Periodic Reporting for period 1 - H2MAC (Hydrogen fuel cell electric non-road mobile MAChinery for Mining And Construction: An innovative, efficient, scalable, silent and modular power-train concept)
Okres sprawozdawczy: 2024-01-01 do 2025-06-30
The European Union (EU) is committed to achieving climate neutrality by 2050 under the European Green Deal, with an interim target of a 40% reduction in greenhouse gas (GHG) emissions by 2030 compared to 1990 levels. Progress has been made, with emissions reduced by 28.3% between 1990 and 2019, largely due to renewables, energy efficiency, and structural economic shifts. However, transport and Non-Road Mobile Machinery (NRMM) remain significant sources of emissions.
NRMM—including construction, mining, and agricultural equipment—contributes disproportionately to air pollution, emitting CO, NOx, particulate matter, and volatile organic compounds (VOCs). Hydrogen fuel cells (FCs) offer a scalable, high-power, zero-emission solution, particularly for heavy-duty sectors where batteries are insufficient. Decarbonizing large equipment is essential, and hydrogen-based technologies provide a strategic pathway to reduce emissions, protect public health, and strengthen EU industrial competitiveness.
The H2MAC project focuses on the design and demonstration of two hydrogen fuel cell (FC)-powered non-road mobile machinery (NRMM) prototypes for mining and construction applications, namely: an excavator and a shredder. Both machines will integrate modular FC powertrains, with the excavator employing a single module and the shredder utilizing two modules, for scalability demonstration.
The primary objective is to validate the reliability, durability, and scalability of complete FC powertrain systems under harsh environmental conditions and in contexts with limited grid access. To this end, a simultaneous 1,000-hour demonstration of both machines in a quarry (real-environment) is foreseen.
The demonstrations will also support regulatory and standardization activities, paving the way for hydrogen FC technology adoption in broader NRMM applications.
Anticipated impacts include substantial greenhouse gas reductions (≥30 tons CO2-eq/year for the excavator and 138.4 tons CO2-eq/year for the shredder), optimized hydrogen consumption (2.54 tonnes/year and 11.78 tonnes/year, respectively), and significant noise reduction (up to –11 dB(A)).
To achieve these objectives, the project will develop a robust balance-of-plant (BoP) tailored to extreme construction and mining conditions (e.g. vibration, dust, mud). Novel protective and conditioning systems will be engineered, validated virtually, tested in laboratories, and subjected to accelerated life testing. Special emphasis will be placed on vibration isolation and high particle concentration resilience.
Finally, H2MAC will address the current lack of hydrogen-related NRMM standards by contributing to the development of interoperable and transparent practices, with active participation in the standardization technical committees CEN/CLC/JTC 6 (ISO/TC 197), CLC/SR 105 (IEC/TC 105) and CEN/TC 151 (ISO/TC 127). The project will establish a foundation for the commercial deployment of FC-powered NRMM, thereby accelerating hydrogen technology adoption across off-road industry sectors.
NRMM—including construction, mining, and agricultural equipment—contributes disproportionately to air pollution, emitting CO, NOx, particulate matter, and volatile organic compounds (VOCs). Hydrogen fuel cells (FCs) offer a scalable, high-power, zero-emission solution, particularly for heavy-duty sectors where batteries are insufficient. Decarbonizing large equipment is essential, and hydrogen-based technologies provide a strategic pathway to reduce emissions, protect public health, and strengthen EU industrial competitiveness.
The H2MAC project focuses on the design and demonstration of two hydrogen fuel cell (FC)-powered non-road mobile machinery (NRMM) prototypes for mining and construction applications, namely: an excavator and a shredder. Both machines will integrate modular FC powertrains, with the excavator employing a single module and the shredder utilizing two modules, for scalability demonstration.
The primary objective is to validate the reliability, durability, and scalability of complete FC powertrain systems under harsh environmental conditions and in contexts with limited grid access. To this end, a simultaneous 1,000-hour demonstration of both machines in a quarry (real-environment) is foreseen.
The demonstrations will also support regulatory and standardization activities, paving the way for hydrogen FC technology adoption in broader NRMM applications.
