Ford is leading an innovation consortium testing hydrogen fuel cell technology on its all-electric E-Transit.

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The trials will explore whether the technology can deliver more zero-emission range to heavy-use E-Transit customers travelling high mileages with maximum loads, including those using ancillary equipment such as chillers and only having limited charging opportunities during working shifts.

The project will develop a low-volume test fleet of eight fuel cell Ford E-Transits that will run for six-month periods over the three-year project to 2025, providing increased range and operating hours to match their diesel-powered equivalents and without the need to charge.

Test fleet data will provide insights into the total cost of owning and operating a large van.

The work, which is part-funded by the Advanced Propulsion Centre (APC), will also help establish the refuelling infrastructure required to support a shift to hydrogen.

The prototype Ford E-Transits will be fitted with a high-power fuel cell stack, in conjunction with significant hydrogen storage capability, optimised for safety, capacity, cost and weight.

Vehicle conversion will be undertaken by Ford Pro, the company’s commercial vehicle and services division, expanding its expertise in the area. This will be supported by engineers and E-Transit specialists from Dagenham and the company’s nearby Dunton Technical Centre, in Essex.

Ford has researched fuel cell technology since the 1990s, developing many prototypes. It demonstrated the first-generation E-Transit fuel cell vehicle at the Cenex Low Carbon Vehicle Show in 2021.

Tim Slatter, chair of Ford in Britain, said:  “Ford believes that the primary application of fuel cells could be in its largest, heaviest CVs to ensure they are emission-free, while satisfying the high daily energy requirements that our customers demand.

“Ford has an unmatched history in the commercial vehicle sector with the indomitable Transit, and we are excited to be exploring new ways to make clean deliveries an option for even our hardest working vans on the road.”

Other partners on the project are BP, which will explore hydrogen usage and infrastructure requirements and Cambustion, which will test the fuel cell system. Viritech is taking part too and is designing the hydrogen storage systems while Cygnet Texkimp is providing the pressure vessels’ carbon fibre tooling.

Ford said the project supports its strategic vision of creating low-volume assembly upfit capability for hydrogen vehicles, with upscaling potential, to add to workforce skills and to develop the hydrogen economy.

The project will also evaluate efficient and viable recycling for end-of-life components.