion to these demanding applications.”
GM has been conducting fuel-cell research and product development for more than 50 years and says it is one of the only companies with advanced, homegrown technology platforms for both lithium-ion batteries (Ultium) and hydrogen fuel cells (Hydrotec). GM and Komatsu believe the complementary technologies can help spur the adoption of lower-emission mobility solutions and help other industries beyond passenger vehicles meet their sustainability goals.
“Finding new ways to power the equipment our customers need to do the vital work of mining and construction is a critical part of our commitment to supporting a more sustainable future,” said Dan Funcannon, Vice President of North America Engineering and Development for Komatsu. “This is essential work that requires cross-industry collaboration, and we are excited to be working with GM on this important solution for a haulage offering without tailpipe emissions.”
Since they are lightweight and quick to refuel, the partners believe that hydrogen fuel cells are ideal for electrifying applications traditionally powered by diesel engines. They say that hydrogen provides an effective method to package large quantities of energy onboard the vehicle, without compromising payload carrying capacity.
In addition, they believe that fuel cells are an excellent zero tailpipe emissions solution for vehicles with extreme hauling requirements like the Komatsu 930E mining trucks, with their nominal payload of 320 ton (290 t). The vehicles typically operate at a single mine throughout their life, simplifying the challenges of sizing and deploying an effective hydrogen refueling infrastructure to service the vehicle fleet. Komatsu’s fuel-cell-powered mining trucks will provide an additional pathway for decarbonization beyond battery-trolley or battery-static charging solutions, without the need for additional charging infrastructure within mines.
Huge mine trucks are not the only application Komatsu is investigating for fuel cells. In May, the company announced it had developed and started testing a concept machine for a medium-sized hydraulic excavator that combines a hydrogen fuel cell with other Komatsu-developed components to help it achieve its carbon-neutrality goals.
In its mid-term management plan, Komatsu is targeting a 50% reduction in CO2 emissions from the use of its products and production of its equipment by 2030 (compared to 2010 levels), with a “challenge target” of achieving carbon neutrality by 2050. The company has been providing products, services, and solutions that reduce environmental impact such as hybrid hydraulic excavators and electric mini excavators that will also help its customers achieve carbon neutrality.
For the new concept based on its medium-sized excavator, Komatsu developed the control technology for a hydrogen fuel-cell system and hydrogen tank produced by Toyota. Komatsu is working on a significant reduction in noise and vibration with the system while delivering the same powerful digging performance and high operability as internal-combustion-engine-driven excavators.
The excavator proof-of-concept tests are further evidence of Komatsu’s accelerating efforts on the commercial production “in the near future” of construction equipment powered by hydrogen fuel cells. Medium- and large-sized construction equipment requires a power source with higher energy density than that of small machines. Because hydrogen has a higher energy density and can be refueled in a shorter time than recharging batteries, Komatsu has been advancing its R&D efforts as a promising electrification choice for its larger models.
According to analyst firm Research & Markets in its most recent report on the subject, in the off-highway industry, hydrogen fuel-cell powertrains will compete with battery-electric powertrains in terms of the ability to scale on storage-system capacity and reduce refueling time. The research company says fuel-cell solutions in the off-highway industry are “nascent,” with very few OEMs initiating development and isolated testing at private test sites. (In addition to Komatsu, it mentions CNH, Hyundai, JCB, Sany, and XCMG.) However, government initiatives, public and private funding, and stringent mandates for green projects are expected to drive the adoption of fuel-cell technologies in construction and mining applications.
