Cummins and its technology partners have completed a major hydrogen internal combustion engine (H2-ICE) development project for commercial vehicles. The project, known as ‘Project Brunel,’ was led by Cummins in collaboration with Johnson Matthey, PHINIA, and Zircotec, with match-funding from the UK government and support from the Advanced Propulsion Centre UK (APC).
The consortium successfully delivered a 6.7-litre hydrogen engine for medium-duty trucks and buses, based on Cummins’ proven spark-ignited platform. The engine features new hydrogen fuel injection technology from PHINIA, after-treatment catalyst and advanced metals chemistry development from Johnson Matthey, and hydrogen barrier coatings from Zircotec, improving both performance and durability.
Using zero-carbon hydrogen fuel, the engine achieves over a 99% reduction in tailpipe carbon emissions and ultra-low NOx compared to the Euro VI diesel standard. Hydrogen internal combustion technology is seen as a viable solution for heavier-duty and longer-range applications, offering a familiar powertrain option without requiring full vehicle redesigns.
Jonathan Atkinson, executive director – product strategy at Cummins, said, “Project Brunel highlights the power of collaboration between industry leaders and underscores our ongoing commitment to industry decarbonisation. This project has successfully delivered a viable, familiar power option that meets the operating requirements of today’s commercial vehicles – with zero-carbon fuel, and without the need for a complete vehicle redesign. This is a major achievement for Cummins Darlington, and for the UK’s hydrogen technology leadership. We hope the government recognises this technology’s potential for commercial vehicles beyond 2035 and 2040, to align regulation with other major global markets.”
At an event held at Cummins’ Darlington facility, project partners presented key findings and discussed how H2-ICE technology could accelerate the decarbonisation of commercial transport.
Matt Shillito, senior project delivery lead at APC, said, “Project Brunel has built on the UK’s already world-leading capability in manufacturing engines and associated systems and has shown how this industry sector and the skilled jobs it supports can evolve to provide new solutions using zero-carbon hydrogen fuel. These products together can help accelerate the decarbonisation journey for vehicle operators.
“The project investment from the Department for Business and Trade, delivered through the APC, offered a significant opportunity for the UK to create a high-value H2-ICE manufacturing base and a competitive export business. It has been a pleasure working with the consortium on this project, and we look forward to seeing success in the market for all the partners.”
Tauseef Salma, chief technology officer – clean air at Johnson Matthey, added, “H2-ICE is a ready to go, near net zero option in the powertrain toolbox to decarbonise the medium and heavy-duty transport sector. JM proudly pioneered automotive emissions control catalysts and has since invested decades of research and development into minimising harmful pollutants that enter the atmosphere. We are proud to have applied this expertise in Project Brunel which demonstrates how the industry can come together to increase the commercial viability of H2-ICE technology.”
Dr. Simon Godwin, vice president of government affairs at PHINIA, commented, “Project Brunel has enabled us to accelerate the development of hydrogen injectors by cooperation with industry peers and by leveraging our own investment with government support. The project strengthens the UK ecosystem for hydrogen combustion engines and promotes the development and manufacture of this important decarbonisation technology in the UK.”
While the 6.7-litre engine is designed for medium-duty applications, its design is scalable to heavy-duty vehicles, including construction and agricultural machinery. Cummins is already working on a 15-litre hydrogen internal combustion engine for heavier applications.
Cummins has also invested over £13 million in a new Powertrain Test Facility at its Darlington Campus to support the development of advanced diesel, natural gas, hydrogen, and battery-electric powertrains across multiple industries.
