The story of the first hydrogen fuel cell vehicle – GM’s Electrovan
Utilising technology originally developed for lunar space missions to create a vehicle unlike anything the world had ever seen seemed like an excellent idea to General Motors’ senior team.
And indeed, it was a brilliant idea – one that, as it later turned out, opened an entirely new direction in the automotive industry.
This nearly 60-year-old concept remains relevant today and continues to inspire major automotive brands in their efforts to completely transform transportation.
This is the story of the first-ever hydrogen fuel cell vehicle – the 1966 GM Electrovan.
How it all began
The 1960s were an era of massive US investment in space missions. As we know, NASA successfully sent the first man to the moon with the Apollo 11 mission in 1969.
This period unlocked many doors in the technical world, and the cutting-edge technologies of the time found applications across various industries – including the automotive sector.
General Motors closely collaborated with NASA on the Apollo and Gemini projects. Many GM chemists actively participated in developing fuel cell power systems, which were ideal for space missions due to their characteristics.
This technology used liquid hydrogen and oxygen to generate the necessary electrical power for missions while simultaneously supplying astronauts with drinking water.
During this period, major American automakers were exploring alternative fuels to replace gasoline.
Concerns about the environmental impact of gasoline engines were already growing, and the US quickly began implementing environmental regulations.
If there was a nationwide refuelling network, would you buy a hydrogen car?
Among the various alternative fuel concepts, turbine-powered vehicles emerged briefly, producing some of the most visually striking cars in history.
In 1966, the idea of a hydrogen fuel cell vehicle was born, and General Motors’ management was determined to bring it to life as quickly as possible – within just 10 months, to be precise.
The plan was to adapt and implement the fuel cell technology used in space missions for use in a vehicle.
Developing the world’s first fuel cell vehicle
Floyd Wyczalek led the project, working alongside 200 engineers in three shifts to meet the ambitious deadline.
The team selected a GMC Handivan as the vehicle platform for a simple reason – it had enough space to accommodate all the necessary components.
Union Carbide, a key partner in the project, played a crucial role by miniaturising the fuel cell system originally designed for space missions to fit inside the van.
The adapted system consisted of 32 fuel cells interconnected by plastic tubing totaling approximately 550 feet in length.
Behind the front seats, two large cryogenic tanks stored super-cooled liquid hydrogen and oxygen, along with an electrolyte reservoir.
During one of the system tests, an unexpected pressure buildup led to a rupture in the tanks.
Fortunately, no one was injured, and this event prompted engineers to refine fuel storage methods.
As a result, advancements in cryogenic tank technology improved the safe handling of liquid hydrogen and oxygen.
The Electrovan utilised an alkaline fuel cell (AFC) system, which used potassium hydroxide (KOH) as an electrolyte to maintain a stable chemical reaction and regulate cell temperature.
However, one major drawback of this system was its immense weight – the van ultimately weighed around 7100 pounds (3200 kg).
In the end, the 32 fuel cells generated a total power output of 150 kW (200 bhp), allowing for a top speed of 70 miles per hour – not a bad figure for the first-ever fuel cell van.
Additionally, with full tanks, the van had a maximum range of 150 miles. After 10 months of intense development, the Electrovan was unveiled to journalists.
At first glance, the project seemed like a success. However, numerous technical challenges lurked beneath the surface.
Why the Electrovan never went into production
Despite its groundbreaking concept and potential, the GM Electrovan was an extremely complex machine to operate.
A striking fact is that it took the team nearly three weeks just to start and run the vehicle for the first time.
Safety procedures were highly demanding, as engineers were working with high-pressure tanks and cryogenic liquids.
These factors significantly impacted the cost of the Electrovan, making both its production and maintenance prohibitively expensive.
This alone was a sufficient reason for General Motors to abandon any plans for mass production.
Furthermore, the infrastructure for hydrogen refueling was virtually nonexistent in the US at the time, making it impractical for potential customers.
Today, the Electrovan is housed at the GM Heritage Center, alongside many other historic automobiles.
However, this vehicle represents far more than just a 10-month-long project – it marks the beginning of an entirely new idea.
The GM Electrovan undoubtedly inspired many companies to explore hydrogen technology and invest in its future.
The full potential of GM’s 1960s vision of “green cars” is something we are only beginning to witness today.
