Whereas battery autos usually seize the headlines, the inner combustion engine continues to be a significant a part of the power transition within the off-highway sector, with environment friendly diesel, dual-fuel, hydrogen combustion and hybrid options being developed
As the development and mining industries search to cut back their carbon footprint, producers are creating revolutionary engine applied sciences that preserve energy and reliability whereas slicing emissions. From dual-fuel hydrogen options to full hydrogen combustion engines, these developments are accelerating the transition to zero-emissions in off-highway purposes.
Volvo Penta and CMB are collaborating on a dual-fuel hydrogen resolution for each land and marine purposes. This partnership builds on profitable pilot tasks courting again to 2017, throughout which Volvo Penta engines have been tailored to run on each hydrogen and diesel utilizing CMB know-how.
The brand new collaboration leverages Volvo Penta’s established Stage V D8 engine platform, enhanced with CMB’s hydrogen injection system. Hydrogen is launched from storage tanks, dropped at low stress, and injected into the engine’s air consumption. This reduces the quantity of diesel required to provide the identical power output, lowering CO2 emissions whereas sustaining efficiency. “The entire Volvo Group is working intensively to discover options to cut back, and finally get rid of, greenhouse fuel emissions,” says Heléne Mellquist, president of Volvo Penta. “We’re teaming up with suppliers, companions, and clients to speed up the journey into fossil-free fuels for each on land and at sea purposes.”
A bonus of the dual-fuel resolution is its fallback functionality. If hydrogen is just not accessible, the appliance can proceed operating on conventional gasoline. This makes it notably appropriate as a transitional know-how whereas hydrogen infrastructure develops. “It is a resolution the place you utilize hydrogen and diesel together,” says Ann Parmar, VP advertising at Volvo Penta. “It’s not the complete hydrogen engine, the place you should construct it from scratch.”
“From the preliminary dual-fuel know-how tasks we have now seen reductions of CO2 emissions as much as 80%” says Roy Campe, CTO of CMB. “It’s clear that the power transition is a significant problem in lots of forms of purposes. With the dual-fuel know-how we have now been creating over the previous couple of years, we are able to present an economical and sturdy resolution for a wide range of purposes.”
Full hydrogen combustion
Whereas Volvo Penta focuses on dual-fuel know-how, JCB is taking a unique strategy with its £100 million funding in absolutely hydrogen-powered combustion engines. After three years of improvement by a workforce of 150 engineers, JCB not too long ago introduced the official certification for its engine for business use in 11 European nations. “It’s a important second for JCB,” says JCB chairman Lord Bamford. “To start out 2025 with certification in place in so many European nations bodes very effectively for the way forward for hydrogen combustion know-how. JCB has proved lately that it’s a correct zero emissions resolution for a variety of development and agricultural autos.”
JCB has already produced over 130 analysis engines powering backhoe loaders, Loadall telescopic handlers and generator units. Furthermore, 2024 noticed over 50,000 hours of hydrogen engine testing. JCB additionally accomplished greater than 25,000 km of on-road testing on the request of the UK Authorities to reveal that hydrogen-powered machines are secure to be used on British roads.
“5 years in the past, hydrogen combustion engine know-how was not even on the radar, and now it’s being authorised and endorsed by governments. That is actually outstanding, however it is just the start,” says JCB’s group director for particular tasks, Tim Burnhope.
Pathways to sustainability
Liebherr is pursuing a number of avenues for lowering emissions in off-highway purposes together with an expanded diesel engine portfolio, superior hydrogen engine improvement, and analysis into ammonia instead gasoline.
At Bauma 2025, Liebherr unveiled its new D9612 diesel engine, delivering a most energy output of 950kW for demanding off-road purposes, notably specializing in agricultural equipment. The corporate additionally showcased revolutionary know-how like its hydraulic air boosting system which improves engine dynamics and effectivity. “In our machines, we transmit energy utilizing pressurised hydraulic fluid,” says Bouzid Seba, head of pre-development at Liebherr Machines Bulle. “Sure actions require the discharge of stress, which ends up in power loss. Our innovation doesn’t solely permit to recuperate and retailer this power, but in addition to make use of it subsequently on demand in our hydraulic air booster. When wanted, the air booster pushes giant portions of air into the motor to assist it ship energy rapidly,.
