The lettering “HYDROGEN” gives it away: No ordinary Opel Vivaro-e are parked in front of the M55 on the Rüsselsheim factory premises – they are small power plants on wheels. The electricity that powers the vans is not stored in large batteries. Instead, it is generated while driving. There are three hydrogen tanks (in the underbody) and one fuel cell (under the hood) on board. The system is additionally supported by an externally chargeable battery. Fuel cell drive plus plug-in charging – is Opel reinventing the plug-in hybrid? We are curious.
On a test drive with Dr. Lars Peter Thiesen we want to learn more about the alternative electric drive à la Opel. And the head of the hydrogen and fuel cell introduction strategy is in a good mood when he takes his seat in the driver’s seat. No wonder, since the doctor of physics joined the company in 1998, he has been working towards this goal: “With the Vivaro-e Hydrogen, we are now the first manufacturer to put a hydrogen LCV on the road – a milestone!” turns the ignition key.
The electric offensive is rolling: Opel has invited journalists to Rüsselsheim for test drives with the Vivaro-e Hydrogen. A hydrogen fuel cell drive is at work under the hood. There is also a battery on board that can be charged externally.
“With the Vivaro-e Hydrogen, we are now the first manufacturer to put a hydrogen LCV on the road – a milestone!”
Competent contact person: Dr. Lars Peter Thiesen is responsible for the hydrogen and fuel cell introduction strategy at Opel. During a test drive, he explains the innovative concept for the Opel Post.
No compromises: the 45 kW fuel cell provides power for longer journeys, and the lithium-ion battery supports it to cover peak loads. At the same time, the full loading volume is available.
The power plant rolls off noiselessly. The manager explains the interaction between fuel cell and battery, processes that take place in secret: hydrogen is fed from the tanks in the underbody towards the fuel cell, the pressure is reduced from 700 to around 1 to 2 bar. The battery under the front seats takes care of starting off for the first few meters. It also provides support during peak loads, for example when accelerating.
Clever overall concept
But the combined plug-in fuel cell concept not only ensures more power, the fuel cell can always work under optimal conditions. “That increases the service life,” says Thiesen, “and plug-in also means that we can recover braking energy.” The biggest plus, however, is the clever packaging that makes the multi-part concept possible. “The body is unchanged. This means that the loading volume of up to 6.1 cubic meters is retained, as are the payload and trailer load – essential parameters for a van.” Last but not least, the battery ensures an extra 50 kilometers of range.
A soft buzzing starts. “The compressor starts,” comments Thiesen. We learn that the compressor is now combining outside air with the hydrogen in the fuel cells. The chemical reaction that produces the electricity starts. And the Transporter – it just drives. No jerking, no hopping. Nothing but smooth gliding. “And the only product of the reaction is pure water vapor from the exhaust.” So we drive with zero emissions.
“The only product of the chemical reaction is pure water vapor from the exhaust – we drive with zero emissions.”
Done quickly: refueling with hydrogen takes just a few minutes. According to WLTP, the range is up to 400 kilometers.
Practical: All hydrogen filling stations in Germany are operated by H2 Mobility; you only need one fuel card.
The emission-free plug-in fuel cell vehicle is the result of decades of hydrogen expertise. For more than 20 years, colleagues in the company have gained experience with the “cold combustion” of hydrogen, conducted basic research and set industry standards. Thiesen remembers the first prototype, the HydroGen1, which attracted media attention as a pace car in the marathon competitions of the 2002 Olympic Games in Sydney, or the HydroGen4, which six years later proved its suitability for everyday use in an internationally important market test. “Long range, zero emissions, short refueling stops: the advantages were and are obvious. And we have always pushed the technology forward – with the utmost conviction.” The biggest problem at the time was the lack of a network of filling stations. Nobody wanted to build that up until hydrogen vehicles were on the road. But this chicken-and-egg dilemma has been overcome.
Core competency: Fast refueling
H2 Mobility GmbH, a consortium consisting of energy companies and car manufacturers, currently operates 95 hydrogen filling stations in Germany alone, and the trend is rising. In the Rhine-Main area, for example, there are two petrol stations in Frankfurt, one in Offenbach and one in Wiesbaden. The Opel manager is currently driving the latter. Because: A test drive in the Vivaro-e Hydrogen is not complete without a demonstration of the core competence – refueling in minutes for a range of up to 400 kilometers according to WLTP.
