Periodic Reporting for period 3 - CoacHyfied (Coaches with hydrogen fuel cell powertrains for regional and long-distance passenger transport with energy optimized powertrains and cost optimized design – “CoacHyfied”)
Reporting period: 2023-01-01 to 2024-06-30
CoacHyfied addressed one of the key challenges in achieving climate-neutral mobility in Europe: the decarbonisation of long-distance and regional coach transport. While electrification has advanced significantly in urban mobility, coach transport—particularly for intercity and tourist routes—remains heavily reliant on diesel due to high demands on range, speed, comfort, and payload. This project tackled the technical and operational barriers to deploying fuel cell (FC) electric coaches as a sustainable alternative.
The issue is particularly important for society as long-distance passenger transport contributes significantly to greenhouse gas emissions and air pollution. Transitioning coaches to zero-emission technologies supports EU climate targets, improves public health, and fosters the deployment of hydrogen infrastructure, which is central to Europe’s broader energy transition strategy.
CoacHyfied aimed to demonstrate that FC electric coaches can match diesel performance while significantly reducing environmental impact. Its objectives included:
• Developing hybrid FC/battery powertrains with minimum 100 kW net FC output.
• Achieving up to 100 km/h driving speeds and at least 400 km range per refuelling.
• Integrating FC systems and hydrogen storage into both newly developed and retrofitted coaches.
• Demonstrating six vehicles in real-world conditions across two European regions (southern France and Latvia).
• Validating technical, operational, economic, and environmental performance in diverse contexts.
The project made substantial progress in system design, simulation-based optimisation, and component integration. Key results include validated powertrain models, advanced thermal management strategies, and hydrogen storage concepts. However, due to external constraints, the project was suspended and terminated in April 2024 before the demonstration phase could begin. Despite this, the work delivered by CoacHyfied lays critical groundwork for future zero-emission coach deployments across Europe.
The issue is particularly important for society as long-distance passenger transport contributes significantly to greenhouse gas emissions and air pollution. Transitioning coaches to zero-emission technologies supports EU climate targets, improves public health, and fosters the deployment of hydrogen infrastructure, which is central to Europe’s broader energy transition strategy.
CoacHyfied aimed to demonstrate that FC electric coaches can match diesel performance while significantly reducing environmental impact. Its objectives included:
• Developing hybrid FC/battery powertrains with minimum 100 kW net FC output.
• Achieving up to 100 km/h driving speeds and at least 400 km range per refuelling.
• Integrating FC systems and hydrogen storage into both newly developed and retrofitted coaches.
• Demonstrating six vehicles in real-world conditions across two European regions (southern France and Latvia).
• Validating technical, operational, economic, and environmental performance in diverse contexts.
The project made substantial progress in system design, simulation-based optimisation, and component integration. Key results include validated powertrain models, advanced thermal management strategies, and hydrogen storage concepts. However, due to external constraints, the project was suspended and terminated in April 2024 before the demonstration phase could begin. Despite this, the work delivered by CoacHyfied lays critical groundwork for future zero-emission coach deployments across Europe.
Throughout the project duration, CoacHyfied advanced the design and virtual validation of key subsystems for hydrogen fuel cell coaches, despite its premature termination in April 2024 prior to the demonstration phase.
WP1 “FC coach operation and management system” successfully delivered a hybrid energy management architecture for fuel cell coaches, with interfaces defined between FC, battery, and H2 systems (D1.1). Health and diagnostic indicators (D1.2) were evaluated and an optimised rule-based energy manager was implemented (D1.3) supporting predictive control strategies and energy-efficient operation across the full state-of-charge range.
WP2 “H2 fuel system” completed a comparative analysis of 350 and 700 bar storage architectures for long- and medium-range coaches. Detailed system designs were developed for both use cases (D2.1–D2.3) including vessel selection, frame integration and balance-of-plant components. Safety considerations, packaging feasibility and supply chain issues were also addressed.
WP3 “Thermal management” defined a thermal system concept optimised for energy efficiency in cold climates, leveraging FC waste heat for cabin heating. The TMS design was validated virtually using digital models of both coach configurations, demonstrating >20% reduction in hydrogen consumption compared to conventional approaches (D3.4).
WP4 “Vehicle certification” analysed the evolving regulatory framework, focusing on the shift from EC79 to UN Regulation No. 134 (R134) and its implications for system and vehicle-level certification. Certification strategies, risk assessment protocols and safety validation procedures were documented (D4.1–D4.6) including a comprehensive Safety Plan.
WP5 “Business models and market development strategy” collected operator needs and market data through stakeholder interviews and questionnaires. A techno-economic analysis of FC coaches versus diesel alternatives was carried out (D5.1–D5.2) including input from operators in Latvia, France, the Netherlands, and the UK.
WP6 “Long distance FC coach demonstration” completed component selection and packaging studies for a newly built coach by OTOKAR. Layouts for FC stacks, batteries, e-motor and auxiliary systems were developed. However, integration and commissioning of the full drivetrain could not be completed due to the project suspension.
WP7 “Regional FC coach demonstration” defined the technical framework for retrofitting regional coaches, comparing high-floor and low-floor vehicle platforms. Operator engagement and feasibility analyses informed the final selection of the retrofit candidate. Integration activities were prepared but not executed.
