ANALYSIS
How hydrogen found its place in the industrial landscape
The vision for hydrogen as a mainstream road fuel might have faded, but its role as a critical energy source for heavy industry, maritime logistics and off-grid construction is now becoming an operational reality that could support small volume in some fleets. By Simon Harris.
In the early 2010s, the roadmap for hydrogen in the United Kingdom was defined by a sense of imminent breakthrough. In 2012, the UK H2 Mobility project outlined a future where 65 refuelling stations would be operational by the end of 2015, scaling up to more than a thousand sites by 2020. At the time, it was a logical projection. Battery technology was in its infancy, charging was slow and hydrogen offered the only credible way to achieve zero-emission driving without compromising the convenience of a five-minute refill.
Those targets did not materialise. Instead of expansion, the network suffered high-profile retreats. High-traffic locations, such as the Shell hydrogen site at Beaconsfield services, were shuttered as the expected wave of fuel cell passenger cars failed to arrive. To date, Toyota has registered only around 200 Mirai models in this country. While Hyundai initially championed the technology with the ix35 FCEV and Nexo, its focus in the British market has turned almost exclusively toward its battery-electric range.
Even the infrastructure that was built suffered from reliability issues. The extreme cold required for high-pressure refuelling could lead to condensation and ice build-up, occasionally causing the connector to freeze onto the vehicle if the pumps were used in quick succession.
The primary reason for this change is the rapid advancement of the battery-electric vehicle. Improvements in energy density and charging architecture have stripped away many of the advantages hydrogen once held. When a modern car can add hundreds of miles of range in the time it takes to buy a coffee, the necessity for a complex, expensive hydrogen refuelling network for private motorists becomes harder to justify.
However, a recent hydrogen showcase at the Port of Tilbury suggests that the technology is finding its natural environment. The event marked the arrival of the Energy Observer, a self-sufficient vessel that serves as a floating laboratory for renewable power. More importantly, it highlighted how hydrogen is becoming a critical tool for heavy industry and construction.
“
Hydrogen has a critical role to play in how ports operate, from decarbonising dockside activity to enabling shore-to-ship power
David Housden, head of engineering from the Port of Tilbury, observed: “The green hydrogen showcase hosted by the Port of Tilbury and our partners shows our collective ambition to deliver innovative low-carbon solutions across the supply chain.” He explained that the port is now “moving at pace to integrate hydrogen-powered vehicles and onsite power generation in Tilbury”.
In a warehouse or factory setting, the operational logic for a fuel cell is undeniable. A forklift truck fitted with a traditional lead acid battery can take eight hours to reach a full charge, creating significant downtime. A hydrogen version can be refuelled in minutes. In these enclosed spaces, the ability to operate around the clock with zero tailpipe pollution provides a clear advantage over both diesel and older battery technologies.
This efficiency is mirrored in the maritime sector. Tilbury has recently become a central maintenance hub for the Uber Boat by Thames Clippers fleet, with a new dry dock facility designed to support the next generation of sustainable river travel. While many of these vessels currently use hybrid systems, their designs are being developed for conversion to green hydrogen as the infrastructure matures.
This logic extends to the massive infrastructure projects currently under construction. At the showcase, delegates explored the partnership between the energy firm GeoPura and the Lower Thames Crossing. This project represents the largest volume of hydrogen ever contracted for a British construction site. On a project of this scale, there is often no connection to the electricity grid. Excavators, cranes and heavy plant machinery require immense amounts of energy that portable batteries cannot yet provide at a reasonable weight or cost.
Andrew Cunningham, chief executive of GeoPura, observed that while maritime activity will use the electricity grid network wherever possible, the public grid in many locations is not sufficient or flexible enough. He argued: “Hydrogen has a critical role to play in how ports operate, from decarbonising dockside activity to enabling shore-to-ship power.” He described the hydrogen infrastructure at Tilbury and the nearby construction work as “the start of a really exciting industrial powerhouse in this region”.
This creates a secondary opportunity for the vehicle fleet. If an industrial hub already has a commercial-scale hydrogen supply for its heavy plant, it makes sense to run light commercial vehicles on the same fuel. Luigi Ksawery Luca, Toyota (GB) president and managing director, said: “Our participation in today’s events with Energy Observer mooring at the Port of Tilbury and the presentation of our prototype fuel cell Hilux is a perfect illustration of how we are developing hydrogen technologies.” He confirmed that the manufacturer “continues to forge relationships with partner businesses, focusing on diverse forms of transport and power generation”.
The production version of the Hilux is expected by 2028. While it may have a slightly lower towing capacity than its diesel counterpart, it retains the four-wheel-drive capability and rapid turnaround times that a busy industrial site requires. For a fleet decision-maker operating in a back-to-base environment, the appeal of a vehicle that can be refuelled as quickly as a diesel truck, but with zero tailpipe emissions, remains high.
Forth Ports, the owner of Tilbury, is now working with GeoPura to develop an onsite green hydrogen production facility. This will make Tilbury the first British port to support commercial-scale hydrogen for heavy industry. By producing the fuel where it is used, the port avoids the logistical challenge of transporting hydrogen by road, which has long been a barrier to widespread adoption. It also provides a buffer for businesses that want to electrify but face significant delays for grid upgrades. In these instances, hydrogen provides a pragmatic way to bridge the time required for the local distribution network to be reinforced.
The future of hydrogen is unlikely to be found on the suburban driveway. Instead, it is being built in the places where the grid is too weak, the machinery is too heavy and the work is too demanding for batteries alone. Hydrogen has moved away from the motorway to become a silent partner in the decarbonisation of the British industrial powerhouse.
