Electric vehicles are on the rise in terms of popularity and adoption, yet a couple of manufacturers are considering hydrogen as an alternative propulsion method. Toyota is among those exploring this avenue and has recently unveiled its prototype of a hydrogen fuel cell electric Hilux pickup truck. Although currently in the concept phase, Toyota plans to deliver 10 examples for rigorous safety, functionality, and durability assessments. As electric power technology still raises some uncertainties, the exploration of hydrogen power serves as a prudent measure for future-proofing. The insights derived from Toyota’s testing efforts could potentially have a significant impact on the automotive industry, further shaping its trajectory.

Since 2015, three car manufacturers have introduced hydrogen-powered vehicles for sale, including the Honda Clarity Fuel Cell, the Hyundai Nexo SUV, and the Toyota Mirai. However, Honda has recently ceased production of all Clarity models, and Hyundai has seen limited sales, with fewer than 1,500 Nexo SUVs sold to date. Toyota, which has shown a strong commitment to hydrogen power as an alternative to battery-electric vehicles, has successfully sold approximately 10,700 Mirai sedans over two generations in the U.S. It’s worth noting that at times, Toyota resorted to significant discounts to boost Mirai sales. It’s also important to note that Honda does not provide separate sales figures for its Clarity Fuel Cell model in comparison to the plug-in hybrid and battery-electric Clarity versions. That said, here’s everything we know so far about the Hilux hydrogen pickup truck:

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What Are HFCVs And How Do They Work?

Before we get to the crux of the matter, let’s get the basics out of the way. A hydrogen fuel-cell vehicle, abbreviated as HFCV, employs a similar electric motor as a battery-electric car to propel the wheels. However, instead of relying on a large, heavy battery, it utilizes a fuel-cell stack. In this stack, pure hydrogen (H2) flows through a membrane, where it combines with oxygen (O2) extracted from the air. This chemical reaction generates the electricity needed to power the vehicle’s wheels and produces water vapor as a byproduct. Essentially, a fuel-cell vehicle operates as a series hybrid, which is why it is occasionally categorized as a fuel-cell hybrid electric vehicle (FCHEV).

In scientific terms, hydrogen is considered an energy carrier rather than a conventional fuel source. Nevertheless, for HFCV drivers, the process of refilling their vehicles’ carbon-fiber high-pressure tanks resembles a visit to a “hydrogen fueling station,” akin to a traditional gasoline station, offering a quick five-minute refueling experience. While it’s true that hydrogen is the most abundant element in the universe at the atomic level, it is rarely found in its pure form; it typically combines with other elements. Its strong affinity for bonding with other elements makes it an efficient energy carrier.

To produce pure hydrogen for use in vehicles, a substantial amount of energy is required to “crack” compounds like natural gas (CH4) into pure H2, with carbon dioxide (CO2) as a byproduct. Currently, the majority of hydrogen is derived from fossil fuels such as natural gas. Once introduced into a fuel cell, the hydrogen promptly releases that stored energy in the form of electricity as it combines with oxygen, resulting in only water vapor (H2O) being emitted from the vehicle’s exhaust.

Related: Toyota’s Hydrogen Ambitions Take Shape In The Form Of The Hilux FCEV Prototype

The Hydrogen Hilux Can Reshape The Industry

Toyota has established itself as a trailblazer in the realm of hydrogen propulsion, notably exemplified by the Mirai, one of the select hydrogen vehicles accessible to the public. Toyota’s pursuits with the Hilux prototype are inherently motivated by their commitment to advancing a zero-carbon future. In contrast to other automakers, Toyota has wholeheartedly embraced a multifaceted strategy aimed at identifying the most optimal powertrain solutions for future vehicles. This approach encompasses hybrid electric, plug-in hybrid electric, and battery electric options, each potentially suitable for diverse operational contexts worldwide.

Paradoxically, Toyota finds itself trailing behind other manufacturers in the fully electric vehicle race. The development of this novel Hilux prototype draws from the foundational elements of the Mirai sedan, a vehicle that has seen nearly a decade of production. Notably, the hydrogen fuel cell system employed generates zero tailpipe emissions, emitting only pure water as a byproduct, with the hydrogen stored within the Hilux in three high-pressure fuel tanks. Furthermore, the hybrid battery for the Hilux has been strategically placed on the rear load deck, ensuring that there is no sacrifice of cabin space for the occupants.

Toyota has provided substantial statistics regarding the hydrogen-powered Hilux, indicating an impressive range of 365 miles between refueling stops. However, this figure still falls short of the range achievable with conventional internal combustion engine-equipped Hilux, which can travel up to 715 miles on a single tank of turbodiesel 2.8-liter fuel in the Australian market. It’s important to note that the hydrogen fuel cell pickup remains a concept vehicle at this stage, leaving room for potential advancements and modifications as it progresses toward production. While this particular Hilux prototype won’t go into production. Toyota is actively working on developing a production version of a hydrogen-powered truck.