WP8 “Project management, dissemination & exploitation” ensured overall coordination, risk monitoring, and knowledge sharing. The project held regular GA and advisory board meetings, maintained SharePoint-based collaboration tools, and disseminated progress through its website and LinkedIn presence. Dissemination was limited in scope due to the early termination.
WP1 “FC coach operation and management system” successfully delivered a hybrid energy management architecture for fuel cell coaches, with interfaces defined between FC, battery, and H2 systems (D1.1). Health and diagnostic indicators (D1.2) were evaluated and an optimised rule-based energy manager was implemented (D1.3) supporting predictive control strategies and energy-efficient operation across the full state-of-charge range.
WP2 “H2 fuel system” completed a comparative analysis of 350 and 700 bar storage architectures for long- and medium-range coaches. Detailed system designs were developed for both use cases (D2.1–D2.3) including vessel selection, frame integration and balance-of-plant components. Safety considerations, packaging feasibility and supply chain issues were also addressed.
WP3 “Thermal management” defined a thermal system concept optimised for energy efficiency in cold climates, leveraging FC waste heat for cabin heating. The TMS design was validated virtually using digital models of both coach configurations, demonstrating >20% reduction in hydrogen consumption compared to conventional approaches (D3.4).
WP4 “Vehicle certification” analysed the evolving regulatory framework, focusing on the shift from EC79 to UN Regulation No. 134 (R134) and its implications for system and vehicle-level certification. Certification strategies, risk assessment protocols and safety validation procedures were documented (D4.1–D4.6) including a comprehensive Safety Plan.
WP5 “Business models and market development strategy” collected operator needs and market data through stakeholder interviews and questionnaires. A techno-economic analysis of FC coaches versus diesel alternatives was carried out (D5.1–D5.2) including input from operators in Latvia, France, the Netherlands, and the UK.
WP6 “Long distance FC coach demonstration” completed component selection and packaging studies for a newly built coach by OTOKAR. Layouts for FC stacks, batteries, e-motor and auxiliary systems were developed. However, integration and commissioning of the full drivetrain could not be completed due to the project suspension.
WP7 “Regional FC coach demonstration” defined the technical framework for retrofitting regional coaches, comparing high-floor and low-floor vehicle platforms. Operator engagement and feasibility analyses informed the final selection of the retrofit candidate. Integration activities were prepared but not executed.
WP8 “Project management, dissemination & exploitation” ensured overall coordination, risk monitoring, and knowledge sharing. The project held regular GA and advisory board meetings, maintained SharePoint-based collaboration tools, and disseminated progress through its website and LinkedIn presence. Dissemination was limited in scope due to the early termination.
CoacHyfied aimed to overcome the critical limitations of existing FC bus technology and apply it to long-distance and regional coach transport—an area not yet addressed by commercial zero-emission solutions. By targeting performance benchmarks equivalent to diesel coaches in terms of range, speed, and comfort, the project tackled a key barrier to the decarbonisation of intercity mobility.
Significant progress was made on several fronts:
1. Powertrain integration and energy optimisation: A hybrid FC/battery system architecture with predictive energy management was developed and validated in simulation, enabling high efficiency and operational flexibility for coach use.
2. Hydrogen storage systems: CoacHyfied delivered a dual-pathway system design (350 bar and 700 bar) optimised for modular range targets (≥400 km and ≥600 km), with packaging and cost-performance trade-offs clearly identified.
3. Thermal system innovation: The project demonstrated a novel thermal management concept that repurposes FC waste heat for cabin conditioning, improving winter range and reducing overall H2 consumption.
4. Data-driven fleet operation: Foundations were laid for predictive maintenance and digital fleet management by specifying SoH indicators, standardised interfaces, and diagnostic frameworks.
5. Certification readiness: The project provided a roadmap for the certification of hydrogen coaches under the updated R134 regulation, including risk mitigation strategies and component-level safety validations.
Although CoacHyfied could not complete vehicle integration or real-world demonstrations, the technical groundwork and validated models it delivered provide valuable resources for future R&D and market uptake. These results directly support the EU’s climate goals, contribute to industrial competitiveness in the hydrogen mobility sector, and help unlock the deployment of zero-emission long-distance transport solutions.
Significant progress was made on several fronts:
1. Powertrain integration and energy optimisation: A hybrid FC/battery system architecture with predictive energy management was developed and validated in simulation, enabling high efficiency and operational flexibility for coach use.
2. Hydrogen storage systems: CoacHyfied delivered a dual-pathway system design (350 bar and 700 bar) optimised for modular range targets (≥400 km and ≥600 km), with packaging and cost-performance trade-offs clearly identified.
3. Thermal system innovation: The project demonstrated a novel thermal management concept that repurposes FC waste heat for cabin conditioning, improving winter range and reducing overall H2 consumption.
4. Data-driven fleet operation: Foundations were laid for predictive maintenance and digital fleet management by specifying SoH indicators, standardised interfaces, and diagnostic frameworks.
5. Certification readiness: The project provided a roadmap for the certification of hydrogen coaches under the updated R134 regulation, including risk mitigation strategies and component-level safety validations.
Although CoacHyfied could not complete vehicle integration or real-world demonstrations, the technical groundwork and validated models it delivered provide valuable resources for future R&D and market uptake. These results directly support the EU’s climate goals, contribute to industrial competitiveness in the hydrogen mobility sector, and help unlock the deployment of zero-emission long-distance transport solutions.