Mahle Powertrain has achieved a major milestone in Project Cavendish, successfully converting a 13-liter heavy-duty engine to run purely on hydrogen. The converted engine has matched the maximum torque of the diesel baseline engine, and measured engine-out NOX suggests that emissions can be readily maintained below 0.2g/kWh across the entire engine operating map using existing aftertreatment technology.
Launched in early 2023, Project Cavendish is a £9.8m (US$13.2m) program supported by the Advanced Propulsion Centre UK (APC) to develop end-to-end hydrogen powertrain capability for heavy-duty applications and enable the UK’s transition to net zero transportation. As part of the project, Mahle Powertrain has upgraded its testing infrastructure in Northampton for hydrogen operation.
“This milestone demonstrates that hydrogen combustion has a place as a clean fuel in the heavy-duty market,” said Jonathan Hall, head of research and advanced engineering at Mahle Powertrain. “Achieving the target torque and low raw engine-out emissions from a hydrogen-fueled 13-liter heavy-duty engine represents a significant step forward, both for Mahle Powertrain and for the wider industry, as we move toward practical hydrogen combustion solutions for heavy-duty applications.”
Achieving target torque is just the first step, says Mahle; the bigger challenge in hydrogen combustion is controlling NOX emissions. The measured raw engine-out emissions of its converted engine are very low and the addition of a simple selective catalytic reduction (SCR) aftertreatment system will enable the tailpipe emissions to be significantly less than EU VII limits. The measured particulate emissions were negligible and readily manageable using existing particulate filter technology. The results demonstrate that hydrogen combustion engines offer a practical, fast-to-market pathway toward zero-carbon heavy-duty transportation.
Project Cavendish also aims to facilitate wider hydrogen adoption by creating opportunities for external partners to undertake hydrogen engine testing at Mahle Powertrain’s facility in Northampton. The site serves as a center of excellence for the design, development, calibration and testing of all aspects of hydrogen and renewable-fuel powertrain engineering. Mahle Powertrain has reported growing interest from new customers and expects commercialization of its hydrogen and renewable fuels infrastructure to expand significantly over the coming year.
The project brings together expertise from Mahle Powertrain, Phinia, BorgWarner, Cambustion, Hartridge and Oxford Brookes University to deliver the next generation of hydrogen combustion technology.
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