And it’s really quick: Open the tank cap, put on the fuel nozzle, an integrated infrared interface recognizes the vehicle type, press the green start button and with a quiet hiss, gaseous hydrogen is pumped into the tank at a pressure of 700 bar. After three minutes, the refueling process is complete, the hydrogen display in the cockpit confirms it – the only detail, by the way, that distinguishes the hydrogen in the interior from an ordinary Vivaro-e.
Made in Ruesselsheim
Compact: The fuel cell is located under the bonnet.
The Opel Vivaro-e HYDROGEN and its group sister models are manufactured at Opel Special Vehicles (OSV) in Rüsselsheim. In the 1,500 square meter production area with 70 employees, several hundred units of the zero-emission van can be produced per year. The drive battery of the Vivaro-e is replaced by three 700-bar hydrogen tanks made of carbon fibers with a total capacity of 4.4 kilos. The 45 kW fuel cell drive is also so compact that it fits under the bonnet together with the 100 kW/136 hp electric drive. The 10.5 kWh lithium-ion battery housed under the front seats provides support when starting or accelerating and at top speed. It can be charged externally so that the vehicle can travel 50 kilometers purely on battery power.
Competent: Hydrogen chief engineer Peter Gross (second from right) explains the conversion procedure to media representatives. Among other things, the drive battery in the underbody of the Vivaro-e will be replaced by three 700 bar hydrogen tanks – shown here in the foreground.
Advantages of the plug-in fuel cell concept: The body structure does not have to be changed and the loading volume also remains unchanged. The van, which is available in lengths M and L (4.96 and 5.30 metres), has 5.3 and 6.1 cubic meters of load compartments that are the same size as the diesel or battery-electric Vivaro variants.
Hydrogen production is currently being ramped up in coordination with the suppliers. The OSV experts already supported the engineering department in the development and construction of prototypes. Because the know-how gained in Rüsselsheim will be used for future series production in the plants. The Opel parent company Stellantis has announced that the drive will also be installed in larger vans and pick-ups.
In demand: Not only the Hydrogen with lightning bolt on the radiator grille, but also the sister models of the group are converted at OSV in Rüsselsheim.
“We have always believed in fuel cells. It was a matter of time. And now she has come.”
The decision to design and develop the Vivaro-e Hydrogen was made three years ago, says the manager on the return trip to Rüsselsheim. “That was a special moment: we always believed in the technology. It was a matter of time. And now she’s come,” he says with conviction. After all, the efficiency of drives with hydrogen fuel cells is about twice as high as that of internal combustion engines. The federal government also sees the potential and has now created an important funding instrument with the KsNI program (climate-friendly commercial vehicles and infrastructure). In addition, the fuel cell specialist points out that hydrogen is an excellent storage medium for electricity from renewable sources.
Contribution to the electric offensive
The fuel cell does not compete with the battery. “It’s not either or, it’s both and,” says Lars Peter Thiesen. Depending on the requirements, every technology can play to its strengths. “Since range and time savings play a major role, especially for fleet customers and in delivery traffic, we decided to launch the fuel cell drive for light commercial vehicles,” he explains. And the more customers decide in favor of a fuel cell vehicle, the further the costs will be reduced. Household appliance manufacturer Miele is one of the first customers to opt for the emission-free Opel van. Service technicians are already using it in the Rhine-Main area. If the Opel strategist has his way, the hydrogen fuel cell drive could also be used in additional vehicle classes. “The potential to fully replace today’s combustion engines – that’s there.”
Versatile: The number of potential customers is large and ranges from household appliance manufacturer Miele – the first vans are already in use here – to parcel delivery companies, municipalities, public utility companies and energy suppliers.
Learned a lot: With the new Vivaro-e HYDROGEN, Opel is consistently continuing its electric offensive. And customers can choose which drive concept in the Opel commercial vehicle portfolio best suits their requirements.
June 2022
Photos: Dani Heyne