Anticipated impacts include substantial greenhouse gas reductions (≥30 tons CO2-eq/year for the excavator and 138.4 tons CO2-eq/year for the shredder), optimized hydrogen consumption (2.54 tonnes/year and 11.78 tonnes/year, respectively), and significant noise reduction (up to –11 dB(A)).
To achieve these objectives, the project will develop a robust balance-of-plant (BoP) tailored to extreme construction and mining conditions (e.g. vibration, dust, mud). Novel protective and conditioning systems will be engineered, validated virtually, tested in laboratories, and subjected to accelerated life testing. Special emphasis will be placed on vibration isolation and high particle concentration resilience.
Finally, H2MAC will address the current lack of hydrogen-related NRMM standards by contributing to the development of interoperable and transparent practices, with active participation in the standardization technical committees CEN/CLC/JTC 6 (ISO/TC 197), CLC/SR 105 (IEC/TC 105) and CEN/TC 151 (ISO/TC 127). The project will establish a foundation for the commercial deployment of FC-powered NRMM, thereby accelerating hydrogen technology adoption across off-road industry sectors.
During the first reporting period, the H2MAC project has made substantial progress in the design and development of fuel cell-based non-road mobile machinery (FC-NRMM).
First, the work was focused on the definition of the FC-powertrain requirements for the selected applications (WP1), taking data from state-of-the art excavators and shredders as a reference.
Next, the efforts shifted towards the technical design of the H2MAC concept, addressing simultaneously the following key aspects:
(1) Conceptualization and digitalization of the zero-emission electric machines (including the novel FC-powertrain and auxiliary subsystems) by developing the corresponding digital twins, as a decision-making supporting tools for design and optimization (e.g. components sizing, energy management strategies, noise reduction solutions).
(2) Development of critical components of the powertrain for the expected harsh environment: (2.1) a fuel cell module has been designed with improved vibration resistance and ingress protection; and (2.2) a novel air filtration system capable of handling extreme dust loads and harmful gases has been designed and validated; (2.3) dedicated vibration isolation systems are being designed based on field data.
(3) The regulatory and standardization dimension of the project has also advanced, with a comprehensive assessment of applicable requirements and initial contributions to European standardization committees, thereby laying the groundwork for future acceptance of hydrogen-powered machinery.
First, the work was focused on the definition of the FC-powertrain requirements for the selected applications (WP1), taking data from state-of-the art excavators and shredders as a reference.
Next, the efforts shifted towards the technical design of the H2MAC concept, addressing simultaneously the following key aspects:
(1) Conceptualization and digitalization of the zero-emission electric machines (including the novel FC-powertrain and auxiliary subsystems) by developing the corresponding digital twins, as a decision-making supporting tools for design and optimization (e.g. components sizing, energy management strategies, noise reduction solutions).
(2) Development of critical components of the powertrain for the expected harsh environment: (2.1) a fuel cell module has been designed with improved vibration resistance and ingress protection; and (2.2) a novel air filtration system capable of handling extreme dust loads and harmful gases has been designed and validated; (2.3) dedicated vibration isolation systems are being designed based on field data.
(3) The regulatory and standardization dimension of the project has also advanced, with a comprehensive assessment of applicable requirements and initial contributions to European standardization committees, thereby laying the groundwork for future acceptance of hydrogen-powered machinery.
The expected key impacts of the project results are:
1 - H2MAC demonstration for NRMM emissions reduction
2 - H2MAC will improve operational costs by reducing hydrogen consumption
3 - Noise reduction of H2MAC solutions for a better surrounding environment
4 - Improved FC power system lifetime
5 - Reduced FC module CAPEX
6 - Extended FC module availability
7 - Improved vibration protection
8 - Improved filtering assets for enhanced system lifetime
9 – Development of solutions technically feasible and commercially viable
10 - Development of new RCS to increase project impacts
1 - H2MAC demonstration for NRMM emissions reduction
2 - H2MAC will improve operational costs by reducing hydrogen consumption
3 - Noise reduction of H2MAC solutions for a better surrounding environment
4 - Improved FC power system lifetime
5 - Reduced FC module CAPEX
6 - Extended FC module availability
7 - Improved vibration protection
8 - Improved filtering assets for enhanced system lifetime
9 – Development of solutions technically feasible and commercially viable
10 - Development of new RCS to increase project impacts