A partnership involving three hydrogen fueling specialists is developing a loss-free service-station delivery system that can serve both trucks and fuel-cell passenger cars.
While launching the initiative at Hydrogen + Fuel Cells Europe conference 2025 in Germany, the partners, Hyroad Energy, Bosch Rexroth and GenH2 Corp, plan to launch the first zero-loss hydrogen refueling station in Dallas, TX, in 2026.
The initiative focuses on the problem of hydrogen boil-off when liquid hydrogen, stored at temperatures of -253 C (-423 F), meets atmospheric temperatures when fueling a vehicle or when filling the storage tanks.
Toyota also is working on reducing boil-off through recycling as part of its fuel-cell and internal-combustion-engine projects, most notably with its “green” racing programs.
The partners intend to deliver a service-station experience that achieves zero-loss of the fuel. The initiative brings together Bosch Rexroth’s Liquid Hydrogen CryoPump technology, GenH2’s Controlled Storage technology and Hyroad Energy’s experience in hydrogen infrastructure development.
The delivery systems are expected to roll out beyond California to other high-demand markets within the U.S.
“The industry has been challenged for too long by significant hydrogen losses during transfer, storage, and refueling,” says Dmitry Serov, CEO and founder of Hyroad Energy. “This project sets a new bar. By combining advanced cryogenic technologies with a seamless system design, our goal is to demonstrate a truly zero-loss refueling station, marking a huge step forward in the commercial viability of hydrogen as a clean energy solution.”
Even with this cost-saving measure, the jury is out on whether hydrogen will impact all transport sectors.
A January report by IDTechEx on the prospects of hydrogen fuel-cell vehicles for last-mile delivery suggests that the longer range and speed of refueling or charging aresignificant advantages for passenger vehicles and heavy-duty trucks, but for light commercial vehicles these are not vital advantages. Privately run fleet depots with charging facilities for these smaller vehicles negates many of the advantages of hydrogen powertrains versus their battery-electric rivals.
The report, titled “Electric Light Commercial Vehicles 2025-2045: Markets, Players, Forecasts,” points out that “an average e-LCV from a major manufacturer will have batteries sized for about 120 miles (193 km) of operation to cover around two days’ worth of mileage. Newer and higher-capacity models are also regularly exceeding this range, providing plenty of operational flexibility.”
Green credentials are another issue for hydrogen-powered LCVs with the type of hydrogen currently available on the open market.
The report points out that more than 95% of the world’s hydrogen production today is of so-called “grey” hydrogen, which is produced through the reformation of methane in natural gas. The result is a fuel source with just as much CO2 emissions output as diesel powertrain.
Conversely, “green” hydrogen, produced through the electrolysis of water using renewable sources of electricity, is significantly more expensive than grey hydrogen and its production hinges on the availability of more renewable energy sources and development in electrolyzer technology. The U.S. and Europe are building out new hydrogen production hubs that have to meet requirements for greater green hydrogen production.
For now, a general lack of green hydrogen production and transport infrastructure remains, leading to low supply and high retail prices in the short-term.
Green hydrogen would have to reach $4/kg ($4/2.2 lb.) in the European market to match the cost of electricity. This figure falls even lower in other global markets, down to $1-2/kg, which is not achievable at scale in the short- or medium-term.
Longer term, the EU, U.S. and China see investments in hydrogen as a way to reduce reliance on fossil fuels, and in the case of the EU, also Russian oil and gas.
With both a higher upfront cost and higher operating costs in the short and medium terms, FCEVs will fall short of BEVs from a cost standpoint without significant government supports,concludes the report
