Last updated: March 2025
The race to decarbonize heavy goods vehicles is accelerating, with both hydrogen and battery technologies vying for dominance. This comprehensive guide examines the future of hydrogen in the HGV sector, comparing operational benefits, infrastructure challenges, and market projections to help fleet operators plan their zero-emission transition.
The Hydrogen HGV Landscape in 2025
The transition to zero-emission heavy goods vehicles represents one of transport’s greatest decarbonization challenges. While battery electric technology dominates the passenger vehicle market, hydrogen offers unique advantages that position it as a key component of future freight transportation.
As of early 2025, hydrogen HGVs remain primarily in demonstration and early commercial deployment. Leading manufacturers are developing two distinct hydrogen powertrain solutions:
Fuel Cell Electric Vehicles (FCEVs)
These vehicles generate electricity on-board using hydrogen and oxygen, powering electric motors with zero tailpipe emissions. UK-based manufacturer HVS recently unveiled a 40-tonne hydrogen-electric HGV with a 370-mile range that refuels in just 20 minutes – comparable to diesel refueling times.
Similarly, Tevva launched the UK’s first hydrogen fuel cell-supported 7.5-tonne HGV in 2022, achieving refueling times between 5 to 20 minutes – a significant operational advantage over battery electric equivalents.
Hydrogen Internal Combustion Engines (HICEs)
Some manufacturers are adapting existing diesel technology to burn hydrogen instead. This approach offers manufacturing simplicity and familiar maintenance procedures but delivers lower efficiency than fuel cells.
According to industry experts, “HICEVs make use of existing combustion and diesel technology: hydrogen is injected into a piston engine and ignited, and the energy released is converted into motion and heat.”
Why Hydrogen Makes Sense for Heavy Transport
Hydrogen fuel cell truck refueling diagram
Several operational characteristics make hydrogen especially attractive for heavy-duty applications:
1. Minimal Operational Disruption
Hydrogen offers a transition path that closely resembles current diesel operations. A hydrogen HGV can be refueled as quickly as a diesel truck and achieves similar operating distances. This operational familiarity makes hydrogen attractive to fleet operators concerned about the productivity impacts of lengthy charging times.
2. Superior Range and Payload Capacity
For long-haul operations, hydrogen’s energy density advantages become significant. Current hydrogen HGVs can achieve ranges up to 370 miles (600km) with quick refueling, addressing two primary concerns with battery-electric alternatives:
Range limitations: Battery electric HGVs typically offer 150-200 miles before requiring recharging
Extended downtime: Electric HGVs require approximately 2.1 hours per day for charging versus 15 minutes for diesel refueling
3. Ideal for Specialized Applications
Certain heavy-duty applications appear particularly well-suited to hydrogen. European demonstration projects show that approximately 25% of hydrogen medium- and heavy-duty trucks currently operating in Europe are used for urban waste collection.
Other promising applications include:
- Regional distribution with high daily mileage
- Temperature-controlled transport requiring significant auxiliary power
- Weight-critical operations where battery weight reduces payload capacity
UK Market Projections: How Big Will Hydrogen Become?
Industry forecasts suggest a significant but not dominant role for hydrogen in the zero-emission HGV transition:
The Advanced Propulsion Centre UK projects that “the UK will manufacture approximately 35,000 HGVs and buses by 2035, with at least 75% of these vehicles expected to produce zero emissions at the tailpipe. Among these, roughly half are predicted to be battery-powered, while a quarter will likely be fuel-cell electric vehicles.”
This represents a £2.4 billion market opportunity in hydrogen components and systems.
European research by Interact Analysis predicts “an accumulated total of 45,000 heavy-duty hydrogen trucks will be deployed in Europe by 2030.” While substantial, this represents a fraction of the total HGV fleet, indicating hydrogen will be one solution among several.
5 Critical Challenges Facing Hydrogen HGVs
UK hydrogen refueling station map
Despite its potential, hydrogen faces significant hurdles that will shape its future role in the HGV sector:
1. Infrastructure Gap
The most immediate challenge is the severe lack of refueling infrastructure. By 2030, the UK would need at least 150–200 strategically located hydrogen refueling stations to service key freight routes and urban hubs, yet currently there are fewer than 20 operational hydrogen refueling stations across the UK.
This chicken-and-egg problem of infrastructure versus vehicle adoption represents the primary barrier to widespread adoption.
