Volvo Begins On-Road Testing of Hydrogen Combustion Engine Trucks

Volvo begins road trials for hydrogen combustion trucks in Europe

Volvo Trucks has started testing heavy-duty trucks with hydrogen combustion engines on public roads in Europe. The trials represent a significant step in the manufacturer’s plan to offer zero-emission transport options by 2040. These trucks use a technology called High Pressure Direct Injection, which burns hydrogen directly in a modified internal combustion engine.

The approach differs from hydrogen fuel cells, which generate electricity from hydrogen. Instead, Volvo’s engines work more like conventional diesel engines but run primarily on hydrogen. A small amount of renewable Hydrotreated Vegetable Oil helps ignite the fuel under compression. This method aims to deliver familiar performance and range while eliminating tailpipe carbon emissions when using green hydrogen.

For UK transport businesses, this development matters because it offers another route to decarbonisation. Battery electric trucks suit some operations but face range and charging constraints. Fuel cells require different infrastructure again. Hydrogen combustion engines could fill gaps where existing solutions fall short, particularly for long-haul and heavy-duty work.

How the hydrogen combustion technology works

Volvo developed this system with Westport Fuel Systems through a joint venture that became operational in the second quarter of 2024. The High Pressure Direct Injection technology has already proven itself in over 10,000 gas-powered trucks. Adapting it for hydrogen builds on established engineering rather than starting from scratch.

The engines burn hydrogen as their main fuel. However, hydrogen does not ignite easily under compression alone. Consequently, the system injects a small quantity of renewable HVO first. This creates the conditions needed for the hydrogen to burn efficiently. The result is an engine that behaves like a diesel unit but produces no direct carbon emissions.

According to Volvo, the technology delivers higher energy efficiency than conventional hydrogen combustion engines. Power and torque outputs match or exceed diesel equivalents. Drivers should notice little difference in how the trucks handle or perform. Jan Hjelmgren, Head of Product Management at Volvo Trucks, stated that these vehicles will operate just like diesel trucks from the driver’s perspective.

The company claims industry-leading fuel efficiency for this type of engine. Lower fuel consumption translates directly into reduced operating costs, assuming hydrogen prices become competitive. The technology also offers the potential for net-zero carbon emissions on a well-to-wheel basis when green hydrogen and renewable HVO are used together.

Testing schedule and commercial availability

Road testing follows earlier laboratory and controlled vehicle trials. Volvo announced the current on-road phase in March 2025. The trucks are being tested in demanding conditions, including the harsh winter climate of northern Sweden. These trials verify performance in real-world scenarios before customer testing begins.

Customer trials are planned for 2026. Selected operators will run the trucks in their own operations, providing feedback on reliability, efficiency, and practical usability. This stage typically reveals issues that controlled testing cannot uncover. Volvo will use this information to refine the design before full production.

Commercial launch is targeted for before 2030 in Europe. The initial focus remains on European markets where hydrogen infrastructure development is more advanced. Volvo has not confirmed plans for North American introduction, citing the need for adequate refuelling infrastructure, supportive regulations, and green hydrogen availability.

The timeline aligns with increasing pressure on fleet operators to reduce emissions. European Union regulations classify these hydrogen combustion trucks as Zero Emission Vehicles under CO2 standards. This classification matters for fleet compliance and access to low-emission zones in cities.

Range capabilities and vehicle applications

Volvo is focusing initial development on heavy-duty models like the FH16. These trucks handle the most demanding haulage work, where electrification faces the greatest challenges. Weight, range, and refuelling time all become more critical as vehicle size and payload increase.

Related hydrogen truck tests have demonstrated ranges up to 1,000 kilometres. This figure comes primarily from fuel cell trials but indicates the distances hydrogen systems can achieve. Combustion engines should deliver similar or better range given their higher energy density compared to batteries. For comparison, battery electric trucks typically manage 300 to 500 kilometres depending on load and conditions.

Long-haul operators need this extended range. Daily distances often exceed what current battery technology can support without lengthy charging stops. Hydrogen refuelling takes minutes rather than hours. This operational rhythm more closely resembles diesel operations, reducing the need to restructure routes or schedules.

The technology suits applications where predictable routes pass hydrogen refuelling points. Operators running set corridors between distribution centres or ports could adopt these trucks without the range anxiety affecting battery electric alternatives. Regional and international haulage become viable for zero-emission operation.

Emissions profile and regulatory classification

When running on green hydrogen produced from renewable electricity and renewable HVO, these trucks can achieve net-zero carbon emissions across their entire fuel lifecycle. Green hydrogen production uses electrolysis powered by wind, solar, or other renewable sources. This process produces no carbon emissions, unlike hydrogen derived from natural gas.

