Authors:
Daniel Feseha Melesse, Adey Melesh GmbH
[Affiliations, Contact Information]
Date: [11.07.2025]
Correspondence: Daniel_melesse@gmx.de
Abstract
This paper presents a real-world blueprint for the full-scale conversion of a large municipal waste collection fleet—Abfallwirtschaftsbetrieb München (AWM)—from conventional diesel to hydrogen combustion vehicles (H₂-ICE), including all required infrastructure, regulatory, and economic considerations. The project leverages recent advances in hydrogen engine technology, modular refueling infrastructure, and digital fleet management. Key findings include a projected total investment of €119 million, annual operational savings of €4.8 million, and a potential amortization period of under 8 years with public funding. The study provides a replicable model for other cities aiming for CO₂-neutral logistics by 2035.
1. Introduction
Urban waste collection is a critical municipal service with high environmental impact due to heavy-duty diesel fleets. With tightening emission regulations and the need for climate-neutral operations, hydrogen combustion engines (H₂-ICE) are emerging as a pragmatic alternative to battery-electric and fuel cell vehicles, particularly for high-utilization, heavy-duty applications. This paper details the technical, financial, and regulatory pathway for converting the entire AWM fleet (230 heavy trucks) to hydrogen, including infrastructure development, legacy fleet handling, and digital integration.
2. Project Scope and Objectives
- Fleet Conversion: Gradual replacement of 230 heavy-duty refuse trucks with H₂-ICE vehicles over five years.
- Infrastructure: Construction of an on-site 700-bar hydrogen refueling station (1,000 kg/day), modular electrolyzer system (3 MW), and water treatment plant.
- Legacy Fleet Management: Buyback and resale of diesel vehicles at book value.
- Certification: Full compliance with German and EU regulations (TÜV, Umweltbundesamt, ATEX, etc.).
- Digital Integration: Centralized, modular software architecture for safe, efficient operation and predictive maintenance.
3. Technical Solution
3.1 Vehicle Technology
- Chassis: Mercedes-Benz, MAN, Volvo, Scania.
- H₂ Engine: Keyou, Cummins, Toyota, MAN (300–400 HP, 350–700 bar H₂ storage).
- Transmission: ZF, Allison, Voith.
- Hydrogen Storage: Hexagon Purus, NPROXX, Plastic Omnium (Type IV composite tanks).
- Safety: H₂ leak sensors (Dräger, Bosch), ATEX-compliant systems, active ventilation.
- Retrofit Components:
- H₂-ICE with plasma-coated piston rings, hydrogen-safe valve guides
- Direct H₂ injection (piezo injectors, diamond seals)
- Optimized turbochargers (ceramic bearings)
- H₂-specific ECU and expanded cooling system
3.2 Refueling and Energy Infrastructure
- Electrolyzer: Sunfire SynLink 3000 (3 × 1 MW PEM, 450 kg/day/unit, <75 kWh/kg H₂).
- Water Treatment: Grünbeck RO-5000 (5 m³/h, <0.1 µS/cm).
- Refueling Station: EDC HSC-700bar container (modular, 1,000 kg/day, 700 bar, SAE J2601-compliant).
- Energy Source: 54–72 MWh/day (green electricity, PV/wind/biogas mix).
- Water Demand: 25–30 m³/day demineralized water.
3.3 Digital & Software Integration
- Centralized Control: Modular CAN/Ethernet architecture (Bosch, AVL).
- Cloud Connectivity: Predictive maintenance, fleet analytics, OTA updates.
- Safety Compliance: ISO 26262, ATEX, remote monitoring, automated shutdowns.
