A novel design using pure platinum, graphene-protective layer and porous carbon support could enable fuel cells to power heavy-duty trucks reliably
For trucks and heavy-duty vehicles that must travel long distances without frequent, time-consuming charging stops, batteries often fall short. Hydrogen fuel cells — which can be refueled as quickly as traditional gasoline — offer a cleaner, more efficient alternative.
Now, researchers at UCLA have made a breakthrough that could dramatically extend the lifespan of these fuel cells, making them a more viable clean energy source that can help bring sustainable, long-haul trucking closer to reality.
Led byYu Huang, a professor of materials science and engineering at the UCLA Samueli School of Engineering, the research team has developed a new catalyst design capable of pushing the projected fuel cell catalyst lifespans to 200,000 hours, which is nearly seven times the U.S. Department of Energy’s target for 2050. Published inNature Nanotechnology, the research marks a significant step toward the widespread adoption of fuel cell technology in heavy-duty vehicles, such as long-haul tractor trailers.
Although medium- and heavy-duty trucks make up only about 5% of vehicles on the road, they are responsible for nearly a quarter of greenhouse gas automobile emissions, according to federal estimates. This makes heavy-duty applications an ideal entry point for polymer electrolyte membrane fuel cell technology.
Because fuel cells are significantly lighter than batteries, they require less energy to move the vehicles. With a projected power output of 1.08 watts per square centimeter, fuel cells featuring the new catalyst can deliver the same performance as conventional batteries that weigh up to eight times more. This difference is especially relevant for heavy-duty vehicles, which not only carry substantial cargo but also tend to be much heavier than standard vehicles. In addition, building a national hydrogen-refueling infrastructure would likely require less investment than establishing an electric vehicle-charging network across the country.
Fuel cells work by converting the chemical energy stored in hydrogen into electricity, emitting only water vapor as a byproduct. This has made them a promising solution for cleaner transportation. However, the slow chemical reaction for the energy conversion has been a challenge, requiring a catalyst to achieve practical speeds.
While platinum-alloy catalysts have historically delivered superior chemical reaction, the alloying elements leach out over time, diminishing catalytic performance. The degradation is further accelerated by the demanding voltage cycles required to power heavy-duty vehicles.
To address this challenge, the UCLA team has engineered a durable catalyst architecture with a novel design that shields platinum from the degradation typically observed in alloy systems.
The researchers began by embedding ultrafine platinum nanoparticles within protective graphene pockets. Composed of a single layer of carbon atoms arranged in a two-dimensional honeycomb lattice, graphene is the thinnest known material. Despite its atomic thinness, it is incredibly strong, lightweight and highly conductive. These graphene-encased nanoparticles were then nested inside the porous structure of Ketjenblack, a powdery carbon material. This “particles-within-particles” design provides long-term stability while preserving the high catalytic activity essential for efficient fuel cell performance.
“Heavy-duty fuel cell systems must withstand harsh operating conditions over long periods, making durability a key challenge,” said Huang, who holds the Traugott and Dorothea Frederking Endowed Chair at UCLA Samueli. “Our pure platinum catalyst, enhanced with a graphene-based protection strategy, overcomes the shortcomings of conventional platinum alloys by preventing the leaching of alloying elements. This innovation ensures that the catalyst remains active and robust, even under the demanding conditions typical of long-haul applications.”
The new catalyst exhibited a power loss of less than 1.1% after an accelerated stress test involving 90,000 square-wave voltage cycles designed to simulate years of real-world driving, where even a 10% loss is typically considered excellent. These superior results project fuel cell lifetimes exceeding 200,000 hours, far surpassing the DOE’s target of 30,000 hours for heavy-duty proton exchange membrane fuel cell systems.
By successfully addressing the dual challenges of catalytic activity and durability, UCLA researchers’ innovative catalyst design holds great promise for the adoption of hydrogen-powered heavy-duty vehicles — an essential step toward reducing emissions and improving fuel efficiency in a sector that accounts for a substantial share of transportation energy use.
The new study’s lead authors are UCLA Ph.D. graduates Zeyan Liu and Bosi Peng, both advised by Huang,whose research groupspecializes in developing nanoscale building blocks for complex materials, such as fuel cell catalysts. Xiaofeng Duan, a professor of chemistry and biochemistry at UCLA, and Xiaoqing Pan, a professor of materials science and engineering at UC Irvine, are also authors on the paper. Huang and Duan are both members of the California NanoSystems Institute at UCLA.
Other authors on the paper are Yu-Han “Joseph” Tsai and Ao Zhang from UCLA, as well as Mingjie Xu, Wenjie Zang, XingXu Yan and Li Xing from UC Irvine.