The small quantity of HVO required for ignition is already a low-carbon fuel. HVO is produced from waste oils and residues rather than fossil sources. Its carbon footprint is significantly lower than conventional diesel. The combination of green hydrogen and renewable HVO delivers the near-zero emissions needed for EU Zero Emission Vehicle classification.

However, the emissions benefit depends entirely on fuel sourcing. Grey hydrogen, produced from natural gas without carbon capture, would undermine the environmental case. Similarly, fossil-derived ignition fuel would increase the carbon footprint. Fleet operators need to verify fuel sources to claim genuine emissions reductions.

EU regulations provide a strong incentive to adopt these vehicles. The Zero Emission Vehicle classification affects manufacturer fleet averages and operator compliance with urban access restrictions. Many European cities are tightening emissions requirements for heavy vehicles. Hydrogen combustion trucks offer a route to compliance without sacrificing payload or range.

Volvo’s three-path decarbonisation strategy

Volvo is pursuing battery electric, fuel cell electric, and hydrogen combustion technologies simultaneously. This multi-path approach recognises that no single solution will suit every transport application. Different operations face different constraints around weight, distance, refuelling infrastructure, and total cost of ownership.

Battery electric trucks work well for urban delivery, refuse collection, and regional distribution where daily distances remain moderate. Predictable routes and depot charging make them practical today. However, batteries add weight, reducing payload capacity. Charging time limits operational flexibility for some businesses.

Fuel cell trucks generate electricity on board from hydrogen, powering electric motors. They offer quick refuelling and long range without the weight penalty of large battery packs. The technology remains more expensive than combustion alternatives. Fuel cell systems are also more complex, with additional components that could affect maintenance costs.

Hydrogen combustion retains familiar internal combustion engine architecture. Mechanics understand these powertrains. Parts availability and service networks already exist for conventional engines. This familiarity reduces the training burden and operational risk for fleet managers considering the switch from diesel.

The strategy spreads risk across multiple technologies. If one approach faces unexpected barriers or costs, alternatives remain available. It also allows Volvo to match specific technologies to customer needs rather than forcing a one-size-fits-all solution. Fleet operators gain choice, selecting the powertrain that best fits their operational profile.

Infrastructure challenges and commercial viability

Hydrogen refuelling infrastructure remains limited outside specific European corridors. Norway, Germany, and the Netherlands are building networks, but coverage remains patchy. The UK has fewer than 15 public hydrogen refuelling stations suitable for heavy vehicles. This scarcity constrains where operators can realistically deploy hydrogen trucks.

Building refuelling networks requires substantial investment. Each station costs several million pounds to construct. Hydrogen production, storage, and distribution all need development. Governments and energy companies must coordinate to create viable networks. Without this infrastructure, even the best hydrogen trucks cannot operate commercially.

Hydrogen production costs currently exceed diesel on an energy-equivalent basis. Green hydrogen production requires renewable electricity, electrolysis equipment, and compression for storage. These costs must fall substantially to make hydrogen trucks economically competitive. Scale and technological improvement should drive prices down, but the timeline remains uncertain.

Fleet operators considering hydrogen trucks must weigh these factors carefully. Early adopters may face higher costs and limited route flexibility. However, those operating on corridors with planned infrastructure could benefit from first-mover advantages. Government grants and low-emission zone access may offset higher fuel costs during the transition period.

The technology’s commercial success depends on coordinated infrastructure development and cost reduction. If hydrogen becomes widely available at competitive prices, combustion engines offer a practical decarbonisation path. If infrastructure lags or costs remain high, battery electric and fuel cell alternatives may prove more viable for most applications.

What UK fleet operators should consider now

Battery electric trucks already serve many urban and regional routes effectively. Therefore, businesses with operations suited to current battery technology should continue evaluating and adopting electric vehicles. Hydrogen combustion trucks target different applications where batteries face greater limitations.

Operators running long-haul routes should monitor hydrogen infrastructure development along their key corridors. The technology becomes practical only where refuelling access exists. Engaging with fuel suppliers and industry groups can help shape infrastructure planning. Early dialogue may influence where networks develop first.

Total cost of ownership will determine adoption rates. Fuel costs, vehicle pricing, maintenance expenses, and residual values all affect the business case. Currently, hydrogen trucks will carry price premiums over diesel equivalents. Operators need to model these costs against fuel savings, grant funding, and regulatory compliance benefits.

Compliance requirements continue tightening. Public sector supply chains increasingly demand emissions reductions. Our net-zero program for carbon reporting compliance helps businesses track and reduce transport emissions to meet these requirements. Understanding your current emissions profile is the first step toward identifying which decarbonisation technologies suit your operations.

