Cummins develops hydrogen engine for trucks and buses

Cummins, along with partners Johnson Matthey, PHINIA, and Zircotec, have successfully completed ‘Project Brunel’, which aimed to create a 6.7-litre H2-ICE for medium-duty trucks and buses.

The project was supported by the UK Government and facilitated by the Advanced Propulsion Centre UK (APC).Cummins B6.7H hydrogen engine (Image: Cummins)

The project partners developed the H2-ICE concept based on Cummins’ existing spark-ignited engine platform.

The engine’s performance and durability were significantly improved with the help of PHINIA’s hydrogen fuel injection technology, Johnson Matthey’s after-treatment catalyst and advanced metals chemistry, and Zircotec’s hydrogen barrier coatings.

The 6.7-litre engine, which uses zero-carbon hydrogen fuel and is equipped with an after-treatment system, delivers more than a 99 per cent reduction in tailpipe carbon emissions and ultra-low NOx, compared to the current diesel engine standard (Euro VI).

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

“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.Jonathan Atkinson from Cummins (Image: Cummins)

“This is a major achievement for Cummins Darlington, and for the UK’s hydrogen technology leadership.”

An event was held at Cummins’ Darlington facility where the project partners presented key learnings and discussed how H2-ICE technology can meet the efficiency, performance, and carbon emissions reductions required to accelerate the decarbonisation of commercial vehicles.

Matt Shillito, senior project delivery lead at the Advanced Propulsion Centre UK (APC), said: “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.Zircotec plasma applied ceramic coating process  (Image: Cummins)

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

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.

“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.”

While the 6.7-litre engine was developed for medium-duty vehicles, the design is scalable to heavy-duty applications, including non-road mobile machinery (NRMM) such as construction and agricultural equipment.

Cummins is already developing a 15-litre hydrogen internal combustion engine for heavy-duty vehicles.

Cummins recently invested more than £13 million in a new Powertrain Test Facility at its Darlington Campus, which expands the company’s test capabilities to include full powertrains powered by advanced diesel, natural gas, hydrogen, and battery electric technologies for multiple industries.