As the commercial vehicle industry navigates the complex shift from fossil fuel-powered internal combustion engines (ICE) to zero-emission powertrains, OEMs and engineers must align their technology evolution with sustainability goals while considering the varied operational demands of heavy-duty vehicles.
In this article, we explore the challenges and strategic considerations that will shape this transition, on how the industry can chart a practical and sustainable path forward.
ENDURING ROLE
The internal combustion engine remains a significant player in heavy-duty applications, particularly in industries where battery-electric and hydrogen powertrains are not yet practical.
Sectors such as agriculture and construction require high power on demand and consistent operation, often in remote areas where access to electricity is limited and durability is a requisite.
In these contexts, ICE is likely to persist, with alternative fuels such as biodiesel, compressed natural gas (CNG) and e-fuels offering effective interim solutions to reduce emissions without compromising performance.
At Johnson Matthey (JM), we continue to develop innovative catalytic solutions to reduce emissions from ICE, especially as fleets begin adopting these bridging fuels. It is essential that catalyst technologies target pollutants such as methane, particulate matter (soot), and nitrogen oxides (NOx), and support emissions reduction across a range of alternative fuels.
By developing efficient catalytic systems for diesel and alternative fuels, we aim to make ICE cleaner and more sustainable as OEMs refine their zero-emission powertrains.
HYDROGEN
Hydrogen powertrains are a promising solution for long-haul commercial vehicles, given their high energy density and suitability for transporting heavy loads over long distances.
However, hydrogen‘s full ecosystem is still developing, and limited access points remain a significant barrier. This impacts the scalability and cost effectiveness needed to make hydrogen competitive with other powertrain options.
Hydrogen powertrains offer distinct configurations for different applications: fuel cells, suited for medium-load and medium-distance transport, and hydrogen internal combustion engines (ICE), which perform efficiently under high-load conditions.
Hydrogen ICE, for example, is particularly well-suited for long-haul transport where heavy payloads and sustained power are required. An additional advantage of hydrogen ICE is its flexibility in fuel quality; unlike fuel cells, which need high-purity hydrogen, hydrogen ICE can operate on lower-purity sources, expanding potential access points.
As hydrogen infrastructure expands, fuel cells will likely become a more viable option, particularly in urban or medium-range applications where high-purity hydrogen is available. In the meantime, hydrogen ICE provides OEMs with an adaptable solution for heavy-duty transport, especially as hydrogen infrastructure and availability are expected to grow over the next five to 10 years.
BATTERY-ELECTRIC POWERTRAINS
For short-haul, urban applications, battery-electric powertrains provide a practical zero-emission solution. These powertrains align well with lower power demands, shorter ranges and urban infrastructure, making them ideal for last-mile delivery and inner-city transport.
Unlike long-haul applications, where payload and range requirements remain challenging for current battery technologies, urban settings provide more accessible charging infrastructure and consistent route planning, facilitating the adoption of electric vehicles.
Our expectation is that battery-electric vehicles will play a leading role in decarbonising urban transport as charging networks expand. While battery electric powertrains currently have limitations for heavy-duty, long-haul transport, advancements in battery density and charging speed may improve their feasibility in broader applications over time. In the near term, however, their deployment in urban areas represents a significant step toward reducing urban emissions.
POLICY
The regulatory landscape significantly influences the adoption of new technologies. In Europe, for instance, stringent CO2 reduction targets drive innovation across powertrains and fuel efficiency.
However, achieving these targets requires flexibility in the types of technologies and fuels allowed under emissions regulations. Technology-neutral policies would permit OEMs to use various options, from biofuels and CNG to hydrogen and electric powertrains, helping to ensure optimal technologies go to scale, while the industry continues to evolve.
Policy adjustments that permit alternative fuels, such as biofuels and hydrotreated vegetable oil (HVO), would allow ICE to remain part of a sustainable solution during the transition to full zero-emission technologies. While hydrogen and electric solutions hold promise for the future, biofuels can provide substantial carbon savings in the near term, making them a valuable addition to the emissions reduction toolkit.
Such policies align with international examples, such as China’s legislative framework, which allows a range of alternative fuel options alongside electric vehicles. A flexible policy framework would enable OEMs to tailor their approach to CO2 reduction, retain adaptability across varied applications, and meet specific operational needs while working toward the broader goal of net-zero emissions.
CONTROL TECHNOLOGIES
While zero-emission powertrains represent the ultimate goal, ICE will remain a critical part of the commercial vehicle landscape during the transition. As such, continued innovation in emissions control technologies is essential to mitigate the industry’s environmental impact.
To this end, advancements in catalytic systems are enabling significant reductions in pollutants from both traditional diesel and alternative fuels.
Modular approaches to catalyst design – pioneered by JM – allow solutions to be tailored to specific engine configurations and fuel types. This flexibility ensures that each catalytic solution is optimally suited to reduce pollutants while meeting the unique demands of diverse powertrains.
For example, JM’s dual injection systems, which integrate two AdBlue injection points, enhance emissions control in heavy-duty applications, achieving cleaner tailpipe emissions and helping OEMs comply with strict emissions standards. Our solutions address not only traditional pollutants like soot and NOx but also greenhouse gases, including methane, ensuring that even unconventional fuels such as CNG operate with minimal environmental impact.
COLLABORATIVE PATH
The pathway to net-zero emissions for commercial vehicles will not be defined by a single solution. Instead, it requires a combination of technologies tailored to the demands of different applications. The industry must balance immediate emissions reductions with the need to develop scalable, long-term solutions.
Hydrogen and battery electric powertrains will play leading roles, but their adoption must be supported by continued investment in infrastructure and policy frameworks that enable flexibility. In the meantime, alternative fuels and advanced emissions control technologies provide critical tools for bridging the gap to zero emissions.
As engineers and policymakers work together to navigate this transition, the focus must remain on practical solutions that meet today’s operational challenges while laying the groundwork for tomorrow’s sustainable transport systems.