Training and maintenance considerations also matter. Hydrogen systems require different handling procedures from diesel. Safety protocols for hydrogen storage and refuelling need implementation. However, combustion engines require less radical change than battery electric powertrains. Existing mechanical knowledge largely transfers across.

Key facts about Volvo’s hydrogen combustion trucks

• Volvo Trucks has begun on-road testing of heavy-duty hydrogen combustion engines using High Pressure Direct Injection technology in Europe during early 2025.
• The engines burn hydrogen directly with a small amount of renewable HVO for ignition, delivering performance comparable to diesel trucks while eliminating direct carbon emissions.
• Customer testing is scheduled for 2026, with commercial launch planned before 2030 in European markets initially.
• The trucks achieve Zero Emission Vehicle classification under EU CO2 standards when using green hydrogen and renewable HVO fuels.
• Range capabilities of up to 1,000 kilometres make the technology suitable for long-haul operations where battery electric trucks face limitations.
• Volvo is pursuing battery electric, fuel cell, and hydrogen combustion technologies simultaneously to serve different transport applications.
• Limited hydrogen refuelling infrastructure and current fuel costs remain the primary barriers to widespread commercial adoption.

Practical steps for evaluating hydrogen trucks

Businesses should start by mapping their vehicle operations against available and planned hydrogen infrastructure. Routes that align with emerging refuelling networks become candidates for hydrogen truck adoption. Operations in isolated areas will need to wait for infrastructure development or consider alternative technologies.

Calculating total cost of ownership requires detailed modelling. Vehicle purchase costs, fuel expenses, maintenance, insurance, and residual values all contribute. Grants and incentives can significantly improve the business case. Several UK and European programs support zero-emission commercial vehicle adoption. Staying informed about available funding is essential.

Pilot programs and trials offer lower-risk ways to gain experience. Manufacturers typically seek partner fleets for early testing. Participating provides insight into real-world performance and operational challenges. It also builds expertise before committing to larger fleet conversions.

Collaboration with other fleet operators can help. Industry groups and trade associations share knowledge about emerging technologies. Collective discussions with fuel suppliers and policymakers can influence infrastructure development. Individual businesses have limited leverage, but coordinated industry voices carry more weight.

Emissions reporting requirements continue expanding. Understanding your current carbon footprint and reduction trajectory is essential for long-term planning. Our ESG compliance and carbon reporting services help businesses measure, report, and reduce transport emissions systematically. This data informs decisions about which vehicle technologies deliver the greatest emissions reductions for your specific operations.

Wider implications for UK transport decarbonisation

The success of hydrogen combustion trucks could accelerate heavy transport decarbonisation where electrification struggles. Long-haul, heavy-duty, and specialist applications may adopt hydrogen more readily than battery alternatives. This diversification of zero-emission technologies helps ensure all transport segments can meet net-zero targets.

Hydrogen infrastructure development serves multiple sectors. Buses, trains, maritime vessels, and industrial processes can all use hydrogen. Investment in refuelling networks creates network effects that reduce costs and improve access. Cross-sector coordination delivers faster infrastructure expansion than transport-only planning.

The technology also affects energy system planning. Large-scale hydrogen production requires substantial renewable electricity. Storage and distribution create new energy infrastructure demands. These systems must integrate with wider grid planning and renewable energy deployment. Transport decarbonisation connects directly to energy transition challenges.

Supply chain emissions increasingly matter for tender qualification and customer requirements. Haulage firms that cannot demonstrate emissions reductions risk losing contracts. Zero-emission vehicle options allow operators to meet these requirements while maintaining service levels. Procurement decisions increasingly favour suppliers with clear decarbonisation plans.

Public sector frameworks already incorporate carbon reduction criteria. Our sustainable procurement support helps businesses understand and meet these evolving requirements. As private sector supply chains adopt similar standards, emissions performance becomes a competitive differentiator rather than just a compliance issue.

Where to find additional information

The Department for Transport publishes guidance on zero-emission heavy vehicles and available grant schemes. Its decarbonisation plan outlines targets and policy support for the transition away from diesel trucks.

The Volvo Trucks UK website provides technical specifications and updates on hydrogen combustion engine development. Businesses interested in trials or early adoption should contact manufacturers directly for the latest information.

The UK Hydrogen and Fuel Cell Association tracks infrastructure development and policy initiatives. Its resources help fleet operators understand where hydrogen refuelling networks are planned and when they might become available.

Industry bodies like the Road Haulage Association provide sector-specific guidance on alternative fuel adoption. They also represent operator interests in policy discussions that shape infrastructure investment and regulatory frameworks.

Staying informed about these developments helps businesses make timely decisions. Technology and infrastructure are evolving rapidly. What seems impractical today may become viable within typical vehicle replacement cycles. Early planning positions businesses to act when opportunities arise.