Hacking the Internal Combustion Engine: Why H2-ICE is the Real Solution for Heavy-Duty Ops

Source: Dev.to

Energy Density Simulation: Diesel vs. Li‑Ion vs. Hydrogen

# Energy Density Simulation: Diesel vs. Li-Ion vs. Hydrogen
# Why Batteries (BEV) fail for Heavy Duty Machinery

def calculate_weight_penalty(target_energy_kwh):
    # Energy Densities (approximate usable)
    energy_density = {
        "Diesel": 12.6,   # kWh/kg
        "Hydrogen": 33.3, # kWh/kg (Upper heating value)
        "Li-Ion": 0.25    # kWh/kg (Pack level)
    }

    print(f"--- Required Mass for {target_energy_kwh} kWh Mission ---")

    for fuel, density in energy_density.items():
        weight = target_energy_kwh / density
        print(f"{fuel}: {round(weight, 2)} kg")

# A typical heavy excavator uses ~1000 kWh in a hard shift
calculate_weight_penalty(1000)

Output

• Diesel: ~79 kg (manageable tank)
• Hydrogen: ~30 kg (fuel only, not including tanks)
• Li‑Ion: ~4 000 kg (a massive 4‑ton battery!)

Adding several tons of deadweight to a machine destroys its efficiency, which is why firms are pivoting to H2‑ICE.

The Patch: How H2‑ICE Works

The Toyota Strategy: Keeping the Supply Chain Alive

• Low Barrier to Entry – Existing engine plants can be used; no need for new factories.
• Reliability – Over a century of data on piston engines.
• Sound – Retains the characteristic engine noise that enthusiasts appreciate.

Toyota is testing H2‑ICE in the GR Yaris H2 and the Corolla Cross H2 Concept, demonstrating a pragmatic approach to hydrogen adoption.

The JCB Strategy: Construction Realities

JCB found electric excavators impractical for remote sites lacking grid power. Their solution:

• Developed a 4.8 L hydrogen combustion engine delivering the same torque as diesel units.
• Emits only water vapor (steam) as exhaust.

Engineering Challenges (The “Refactoring”)

Embrittlement

Hydrogen can cause metal brittleness, requiring new alloys for engine blocks and fuel system components.

Pre‑ignition

Hydrogen burns roughly ten times faster than gasoline, increasing the risk of knocking. Precise control of ignition timing and mixture is essential.

NOx Emissions

While H2 produces no CO₂, high combustion temperatures can form NOx. Mitigation strategies include:

• Lean‑burn operation (air‑fuel ratio λ > 2) to keep temperatures down.
• Selective catalytic reduction (SCR) catalysts for post‑combustion treatment.

For a detailed breakdown of thermal efficiency and JCB’s specific modifications, see the comprehensive analysis on Hydrogen Combustion Engines (H2‑ICE) Strategy.

Why H2‑ICE Wins for Heavy Industry

• Durability – Combustion engines tolerate dust, vibration, and heat better than delicate electronics and batteries.
• Cost – Leveraging existing manufacturing lines is cheaper than building fuel‑cell systems that rely on expensive platinum catalysts.

Conclusion

Adopting H2‑ICE isn’t about clinging to the past; it’s about choosing the most efficient path toward a carbon‑neutral future for heavy‑duty operations.