In the past, fuel cell (FC) systems have been successfully developed for city buses. No activities towards the development of coaches are known in Europe so far. The target of this project is both to carry the experience from the development of FC city bus systems one step further into the more challenging constraints of typical coaches as well as to strengthen the European vehicle manufacturing base and supply chain of hydrogen components. The project presents two coach solutions to solve the challenges of longer driving distances of regional and long-distance coaches (400-800 km), the more stringent packaging constraints, less favourable driving patterns (lower recuperation) and higher auxiliary powers (air conditioning & heating) and demonstrates the coaches at two regions in 2 to 3-year demo phases. The project is based on a coherent structure and balanced partnership, addresses all call specific requirements and aims for the highest benefits from a technological and market perspective: -both coach types being equally addressed by applying a common hybrid system concept and preparing for the development of FC drive system synergies, -comparing different and modular FC packaging concepts by the use of multiple and single FC units being tested in fulfilment of the 100 kW power requirement, -one set of coaches to develop an OEM-based new-built FC coach and another one an existing coach retrofit to also provide answers for the second life use of environmentally outdated coach chassis, -partnering with established FC manufacturers promising to reach the required 25,000 operating hours minimum, and validated in the project possibly with used stacks. -an experienced composite tank manufacturer to discuss the design option of potentially applying 350 bar and 700 bar technology for the coaches in fulfilment of targeting the required driving ranges at lowest costs and -experienced automotive system developers to search for operational minimum energy consumption patterns.

H2Haul will develop and demonstrate a total of 16 new heavy-duty (26–44t) hydrogen fuel cell trucks in real-world commercial operations. The project includes two major European truck manufacturers (IVECO and VDL), who will build on existing small-scale prototyping activities to develop new zero-emission trucks tailored to the needs of European customers, mainly in large supermarket fleets. The vehicles will be standardised as far as possible to help encourage the development of the European supply chain. New high-capacity hydrogen refuelling stations will be installed to provide reliable, low carbon hydrogen supplies to the trucks. Most of the stations will be publicly accessible and this project will thus support the uptake of a broader range of hydrogen-fuelled vehicles. The vehicles and infrastructure will be thoroughly tested via an extended trial with the high-profile end users over several years. The comprehensive data monitoring and analysis tasks will ensure that the technical, economic, and environmental performance of the hardware is assessed, and that the business case for further deployment of heavy-duty fuel cell trucks is developed. The scope and ambition of this innovative project will create a range of valuable information that will be disseminated widely amongst truck operators, representatives of the retail sector, policy makers, and the broader hydrogen industry. Hence, H2Haul will validate the ability of hydrogen fuel cell trucks to provide zero-emission mobility in heavy-duty applications and lay the foundations for commercialisation of this sector in Europe during the 2020s.

This project will develop an open standard for heavy-duty fuel-cell modules in terms of size, interfaces, control and test protocols, with the objective of kickstarting the use of fuel cells and hydrogen in the heavy-duty mobility sector, where electrification with batteries is impractical. Multiple modules may be integrated in a system, similar to AA batteries; this will allow using the same modules for multiple sizes. Combined with the standardisation across several sectors (road, offroad, rail, maritime, etc.) represented by participating OEMs, the same modules will address a large pooled market. The size of the market, and the availability of multiple module suppliers (8 in this project alone) will create a fair competition environment where OEMs may choose and change vendors, driving down prices and activating a virtuous cycle through economies of scale and achieving one of the main goals of the FCH JU's Work Programme in the heavy-duty mobility sector. This project will also produce prototypes form 8 leading FC vendors, which will then be thoroughly tested by two independent institutes for compliance with the open standards produced by the project itself. The project will feature significant dissemination and outreach activities, especially towards external OEMs that may become customers of the module suppliers.

Long-haul BEVs and FCEVs need to become more affordable and reliable, more energy efficient, with a longer range per single charge, and a reduced charging time to meet the user’s needs. Next to those, there is a real need to take zero-emission long-haul goods transport in Europe to the next level by executing real-world demonstrations of BEVs and FCEVs spread all over Europe; this also requires that technology soon can deliver on promised benefits (easy handling, similar driving hours & charging/fueling, and high speeds, and ability to operate in complex transport supply chains); flexible and abundant charging points for the rising number of vehicles must be implemented fast and to support this, novel charging concepts are needed. In addition, as multiple needs in the logistics chain exist, require novel tools for fleet managers providing them with better information on ZEV in logistic operation, providing a twin of the real use thereby giving valuable information regarding predictive maintenance, eco-driving etc., providing information on better logistics planning, the (available) charging and refuelling along the route, access to roads and traffic information. ZEFES major outcomes: Executing of real-world demonstrations of long-haul BEVs and FCEVs across Europe to take zero-emission long-haul goods transport in Europe to the next level. Pathway for long-haul BEVs and FCEVs to become more affordable and reliable, more energy efficient, with a longer range per single charge and reduced charging times able to meet the user’s needs. Technologies which can deliver promised benefits (easy handling, similar driving hours & charging/fueling, high speeds and ability to operate in complex transport supply chains). Mapping of flexible and abundant charging/fueling points and novel charging concepts. Novel tools for fleet management to support the rising number of long-haul BEVs and FCEVs vehicles in the logistics supply chains.