UCLA’s Technology Development Group has filed a patent on the technology.
MI 4MW PEM Electrolyser Boosts Green Hydrogen Production at API SARPOM Refinery
IMI is supplying a 4 MW PEM electrolyser to the SARPOM Refinery in Trecate, Novara, Italy operated by IP Gruppo API.
The investment forms part of API’s ‘Impianto di Produzione Idrogeno Verde’ (Green Hydrogen Production Plant) project. Funded by the Piedmont Region through the Piano Nazionale di Ripresa e Resilienza (National Recovery and Resilience Plan), this initiative aims to produce green hydrogen using energy generated by two photovoltaic fields located within the refinery. These fields will deliver an estimated annual production of more than 8,500 MWh of renewable energy.
Hydrogen will be produced by a 4 MW PEM electrolyser designed and built by IMI, which will be installed in a decommissioned area of the refinery previously used for hydrocarbon storage. This area will be revitalised, aligning with the regional funding guidelines. The estimated annual production is at least 167 metric tons of renewable hydrogen, which will replace a portion of the non-renewable hydrogen currently used in refining processes.
Factory testing was completed in December 2024, and the final assembly of the electrolyser is already underway, with delivery and commissioning planned for the first half of 2025.
Giuseppe Buscemi, EMEA President of Process Automation at IMI, said:
This project showcases the power and versatility of our PEM electrolysers.
“We are pushing decarbonisation forward within heavy industry, and our work with API sets a great precedent as one of Italy’s first 4 MW PEM hydrogen electrolysers.”
One of the IMI VIVO electrolyser’s key strengths is its electrical connection system. Use of Insulated Gate Bipolar Transistors’ (IGBT) high-frequency switching technology improves the quality of energy supplied to the electrolyser while also offering greater modularity, making the system more flexible.
Each skid-mounted module from IMI incorporates a complete system for water treatment, purification, and cooling, designed with robust safeguards at every stage. Advanced calculation techniques, such as finite element analysis (FEA), evaluate the impact of overpressure on oxygen vessels, while fluid dynamics simulations continuously monitor hydrogen leaks to ensure the efficiency of venting fans. Additionally, a detailed hazard and risk analysis (HAZOP) is conducted, informed by IMI’s experience in the oil & gas sector to ensure reliability and operational security.
Duferco Energia and Ansaldo Green Tech have signed a strategic agreement for the supply and commissioning of a 1 MW electrolyser, designed to produce green hydrogen as part of the Hydrogen Valley project in Giammoro, in the province of Messina, Sicily, Italy.
Supported by the National Recovery and Resilience Plan (PNRR) through the Sicilian Region, this initiative represents one of the key projects of European relevance in the energy transition and the development of Italy’s hydrogen value chain.
The electrolyser, supplied by Ansaldo Green Tech, employs anion exchange membrane (AEM) technology, offering high efficiency and operational flexibility. Developed within the framework of the IPCEI project and funded by the European Union’s ‘NextGenerationEU’ programme, the system will be assembled on a new production line currently under construction in Genova Campi, Italy. It will be capable of producing over 500 kg/d of green hydrogen, with optimised energy consumption and a purity level of 99.9%.
The Giammoro Hydrogen Valley project includes the installation of a 4 MW photovoltaic system to power the electrolyser, enabling the production of around 100 tpy of green hydrogen. The hydrogen produced will primarily support the decarbonisation of key industrial sectors, including steel, logistics, and mobility.
With a total investment of €10 million, the Hydrogen Valley project represents a sustainable development model for southern Italy. It is expected to significantly boost the local economy by creating new job opportunities and promoting the growth of industries related to the production and distribution of green hydrogen.
“The Hydrogen Valley in Sicily represents a concrete step toward the energy transition and the strengthening of the island’s energy independence,” said Massimo Croci, CEO of Duferco Energia. “This initiative will not only generate environmental benefits but also provide new economic and employment opportunities for the region. Environmental sustainability can go hand in hand with industrial and social development.”
“We are proud to contribute to the Giammoro-Messina Hydrogen Valley project led by Duferco Energia,” added Vittorio Olcese, CEO of Ansaldo Green Tech. “This agreement is a strong endorsement of Ansaldo Green Tech’s technology, focused on efficiency and flexibility in the production of green hydrogen to decarbonise sectors such as mobility, logistics, and hard-to-abate industries like steel.”
The initiative is aligned with the European decarbonisation strategies outlined in the RePowerEU plan, which aims to reduce reliance on fossil fuels and accelerate the adoption of renewable energy. The Giammoro Hydrogen Valley will therefore contribute not only to local environmental sustainability but also to the EU’s climate neutrality goals.
