Ford is at the forefront of investigating fuel-cell technology for its E-Transit electric van to assess the viability of hydrogen-powered, zero-emission solutions for commercial users who cover long distances and transport heavy cargo.

Co-funded by the Advanced Propulsion Centre (APC), Ford Pro — Ford’s commercial vehicles and services division — will collaborate with various partners on a three-year project. Having dominated the diesel-powered van market for 57 years, Ford engineers and E-Transit experts from Dagenham and the nearby Dunton Technical Centre in Essex will team up with Ocado to establish the feasibility of hydrogen-powered alternatives.

Other partners in the £16.3 million research initiative include BP, which will monitor hydrogen consumption and calculate infrastructure needs. Cambustion will test the fuel cell system, Viritech will design the hydrogen storage system, and Cygent Texkimp will supply the carbon fibre tooling for the pressure vessels.

“Ford believes that the primary application of fuel cells could be in its largest, heaviest CVs to ensure they are emission-free, while satisfying the high daily energy requirements our customers demand,” explains Tim Slatter, chair of Ford in Britain. “Ford has an unmatched history in the commercial vehicle sector with the indomitable Transit, and we are excited to be exploring new ways to make clean deliveries an option for even our hardest working vans on the road.”

Ford hydrogen powered E-Transit

The government has mandated that by 2030, sales of new diesel and petrol vehicles will be banned, followed by hybrid models in 2035. LCV manufacturers will be required to progressively boost their zero-emission vehicle sales annually.

While many are transitioning to electric power, battery-electric models are not the sole alternative. The government has specified that only genuine zero-carbon technologies will be allowed post-2035, providing an opportunity for hydrogen-fueled systems.

Hydrogen-powered fuel cell vehicles offer distinct advantages, particularly for long-distance drivers. The fuel cell transforms hydrogen into electricity to drive an electric motor, releasing only pure water as a byproduct. However, unlike battery-electric vehicles, a hydrogen tank can be replenished in mere minutes at an appropriate service station, providing a fast and convenient solution for long-haul users.

However, the infrastructure must keep pace, as only 11 filling stations remain in the UK after Shell closed its network. Hydrogen production is also an energy-intensive procedure, potentially leading to significant emissions.

Ford Testing Fuel Cell Powered E-Transit

Ford has been exploring fuel cell technology since the 1990s, creating multiple prototypes and showcasing the initial version of the E-Transit fuel cell vehicle at the 2021 CENEX Low Carbon Vehicle Show.

Throughout a three-year project, a small-scale test fleet of eight fuel-cell Ford E-Transits will be deployed in six-month intervals until 2025. This test fleet will offer valuable data on the total cost of ownership and operation of large vans, providing increased range and operating hours comparable to diesel-powered counterparts without the necessity for charging.

The Ford E-Transit prototypes will be equipped with a fuel cell stack and significant hydrogen storage designed for safety, capacity, cost, and weight optimisation. An essential aspect of the project will examine efficient and viable recycling methods for end-of-life components.

This hydrogen E-Transit initiative aligns with Ford’s ‘Road to Better’ sustainability pledge, demonstrating the company’s commitment to making its European operations the first to achieve carbon neutrality worldwide by 2035.

Phil Huff
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