Hydrogen Truck Breaks World Record: 1,806 Miles Without Refueling

1,806 Miles Without Refueling: US DOE’s Hydrogen Truck Sets World Record

A groundbreaking hydrogen fuel cell electric truck, H2Rescue, has set a Guinness World Record for the longest distance traveled without refueling, highlighting the potential of zero-emission haulers for emergency response.

The Record-Breaking Journey

• Distance Traveled: 1,806 miles (2,906 kilometers)
• Hydrogen Consumption: 386 pounds (175 kilograms)
• Verified by: Guinness World Records adjudicator, who ensured the hydrogen tank remained sealed during the trip.

The H2Rescue’s journey between Oakland and West Sacramento, California, demonstrated its reliability in real-world conditions. Navigating public roads at speeds of 50–55 mph (80–89 km/h), the truck operated in temperatures ranging from 60°F to 80°F (16–27°C).

Collaborative Innovation

The project is a joint effort involving:

• US Army Engineer Research and Development Center (ERDC)
• US DOE’s Hydrogen and Fuel Cell Technologies Office
• US Army Ground Vehicle Systems Center (GVSC)
• US Department of Homeland Security’s Science & Technology Directorate (DHS S&T)
• US Naval Research Laboratory
• Accelera by Cummins

This team envisioned the truck as a solution to increasing natural disasters and the need for energy-efficient emergency response vehicles.

H2Rescue: A Revolution in Disaster Response

The H2Rescue is not just a truck—it’s a mobile command center, emergency shelter, and power generator.

Key Features:

1. Zero-Emission Technology
   • Powered by a Cummins Accelera hydrogen fuel cell engine.
   • Utilizes hydrogen storage, an electric drivetrain, and high-energy lithium-ion batteries.
   • Byproducts: Only water and heat, ensuring environmental friendliness.
2. Energy Efficiency
   • Delivers 25 kW of continuous power—enough for 20 homes, shelters, or communication trailers.
   • Energy utilization exceeds 80%.
3. Emergency Water Supply
   • The fuel cell generates water, which can be treated for drinking or other uses during crises.
4. Roadworthy Design
   • Classified as a Class 7 heavy-duty truck, weighing 33,000 pounds (15,000 kilograms).
   • Carries up to 388 pounds (176 kilograms) of hydrogen at 700 bar.

Field Testing and Demonstrations

• In 2023, the truck completed two 180-mile (290-kilometer) round-trip demonstrations, powering shelters for 72 continuous hours.
• In April 2024, H2Rescue was showcased at Capitol Hill during the World Fire Congress, introducing global decision-makers to its capabilities.

Record-Setting Impact

• Hydrogen Efficiency: During the record run, the truck consumed 168 kilograms (370 pounds) of hydrogen.
• Environmental Benefits: Transitioning to H2Rescue could save 1,825 gallons (6,908 liters) of gasoline annually per truck and reduce greenhouse gas emissions by 2.5 metric tons (2.8 tons) each year.

A Vision Realized

“This project started with an idea on paper during the California wildfires. A group of federal researchers asked, ‘How can we create something to support emergency situations?’ Five years later, that idea set a world record,” said Nick Josefik, an ERDC-CERL industrial engineer and H2Rescue team lead.

H2Rescue represents a new era of emergency response—one that combines innovation, sustainability, and practicality to address the growing challenges of disaster relief.

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