Related: What Toyota’s New Solid-State Battery Means For Hydrogen

How Did The Hilux HFCV Come To Be

In 2022, Toyota announced its collaboration with “allied automakers” to create compact electric commercial vans and a light-duty electric pickup truck featuring hydrogen fuel-cell technology. Toyota is not embarking on this endeavor alone but is partnering with Isuzu and Hino to bring hydrogen fuel-cell trucks to reality. These efforts are part of a larger project aimed at deploying 600 electric vehicles for transporting goods between Tokyo and Fukushima prefecture.

Although there isn’t a specific timeline available for these trucks, they are indeed planned for production rather than remaining in the prototype phase. This project, in conjunction with the Toyota Hilux prototype, underscores Toyota’s continued commitment to promoting hydrogen as a viable alternative fuel source. The newly appointed Toyota CEO, Koji Sato, firmly believes in the potential of hydrogen technology and envisions its future relevance within Toyota and the broader automotive industry. Sato’s philosophy revolves around the idea that reducing emissions should encompass more than just electric and hybrid powertrains. Additionally, Toyota has hinted at the possibility of exploring sportier vehicles equipped with hydrogen fuel cells.

At the 2023 Fuji 24 Hours event, Toyota unveiled the Mirai Sport Concept, a visually striking iteration of the hydrogen sedan with a more angular and muscular design. Toyota has remained relatively tight-lipped about this vehicle, refraining from releasing an official press statement to confirm its existence. Nevertheless, it serves as a clear indication that Toyota envisions a wide range of applications for hydrogen power. The company even showcased a hydrogen-powered GR Yaris H2 at the 2023 Goodwood Festival of Speed, driven by the renowned Rowan Atkinson, popularly known as Mr. Bean.

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Electric Vehicles Are The Future But Hydrogen Is Still Relevant

How does it feel to drive a Hydrogen Vehicle? In practical terms, a driver of an HFCV will encounter a driving experience nearly indistinguishable from that of a battery-electric vehicle, albeit perhaps not one of the swiftest varieties. These vehicles lack a traditional transmission and are equipped with regenerative braking systems designed to recapture and utilize energy that would otherwise go to waste during deceleration. The primary challenge facing automotive engineers lies in the fact that hydrogen fuel cells operate most efficiently at a consistent power output, which makes them suitable for applications such as backup power generation.

However, the power demands within an average automobile can vary significantly, spanning an order of magnitude. For instance, power requirements may range from approximately 15 kilowatts (equivalent to 20 horsepower) to maintain a steady highway speed on a level road, to potentially 10 to 20 times that amount during rapid acceleration, such as when reaching speeds of 60 mph or higher. The fuel cell integrated into the Toyota Mirai, currently the top-selling hydrogen car in the U.S., boasts a rating of 90 kW (equivalent to 120 horsepower). Nevertheless, this power output may not be sufficient for swift highway merges.

To address this limitation, Toyota, along with other manufacturers of HFCVs, incorporates a high-voltage, low-capacity battery into the vehicle’s design, closely resembling those employed in gasoline-electric hybrid vehicles. This battery serves the purpose of providing additional power during brief intervals of intense acceleration and is recharged either from excess fuel-cell output when the vehicle cruises at a constant speed or via regenerative braking when the vehicle decelerates. Notably, all three of the hydrogen-powered cars sold in recent years have received EPA-rated ranges exceeding 300 miles, although, akin to electric vehicles (EVs), the range tends to diminish notably at higher speeds.

Related: Differences Between ICE-powered And Hydrogen-powered Vehicles

Are Hydrogen Cars Safe?

Hydrogen fuel cell vehicles (HFCVs) are generally regarded as safe on par with any other conventional car. This is primarily because the high-pressure tanks used to store hydrogen are engineered to withstand even high-speed collisions without leaking or rupturing. While skeptics of hydrogen technology often reference the Hindenburg disaster of 1937, it’s worth noting that the hydrogen tanks and associated components in modern HFCVs are designed to survive crashes intact. In the event of a severe accident, these tanks and their hardware would likely remain undamaged, even if the rest of the vehicle were extensively impacted. Importantly, there have been no recorded injuries or fatalities specifically attributed to the hydrogen components in the relatively limited number of HFCVs sold to date.

Refueling a hydrogen car becomes more natural with experience, but it requires aligning the bulky nozzle and ensuring a proper seal for electronic communication between the vehicle and the pump, which may take some practice. Present-day hydrogen stations often serve only two to five vehicles before going offline for up to 30 minutes or more for repressurization. As HFCV drivers in the San Francisco Bay Area discovered in June 2019, the hydrogen supply infrastructure for retail outlets can be quite limited. An explosion incident disrupted the supply to nine out of the 11 hydrogen stations in the area, necessitating the use of diesel trucks to transport compressed hydrogen tanks hundreds of miles overnight from Southern California. Drivers who relied on their hydrogen vehicles for daily commuting had to set early alarms in hopes of reaching a fueling station in time to secure some of the limited hydrogen fuel available.

