Heavy-Duty & Industrial Hydrogen Fuel Cell Systems

SOLIDHYDRO HYDRA-G series delivers 120–205kW of high-performance PEMFC power for Class 8 trucks, mining haulers, marine vessels and MW-scale stationary power. CAERI type-approved, IP67 protected and engineered for -40°C cold starts.

Heavy-Duty Hydrogen Fuel Cell Power: Diesel, Battery & Emissions Challenges

Long‑Haul Needs 650–1000km

Batteries struggle to meet the range and payload requirements of Class 8 trucks, which can demand 500–800kWh for a single shift. Battery‑electric adds 3–5 tonnes — eating payload. Hydrogen refueling takes 8–20 minutes while avoiding the multi-ton battery payload penalty.

Mining & Construction

Every tonne of battery is a tonne of payload lost. HYDRA-G helps preserve haul capacity with high-power-density fuel cell systems and lightweight 70MPa hydrogen storage.

IMO / Euro VII / EPA

Emissions regulations are tightening across ports, marine transport and heavy-duty vehicles. Hydrogen PEMFC systems produce water at the point of use and can support zero-emission vehicle strategies where applicable.

Extreme-Environment Operation: -40°C to +60°C

Where batteries fail arctic mining. Desert construction. Salt spray. Dust. Vibration. HYDRA‑G operates across all of it. IP67 sealed. MIL‑STD‑810G compliant.

HYDRA-G Series: 120–205kW Heavy-Duty PEMFC Portfolio

HYDRA‑G 120kW

High-efficiency powertrain for heavy-duty fleets

Parameter	Value
Rated Power	120kW (Scalable to 200kW+)
Power Density	510W/kg
Peak Efficiency	61.25%
Dynamic Response	5.1kW/s Ramp‑Up Rate
H₂ Input	70MPa CGH₂
Cooling	Liquid‑Cooled Closed‑Cathode Stack
Protection	IP67 / MIL‑STD‑810G
Certification	CAERI Type Approval
Typical Apps	Class-8 Trucks, Transit Buses, Construction Machinery, Port Vehicles

HYDRA-G 205kW Hydrogen Fuel Cell for Industrial Power

The Metallic-Plate Powerhouse for MW-Scale Stationary Applications

Parameter	Value
Rated Power	205kW (Parallel‑Ready for MW‑Scale)
Gravimetric Density	702W/kg
Volumetric Density	4.71kW/L
H₂ Input	70MPa CGH₂
Output Voltage	330–750V DC
Operating Temp	-40°C to +60°C
Protection	IP67
Integration	Highly Integrated BoP (Air, H₂, Coolant, Control)
Certification	CAERI Type Approval
Typical Apps	Data Centers, Mining Haulers, Marine Vessels, Island Microgrids, MW‑Scale Stationary

Heavy-Duty Hydrogen Fuel Cell Performance Comparison

Feature	HYDRA‑G 120kW	HYDRA‑G 205kW	Industry benchmark (Heavy-Duty PEMFC)	Modular PEMFC Platform
Rated Power	120kW	205kW	120kW	125kW
Gravimetric Density	510W/kg	702W/kg	400W/kg	~350W/kg
Volumetric Density	—	4.71kW/L	2.5kW/L	2.0kW/L
Peak Efficiency	61.25%	—	57%	55%
Cold Start	-40°C	-40°C	-30°C	-25°C
Dynamic Response	5.1kW/s	—	3kW/s	—
Certification	CAERI	CAERI	ISO/SAE	ISO/SAE
Protection	IP67 / MIL‑STD‑810G	IP67	IP6K9K	IP66
BoP Integration	Full (Air, H₂, Coolant)	Highly Integrated	Modular	Modular

Hydrogen Fuel Cell vs. Battery-Electric vs. Diesel: TCO Comparison

Metric	H₂ PEMFC	Battery‑Electric	Diesel
Range	650–1000km	200–400km	800–1200km
Refuel / Recharge	8–20 min	1–8 hours	5–10 min
Payload Impact	Minimal (70MPa tanks)	3–5t penalty	Minimal
Cold Weather	-40°C stable	Capacity loss / slow charge	Requires pre‑heat
Emissions	Zero (H₂O)	Grid‑dependent	CO₂, NOx, PM
Maintenance	Low (few moving parts)	Moderate	High (oil, filters, DPF)
Regulatory	ZEV credits eligible	ZEV credits eligible	Euro VII non‑compliant
TCO Outlook	↓ Declining (H₂ scaling)	↔ Stable	↑ Rising (carbon tax)

Key Application Verticals

Heavy-Duty Hydrogen Fuel Cell Applications

Heavy‑Duty Transport

Class 8 trucks, transit buses, construction machinery. 650–1000km range. 8–20 min refueling. 61.25% peak efficiency.

Marine & MW‑Class Power

Harbor craft, ferries, island grids. Silent, low‑vibration. IP67 salt‑spray protected.

Stationary Power Generation

Data centers, industrial parks, microgrids. 205kW modules parallel to MW‑scale. 48‑hour backup runtime. Zero diesel emissions.

Mining Haul Trucks

Extreme off‑highway environments. 702W/kg power density. MIL‑STD‑810G vibration and salt compliance.

Frequently Asked Questions

Q: Are SOLIDHYDRO systems certified for commercial deployment?

A: Yes. The HYDRA-G 120kW and 205kW platforms have received CAERI type approval, meeting national fuel cell certification requirements for road and industrial use.

Q: How does TCO compare to diesel gensets?

A: While hydrogen fuel cell systems currently have higher upfront costs, their lower maintenance requirements, zero tailpipe emissions and potential fuel-cost reductions can improve total cost of ownership as hydrogen infrastructure scales.

Q: What hydrogen storage is compatible?

A: All systems are engineered for 70MPa CGH₂ and integrate seamlessly with Type IV composite tanks and COPVs.

Q: What hydrogen infrastructure is required?

A: 70MPa CGH₂ refueling stations. For stationary applications, we offer BoP solutions including tube trailers and on‑site compression skids to bridge infrastructure gaps.

Q: How does HYDRA‑G compare to Ballard's FCmove® series?

A: In the 120kW class, the published figures shown here indicate HYDRA-G at 510W/kg versus the benchmark figure of 400W/kg, with a -40°C cold-start target. Ballard has extensive field deployment experience, while HYDRA-G focuses on high power density and extreme-environment operation.

Q: What's the typical lead time for system integration?

A: We provide turnkey engineering support from feasibility study through on‑site commissioning. Typical timelines: 8–14 weeks for single‑unit evaluation, 16–24 weeks for fleet integration. Custom configurations available.

Q: What is a heavy-duty hydrogen fuel cell?

A:A heavy-duty hydrogen fuel cell is a high-power PEMFC system designed to provide continuous electrical power for trucks, buses, mining equipment, marine vessels and stationary applications.

Q:What power range does the HYDRA-G series support?

A: The HYDRA-G series currently covers 120kW and 205kW platforms, with modular configurations available for higher-power and MW-scale applications.

Decarbonize Your Heavy‑Duty Fleet: Start with a Feasibility Study

Complimentary feasibility analysis, BoP sizing, and integration roadmap for trucks, buses, mining haulers, marine vessels, and stationary power plants.

Talk to SOLIDHYDRO

Need technical information, product specifications or application support? Contact our engineering team.