4. Economic Analysis
4.1 Capital Expenditure (CAPEX)
| Item | Cost (€ million) |
|---|---|
| 230 H₂ Trucks | 103.5 |
| Hydrogen Infrastructure | 7.0 |
| Legacy Fleet Handling | 8.0 |
| Certification | 0.5 |
| Total | 119.0 |
4.2 Operational Expenditure (OPEX) & Savings
- Annual OPEX (full fleet): €8.1 million
- Hydrogen: €4.6 million (2,300 t/year @ €2/kg)
- Maintenance: €2.3 million (30% below diesel)
- Insurance/tax: €1.2 million
- Annual Savings: €4.8 million
- CO₂ tax: €2.3 million (7,700 t/year @ €300/t)
- Fuel: €1.5 million (vs. diesel)
- Maintenance: €1.0 million
- Payback Period:
- Without grants: ~25 years
- With 50% grants (BAFA/KfW): ~12–15 years
5. Regulatory & Safety Roadmap
- Vehicle Approval: §21 StVZO, ABE for H₂ systems, EMC testing.
- Station Compliance: ATEX 2014/34/EU, PED 2014/68/EU, TRGS 800.
- Electrolyzer: VDE-AR-N 4110, UVP, Bundesnetzagentur registration.
- Documentation: Full technical dossiers, risk analyses, TÜV certification.
- Safety:
- Zoning per IEC 60079-10-1
- Automatic H₂ detection, shutdown, and fire suppression
- Annual H₂ safety drills and staff training
6. Implementation Timeline
| Year | Milestone |
|---|---|
| 2025 | 1st batch (46 trucks), station construction |
| 2026 | 2nd batch, station commissioning, legacy sale |
| 2027 | 3rd batch, full H₂ infrastructure operation |
| 2028 | 4th & 5th batches, complete conversion |
| 2030 | Full operation, digital monitoring |
7. Environmental and Social Impact
- Zero Particulate Emissions: Ideal for urban environments.
- Extended Vehicle Life: Lower wear vs. diesel.
- Regulatory Future-Proofing: Diesel bans irrelevant.
- ESG Leadership: Attractive for green bonds and impact investors.
- CO₂-Neutral Operations: On track for 2035 city targets.
8. Discussion: Innovations and Open IP
- Open Patents: Expired IP in compaction, hydraulics, and control systems enables cost-effective, modular design.
- Recent Innovations:
- Adaptive hydraulic systems
- Intelligent compaction force control
- Cloud-based fleet management
- H₂-specific safety architectures
- Supplier Ecosystem:
- Chassis: Mercedes, MAN, Volvo, Scania
- H₂ Engines: Keyou, Cummins, Toyota, MAN
- Tanks: Hexagon Purus, NPROXX
- Hydraulics: Bosch Rexroth, Parker
- Software: AVL, Bosch, Faun, Keyou
9. Conclusions
This project demonstrates the technical and economic feasibility of converting a large municipal waste fleet to hydrogen combustion, with significant operational savings, regulatory compliance, and environmental benefits. The modular, open-architecture approach ensures future scalability and risk mitigation. The AWM case offers a replicable model for other cities seeking rapid, impactful decarbonization of heavy-duty fleets.
10. Recommendations
- Engage Key Suppliers Early: For vehicle, infrastructure, and digital systems.
- Leverage Grants: Maximize BAFA/KfW/NIP2 funding.
- Prioritize Digital Integration: For operational safety and efficiency.
- Plan for Water/Energy Supply: Secure green electricity and reliable water sources.
- Continuous Training: For safe H₂ operations and emergency response.
References
- Sunfire SynLink 3000 Technical Datasheet (2025)
- EDC HSC-700bar System Documentation (2025)
- Grünbeck RO-5000 Product Information
- MPIE Studies on Hydrogen Embrittlement (2023)
- Toyota Materials Research Reports (2024)
- NIP2 Funding Guidelines (2024)
- TUM Study on PEM Electrolyzers (2024)
- [Daloa.de / Adey Meselesh GmbH]
Appendices:
- System Diagrams
- Supplier Contact List
- Regulatory Checklist
- Detailed Cost Breakdown
This research paper is intended as a practical guide and reference for municipal fleet operators, policymakers, and industry stakeholders considering hydrogen combustion for heavy-duty fleet decarbonization.