Cummins completes hydrogen combustion engine project

Engine technology specialist Cummins Inc. is celebrating the completion of a joint project with key partners to develop hydrogen internal combustion engine technology for commercial vehicles.

Cummins led a consortium of technology firms including Johnson Matthey, Phinia and Zircotec in Project Brunel, whose mission was to successfully deliver a 6.7-litre hydrogen internal combustion engine (H2-ICE) for medium-duty trucks and buses.

The project, which was match-funded by the British government and facilitated by the Advanced Propulsion Centre UK (APC), involved the development of a hydrogen internal combustion engine concept based on Cummins’ spark-ignited engine platform.

The concept incorporated new hydrogen fuel injection technology from Phinia, in addition to aftertreatment catalyst and advanced metals chemistry development from Johnson Matthey, and hydrogen barrier coatings from Zircotec.

Project Brunel is said to have delivered significant improvements in H2-ICE engine performance and durability.

The 6.7-litre engine, using zero-carbon hydrogen fuel and fitted with an aftertreatment system, is said to provide a more than 99 per cent reduction in tailpipe carbon emissions and ultra-low NOx, compared to the current Euro VI standard. Cummins highlights the viability of hydrogen internal combustion engine technology as a path to cutting the air quality impact of heavier duty or longer range applications.

While the engine was developed for medium-duty vehicles, the design is scalable to heavy-duty applications, says Cummins – including non-road mobile machinery such as construction and agricultural equipment. Development is already underway on a 15-litre hydrogen internal combustion engine for heavy-duty vehicles.

Cummins cites recent investment of more than £13 million in a new Powertrain Test Facility at its Darlington Campus, which it says expands its test capabilities to include full powertrains powered by advanced diesel, natural gas, hydrogen and battery electric technologies for multiple industries.

“Project Brunel highlights the power of collaboration between industry leaders and underscores our ongoing commitment to industry decarbonisation,” said Jonathan Atkinson, executive director for product strategy at Cummins.

“This project has successfully delivered a viable, familiar power option that meets the operating requirements of today’s commercial vehicles – with zero-carbon fuel, and without the need for a complete vehicle redesign.

“This is a major achievement for Cummins Darlington, and for the UK’s hydrogen technology leadership. We hope the Government recognises this technology’s potential for commercial vehicles beyond 2035 and 2040, to align regulation with other major global markets.”

The project partners presented key learnings at an event held in March at Cummins’ Darlington facility, which also featured discussion of how H2-ICE technology can meet the efficiency, performance and carbon emissions improvements needed to accelerate CV decarbonisation.

“Project Brunel has built on the UK’s already world-leading capability in manufacturing engines and associated systems and has shown how this industry sector and the skilled jobs it supports can evolve to provide new solutions using zero-carbon hydrogen fuel,” said Matt Shillito, senior project delivery lead at the Advanced Propulsion Centre UK (APC).

“These products together can help accelerate the decarbonisation journey for vehicle operators.

“The project investment from the Department for Business and Trade, delivered through the APC, offered a significant opportunity for the UK to create a high-value H2-ICE manufacturing base and a competitive export business.

“It has been a pleasure working with the consortium on this project, and we look forward to seeing success in the market for all the partners.”

Tauseef Salma, chief technology officer for Clean Air at Johnson Matthey, said: “H2-ICE is a ready to go, near net zero option in the powertrain toolbox to decarbonise the medium and heavy-duty transport sector. JM proudly pioneered automotive emissions control catalysts and has since invested decades of research and development into minimising harmful pollutants that enter the atmosphere.

“We are proud to have applied this expertise in Project Brunel which demonstrates how the industry can come together to increase the commercial viability of H2-ICE technology.”

Dr. Simon Godwin, vice president of government affairs at Phinia, said: “Project Brunel has enabled us to accelerate the development of hydrogen injectors by cooperation with industry peers and by leveraging our own investment with government support. The project strengthens the UK ecosystem for hydrogen combustion engines and promotes the development and manufacture of this important decarbonisation technology in the UK.”