2. Green Hydrogen Production
While hydrogen vehicles produce zero tailpipe emissions, the production method determines their overall environmental impact. Current hydrogen production is dominated by blue hydrogen (derived from natural gas with carbon capture). While green hydrogen projects are emerging, these remain in their infancy.
The UK government aims to scale green hydrogen production to 5 GW by 2030, but meeting demand for transportation will require substantial growth.
3. Energy Efficiency
A fundamental challenge for hydrogen is its lower energy efficiency compared to direct electrification. Hydrogen is much more energy intensive than electricity to produce. David Cebon of the Centre for Road Freight Sustainability notes that “hydrogen powered vehicles require three times the amount of electric power generation of electric vehicles.”
4. Economic Viability
The total cost of ownership remains higher than conventional vehicles. A SCALA industry debate concluded that “the total cost of ownership of electric vehicles was less than the cost of running vehicles currently, whilst the opposite applied for hydrogen vehicles which would cost more,” though technological improvements and scale could improve this equation.
5. Limited Model Availability
While manufacturers are investing in hydrogen technology, the variety of available models remains limited compared to both conventional and battery electric alternatives. This restricts adoption to specific use cases where current offerings meet operational requirements.
Government Support Driving Hydrogen Adoption
The UK government has implemented several supportive measures to accelerate hydrogen HGV development:
- The £240 million Net Zero Hydrogen Fund supports production capacity
- Public-private partnerships in industrial clusters develop regional hydrogen ecosystems
- The Zero Emission HGV and Infrastructure Demonstrator programme aims to deploy up to 370 zero-emission HGVs and deliver approximately 57 refueling and electric charging sites
- Regulatory weight allowances accommodate the additional weight of hydrogen systems
International collaboration through initiatives like H2Accelerate brings together major industry players including bp, Daimler Truck AG, Iveco Group, Linde, Shell, TotalEnergies, and Volvo Group to accelerate hydrogen truck deployment.
The Future: A Multi-Technology Approach
Rather than a single winning technology, evidence suggests the future HGV market will feature multiple zero-emission solutions based on specific operational needs:
Battery electric vs hydrogen truck application chart
As Asher Bennett, Tevva founder and CEO, notes: “We firmly believe that the post-fossil fuel future, which is quickly approaching, will see a range of technologies and fuels take centre stage in the transport industry.”
By 2030-2035, hydrogen HGVs will likely represent approximately 25% of new zero-emission heavy vehicles, with battery electric technologies capturing a larger share.
This mixed technology approach allows the industry to leverage unique strengths of each solution while addressing varied operational requirements:
Best applications for hydrogen HGVs:
- Long-haul routes (300+ miles daily)
- Operations requiring minimal downtime
- Weight-sensitive transportation
- Specialized heavy-duty applications
Best applications for battery electric HGVs:
- Urban delivery (under 150 miles daily)
- Return-to-depot operations with overnight charging
- Fixed routes with predictable energy requirements
- Applications where maximum torque delivery is beneficial
What This Means for Fleet Operators
For fleet managers planning their zero-emission transition, this mixed-technology future requires careful consideration:
- Assess your operational profile: Analyze route distances, payload requirements, and downtime tolerance to determine which technology best suits specific applications
- Consider pilot projects: Small-scale trials of both technologies can provide valuable real-world data specific to your operations
- Plan for infrastructure needs: Depot charging infrastructure offers short-term viability for electric HGVs, while hydrogen adoption may require partnerships with refueling providers
- Monitor policy developments: Government incentives, infrastructure investments, and regulatory frameworks will significantly influence the economic case for each technology
- Adopt a phased approach: Begin transitioning applications best suited to current technology while maintaining flexibility for future developments
Conclusion: Hydrogen’s Place in a Zero-Emission Future
The future of hydrogen in HGVs appears substantial but not universal. The technology offers compelling advantages in range, refueling time, and operational similarity to diesel that make it attractive for specific segments of the HGV market.
However, challenges in infrastructure development, production efficiency, and cost competitiveness suggest it will be part of a diversified approach to freight decarbonization rather than a complete solution.
While not the single answer to freight decarbonization, hydrogen will undoubtedly play a crucial role in the zero-emission heavy transport ecosystem of the future. Fleet operators who understand the strengths and limitations of both hydrogen and battery technologies will be best positioned to navigate the transition successfully.
