Balfour Beatty: Retrofits hydrogen hybrid system to HGVs, proving success

Balfour Beatty has taken a pioneering step in decarbonising its existing heavy machinery by retrofitting vehicles with a hybrid hydrogen system.

This initiative is part of the M77 Hydrogen project which aims to create Scotland’s first construction hydrogen hub, demonstrating the potential of hydrogen technology in the industry.

The M77 Hydrogen project

In collaboration with ULEMCo, Logan Energy, and PlusZero Power, Balfour Beatty has retrofitted two salt spreader HGVs and one Impact Protection Vehicle (IPV).

The early results are promising, showing a 26% reduction in carbon emissions during road tests for the spreaders, vs. the previous fully-diesel powertrains.

Retrofitting hydrogen to HGVs

One of the standout aspects of the M77 Hydrogen project is the straightforward nature of retrofitting existing vehicles. The hybrid system allows these machines to switch to diesel if needed, offering flexibility and reducing the risks associated with hydrogen supply.

This adaptability positions the hydrogen hybrid system as a practical interim solution as the industry moves towards broader hydrogen adoption.

The project faced challenges, particularly the high costs of retrofitting and the limited availability of hydrogen refuelling stations in Scotland. However, Balfour Beatty has addressed these issues by developing a mobile refuelling model which can be easily driven to where operational demand requires.

Safety has also been a focus, with stringent training and anti-static measures ensuring that the hydrogen refuelling process is conducted safely.

Balfour Beatty’s said about their learnings:

“Whilst retrofitting existing vehicles with hydrogen hybrid technology may not be the ultimate solution for decarbonising heavy plant and equipment, it is an effective, fast, and straightforward technology that is available today.

“It delivers a substantial reduction in tailpipe carbon emissions, as seen during our road trials, making it a valuable interim measure as we work towards our carbon reduction targets with other benefits including:

• “Retrofitting is an effective way to gradually build demand for hydrogen. This allows for the supporting hydrogen infrastructure, such as supply and refuelling technology, to grow to the necessary capacity that will be needed and avoids a sudden need for large volumes of hydrogen that the market may not be ready to supply.
• “The equipment can operate in diesel-only mode, reducing the risks associated with hydrogen availability and new technology adoption.
• “The hydrogen system is automatic, requiring only familiarisation training for drivers, with no changes in vehicle operation except for during refuelling.
• “The vehicles will run in hydrogen mode when the engine reaches its optimum running temperature and when engine regeneration is not happening, meaning the technology has the potential to be used across a wide variety of plant and equipment. However, it is less useful for vehicles used intermittently where the engine does not stay at an optimum temperature for extended periods.”

Industry collaboration

Balfour Beatty remains committed to sharing its findings and best practices with the broader industry.

By collaborating with partners like Aberdeen City Council and First Bus Aberdeen, the company is not only implementing hydrogen technology but also laying the groundwork for a future where hydrogen plays a central role in construction.

Balfour Beatty’s M77 Hydrogen project exemplifies the power of innovation and collaboration in driving the construction industry towards a sustainable, zero-emission future.

As hydrogen infrastructure continues to develop, projects like this will be crucial in making hydrogen a viable and widely adopted solution in heavy industry.

The future of construction is looking greener, and hydrogen is at the heart of this transformation.