In the United States (US), Cummins Inc., a global power technology leader, confirmed its commitment at Con Expo in Las Vegas, Nevada (NV) to playing a major role in the hydrogen economy as part of its Destination Zero initiative and the recent launch of Accelera by Cummins, a new brand representing a quickening pace of bringing zero-emissions solutions to market.
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Cummins is a corporation of complementary business segments that design, manufacture, distribute, and service a broad portfolio of power solutions. The company’s products range from internal combustion, electric, and hybrid integrated power solutions to components including filtration, after-treatment, turbochargers, fuel systems, control systems, air handling systems, automated transmissions, electric power generation systems, microgrid controls, batteries, electrolyzers, and fuel cell products.
At the ConExpo/ConAgg 2023 show in Las Vegas, Cummins reaffirmed the company’s commitment to reach net-zero emissions from its products and business by 2050.
This will be achieved by focusing on two key areas:
- Advancing internal combustion engine (ICE) technology while reducing carbon emissions without impacting operations, weight, or uptime;
- Building the broadest combination of zero-emissions technologies dedicated to the commercial vehicle industry, including battery electric and fuel cell electric powertrain solutions and electrolyzers for green hydrogen production.
According to the company, this complementary approach lowers emissions today by matching technology readiness with infrastructure readiness to drive wide-scale adoption using the right technology at the right time.
Our aim is to support our customers on their path to zero carbon emissions. This means meeting them wherever they are on their journey. We are leading the energy transition by providing our customers with the right technology and utilizing our deep understanding of their needs and applications, Eric Neal, Executive Director of Cummins Off-Highway business.
Cummins has the knowledge, expertise, and scale across a range of solutions through growth and acquisitions to continue leading in the off-highway industry today and in the future.
Cummins powers more types of machines and vehicles than anyone else. The breadth of our business across market segments and regions means that we are the ideal partner to help our customers through this transition, Eric Neal said.
Next-generation 15L engine
Cummins showcased its new fuel-agnostic 15-litre engine platform with hydrogen, natural gas, and advanced diesel engines offering low-to-zero carbon fuel capability. The next-generation engine is designed to accelerate the decarbonization of heavy-duty off-highway applications.
Cummins’ all-new platform takes internal combustion to a new level, capable of meeting future ultra-low emission standards, such as EPA Tier 5 and EU Stage 6, together with a low-to-zero carbon fuel capability to help put construction and quarrying sites on a lower cost path to decarbonization, said Antonio Leitao, VP Global Off-highway Engine Business.
The new engine is a clean sheet design that points to the future of diesel: more capability with less environmental impact.
Its high power density sets the standards for heavy-duty performance in key off-road applications including excavators, wheel loaders, drilling rigs, road planning, milling machines, haul trucks, and air compressors.
Innovatively designed hardware provides lower weight with maximum engine durability, even when working on the most challenging jobs
The fuel-agnostic architecture of the 15-litre platform utilizes a common base engine with cylinder heads and fuel systems specifically tailored for it to use carbon-free hydrogen or biomethane (aka renewable natural gas – RNG) with up to a 90 percent carbon reduction.
A key design feature of the new platform is a Double-Overhead-Camshaft (DOHC) realizing significant advances in combustion and thermal efficiency.
Friction losses across the engine design have also been reduced and a sculpted block contributes to weight saving. The DOHC design also enables a more efficient integral engine brake to be accommodated.
The 15-liter has a significant increase in power density with a more compact installation envelope providing equipment manufacturers with the capability to do more with their machines, added Antonio Leitao.
The 15-liter hydrogen engine with direct-injection, lean-burn combustion will be available with ratings from 400-to-530 hp (298-395 kW) and a peak torque of 2600 Nm.
Running on zero-carbon green hydrogen, it can use a 700-bar pressure high-capacity fuel storage system for maximum operating hours between refueling.
The 15-liter advanced diesel features Cummins’s latest XPI ultra-high pressure fuel injection system and will offer a broad power range of 450-to-675 hp (335-503 kW) with an impressive 3000 Nm peak torque.
A hydrogen combustion engine fits in today’s machines, works with today’s transmissions, and integrates seamlessly into the industry’s existing service networks and practices commented Antonio Leitao.
Using B100 biodiesel enables up to a 70 percent reduction in carbon and using renewable diesel achieves up to a 90 percent reduction.
For applications powered by RNG, the 15-litre natural gas will offer ratings extending from 400-to-510 hp (298-380 kW) with a peak torque of 2500 Nm available. Very low noise is a further benefit of this engine, particularly when operating in urban areas.
Moving forward, our aim is to offer the same agnostic capability across the next generation of our current 6.7-litre and 9-litre engine platforms, Antonio Leitao said.
ePowertrain developments
The hydrogen version of Cummins’ fuel-agnostic platform could become the initial step to reaching zero emissions for construction equipment manufacturers.