Toyota ultimately provided several months’ worth of lease payment refunds to Mirai drivers throughout the state who faced reliability issues in using their vehicles. The key distinction, and a significant drawback, of hydrogen cars compared to electric vehicles (EVs) is their inability to be refueled or recharged at home overnight. Unlike gasoline cars, which can access a well-established network of over 100,000 fuel stations nationwide, hydrogen drivers depend entirely on a reliable supply of hydrogen gas and the availability of properly functioning high-pressure fueling stations. Given that hydrogen fuel remains a specialized commodity for the general public, the limited network of retail stations typically charges high prices.

According to the California Hydrogen Business Council, “Currently, a kilogram of hydrogen costs between $10 and $17 at California hydrogen stations, which equals about $5 to $8.50 per gallon of gasoline” to cover the same distance. For reference, a Toyota Mirai hydrogen car typically holds about five gallons of hydrogen fuel. To mitigate this disadvantage, Honda, Hyundai, and Toyota have all offered lessees and buyers free hydrogen fuel for varying durations. Each manufacturer has its unique offer: A Toyota Mirai, for instance, includes up to $15,000 worth of complimentary hydrogen, while a Hyundai Nexo offers the same amount over a three-year lease or up to six years of ownership. Once these promotional offers expire, however, the driver is responsible for covering the cost of hydrogen. It’s worth noting that, in comparison, charging an EV overnight generally equates to the cost of gasoline at just $1 to $2 per gallon.

Like electric cars, hydrogen vehicles require special precautions when serviced at dealership service centers. HFCVs feature high-voltage battery packs similar to those found in hybrid, plug-in hybrid, or electric cars. Additionally, they include one or more armored, carbon-fiber tanks designed to store pure hydrogen at extremely high pressure, typically around 10,000 pounds per square inch (psi), or 700 bar in metric units. Routine service for a hydrogen car that doesn’t involve the hydrogen tanks, the fuel-cell stack, or the associated plumbing is no different from servicing any other vehicle.

However, when handling any of these specific components, the state of California has established a set of rules to ensure that any released hydrogen does not pose the risk of an explosion. These measures often entail completely draining the hydrogen tanks in designated outdoor areas away from buildings, followed by purging the remaining hydrogen from the system by flushing it with various gases—a process that can take between 30 and 180 minutes.

Related: Are Solid-state Batteries A Threat To Hydrogen Fuel-cell Technology?

Hydrogen Still Comes With Its Own Problems

Hydrogen presents several advantages that make it a compelling alternative to electric vehicles. A hydrogen fuel-cell engine operates in a manner akin to an internal combustion engine (ICE), with hydrogen serving as the fuel source. What sets hydrogen apart is its refueling process, which mirrors that of gasoline or diesel, involving a simple visit to a pump. This eliminates the need for extended waits at charging stations, which can be as long as half an hour or more for electric vehicle recharging. By harnessing hydrogen to power an electric powertrain, Toyota can effectively combine the strengths of both worlds without the burden of carrying large, heavy batteries.

Such a development could, in many respects, revolutionize the automotive industry. Internal combustion engines might become obsolete, leading to reduced demand for battery production. This, in turn, would alleviate the pressure on sourcing rare materials like lithium, nickel, and cobalt. While not necessarily a dealbreaker, the ability to quickly refill a vehicle at a conventional pump would address consumer concerns about lengthy waits at charging points for energy replenishment. Unlike lithium, which may face supply shortages by the end of the decade according to experts, hydrogen is abundantly available as it is readily accessible in the atmosphere.

Despite the promising developments by Toyota, it’s important to acknowledge that hydrogen does come with a few challenges. One of the most apparent issues is its range limitation, although it’s worth noting that some electric vehicles also grapple with this concern, struggling to meet the expectations of many consumers. Another challenge lies in the extraction and management of hydrogen, which can be intricate due to its volumetric energy density doubling when transitioning from a gas to a liquid. Achieving this liquid state requires extremely low temperatures, specifically at around -423.4 degrees Fahrenheit.

Consequently, any hydrogen fuel tank must be meticulously insulated, and the pump system must be designed to resist freezing and potential breakage. Furthermore, both the storage and production of hydrogen can be expensive endeavors, and it’s worth noting that compressed hydrogen is highly flammable and explosive. While hydrogen does offer substantial advantages, such as its minimal environmental impact and rapid refueling capabilities, it still has a considerable journey ahead before it can establish itself as a mainstream and cost-effective fuel source.

Nevertheless, experiments like Toyota’s Hilux prototype could serve as a catalyst for overcoming these challenges. If hydrogen can become more cost-efficient, easier to store, and safer to handle, it has the potential to revolutionize the automotive industry, and once those hurdles are surmounted, the automotive world may indeed never look back.