Liebherr’s elements product phase has additionally invested considerably in hydrogen engine improvement and testing amenities. Since 2020, prototype engines have undergone rigorous testing, and the corporate is at the moment evaluating completely different injection and combustion applied sciences. This contains port gasoline injection (PFI) and direct injection (DI).
To future-proof its portfolio additional, Liebherr showcased an idea ammonia engine at Bauma 2025. Inexperienced ammonia serves as a hydrogen service, providing diminished transportation and storage prices. The corporate means that mills and off-highway powertrains fuelled by inexperienced ammonia might present low- or zero-emission options, notably for mining.
Hybrid energy enlargement
Caterpillar Industrial Energy Methods is advancing its electrification technique with the introduction of its Sequence Hybrid Energy Growth powertrain, combining diesel-electric and battery know-how to optimise energy effectivity and scale back emissions.
Additionally launched at Bauma, the brand new powertrain operates via an built-in system the place a Cat engine drives a generator to transform mechanical power into electrical energy. An inverter then manages energy distribution from each the generator and battery to the electrical motors that drive the machine. This setup permits the battery to retailer unused power for peak energy calls for, enhancing system effectivity.
“This is a perfect resolution to satisfy the present wants of a lot of our clients,” says Steve Ferguson, senior vice chairman of Caterpillar Industrial Energy Methods. “Combining the engine and battery offers greater energy functionality than utilizing both an engine or battery alone. This permits for management optimisation to distribute energy from a number of sources, maximising powertrain effectivity. Prospects profit significantly from diminished downtime, improved gasoline effectivity, and lowered restore frequency, minimising the overall value of possession.”
The hybrid powertrain system consists of 5 key elements working in concord. The engine serves as the first energy supply, offering mechanical energy to the generator. This technique is designed to be suitable with engines throughout the Caterpillar vary, together with future developments operating on different fuels. The generator is intently coupled to the engine and chosen to align with engine capabilities to supply electrical energy.
On the coronary heart of the system is the inverter, the central element that manages power from the generator or battery and distributes it to the motors. It might additionally settle for recuperated power from the motors to recharge the battery. The motor converts electrical output from the inverter into the required torque and velocity. Moreover, the motors are able to absorbing mechanical power and rework it into electrical output for braking and regeneration.
Finishing the system is the battery, which shops extra power from the engine or regenerative power from the motors, offering fast energy response to satisfy essential cycle necessities. It might complement engine energy or act as the only energy supply when wanted.
The hybrid functionality permits for zero-exhaust emissions when operating on battery energy. Moreover, with applicable tools, the Sequence Hybrid Energy Growth powertrain can perform as a cell energy supply with export functionality.
Past hybrid know-how, Caterpillar is actively creating hydrogen options for its engines. A workforce of engineers is testing numerous different fuels, together with hydrogen, methane, methanol and ethanol. “We’re doing this work now. This implies when our clients are prepared to maneuver to hydrogen or different fuels, we can present them with our deep experience and studying to make sure a clean adoption,” says Luke Bennett, Caterpillar product specialist.
At Bauma, Caterpillar demonstrated its hydrogen improvement progress via a simulated check cell surroundings for the C18, a fuel engine transformed to run on hydrogen.
“We’ve been working it on high and low ambient temperatures and looking out on the vibration results of the engine, which is how we examine different fuels within the evolving power panorama. We’re utilizing what we’ve realized from this know-how for our different engines in improvement,” says Bennett.
A greener future
It’s clear that whether or not via bettering the effectivity of diesel combustion, implementing different gasoline options or combining electrical energy in hybrid powertrains, the inner combustion engine nonetheless has an important position to play within the drive to decarbonise off-highway.
The event of those applied sciences highlights how completely different approaches may be taken to reaching the identical aim: lowering emissions whereas sustaining efficiency and reliability. What unites them is the popularity that the trade wants sensible, dependable options that may be applied within the real-world, as Burnhope highlights: “It’s not nearly what’s written on paper; it’s about actual machines engaged on actual job websites, making an actual distinction to the trade.”
This text first appeared within the June problem of iVT