As a result of Cummins’ acquisition of Meritor last year, Accelera’s product portfolio was broadened to include complementary ePowertrain products and EV powertrain integration capabilities.
We understand that no single solution or path to zero will work for all power needs, which is why we are developing the broadest combination of zero-emission technologies: fuel cells, battery systems, and fuel storage technologies, commented Amy Davis, President of Accelera.
The Electric Central Drive Unit (eCDU) is a remote-mount electric powertrain designed for space-limited off-highway applications. Its innovative architecture enables increased vehicle design flexibility with the ability to be located as needed.
It helps reduce investment in vehicle architecture changes such as hydraulic brakes and driveline parking brakes.
The latest NMC battery, the BP95E, which has a long life and fast charging times, is suitable for compact equipment, particularly those that work in urban environments was also on display. Its modular design means it can be scaled to fit a number of installations based on the changing energy and packaging requirements.
Because of our global service, technical expertise, and ability to optimize the performance of applications, Accelera is in a unique position to help our end customers succeed during the energy transition. Working together with customer partners, we are rapidly evolving our zero-emissions technology to meet the diverse needs of our customers and further our shared goals of lessening our impact on the planet, said Neal Davis.
Hydrogen fuel cell
As a result of acquisitions and investment, Cummins is focusing on three key areas for hydrogen: the production of green hydrogen, the management and transportation of hydrogen, and the application of hydrogen in engines and fuel cells.
Cummins has developed leading power solutions for over a hundred years, and we continue to demonstrate our leadership in developing a broad range of sustainable drivetrains looking to the future – with hydrogen playing a key role. Our strategy is to focus on the complete hydrogen value chain to drive sustainability and enable faster adoption, said Antonio Leitao.
Hydrogen fuel cell (HFC) technology can offer an efficient power solution for heavy-duty vehicles with high utilization and energy demands while meeting zero-emission needs.
The fuel cell uses oxygen to create a reaction, turning the hydrogen into electricity. It works alongside battery technology – ultra-capacitors, lithium-ion, or lead-acid – in a parallel hybrid set-up to deliver an instantaneous response.
We see hydrogen engines and fuel cells as complementary power sources, offering different options to customers depending on where they are on their path to zero carbon. Introducing hydrogen engines in the market will also accelerate the growth of hydrogen infrastructure to support the widespread adoption of fuel cell powertrains, said Antonio Leitao.
Accelera displayed its fourth-generation fuel cell engine at Con Expo which provides improved power density, efficiency, and durability while delivering zero greenhouse gas and zero criteria air emissions.
Well suited to the duty cycle, performance, and packaging requirements of heavy-duty off-highway applications, it is available in single 150 kW and dual 300 kW module engines for heavy-duty off-highway applications.
The fuel cells incorporate variable pressure technology, which provides improved power density, efficiency, and durability, all while delivering a lower total cost of ownership.
Accelera is committed to raising awareness of the flexibility and dependability of hydrogen and fuel cell engines. We are building long-lasting partnerships with our customers based on the shared knowledge that the best power solutions of the future are zero-emissions, said Alison Trueblood, General Manager of Fuel Cell and Hydrogen Technologies for Accelera.
Green hydrogen production
Green hydrogen is produced using electrolysis to turn sustainable power (wind, solar, hydro) into hydrogen with zero carbon dioxide (CO2) emissions. The key tool to do this is an electrolyzer.
Accelera is establishing new electrolyzer plants in La Mancha, Spain, and Minnesota (MN), USA as well as expanding production at Oevel, Belgium, and Mississauga, Canada.
With over 600 electrolyzers deployed globally in 100 countries, Accelera’s investment is growing in this technology.
One of the latest projects includes providing a 35 MW proton exchange membrane (PEM) electrolyzer system for Linde’s new hydrogen production plant in Niagara Falls, New York (NY).
Once commissioned, Accelera’s electrolyzer system will power Linde’s largest green hydrogen plant in the United States.
On display in Las Vegas was Accelera’s 1500E stack which forms part of a 2.5 MW PEM Electrolyzer.
Hydrogen storage and supply
On-board storage is a critical component of hydrogen power. Hydrogen needs to be compressed into the available space to store enough to meet vehicle duty cycle requirements.
Cummins has a joint venture with NPROXX, a world leader in high-pressure hydrogen storage for both stationary and mobile applications, to support the OEM integration process.
Storage tanks will have a 700-bar pressure capability to maximize capacity and operating range.
Supply and infrastructure will take time to develop. Adoption of hydrogen will likely begin with applications where fueling can be done centrally such as at home base operations or close to large hydrogen hubs, ended Antonio Leitao.
