IE-DRIVE HD100 100kW fuel cell systems

100kW fuel cell system for buses, trucks and stationary power applications

IE-DRIVE HD100 hydrogen fuel cells for buses, trucks and stationary power

IE-DRIVE™ HD100 is Intelligent Energy’s (IE) as a complete heavy duty fuel cell system, engineered to deliver up to 100 kW of continuous zero-emission power. Designed for demanding automotive and industrial applications, it combines high performance with compact packaging and simplified integration

At the heart of the HD100 system is a robust fuel cell module that houses both the PEM fuel cell stack and the majority of the balance of plant (BoP) components. This integrated design minimises system complexity and installation. To further streamline deployment, IE provides essential auxiliary components – including a heat exchanger and exhaust system – ensuring that customers receive a near-complete solution ready for integration.

The HD100 system adheres to the StaSHH (Standardisation of Heavy-Duty Hydrogen) interface standard, enabling compatibility with a wide range of vehicle platforms and simplifying the adoption of hydrogen technology across the industry. It has been developed with road-use certification in mind, making it ideal for integration into buses, trucks, and other on-road commercial vehicles.

 

Applications of IE-DRIVE HD100 fuel cell systems

The system is highly versatile and suitable for a broad spectrum of motive and stationary applications, including:

  • Heavy duty road vehicles such as coaches, buses and trucks
  • Material handling equipment (MHE) such as forklifts and port vehicles
  • Off-highway vehicles used in mining, agriculture, and construction
  • Rail and marine propulsion systems seeking clean alternatives to diesel
  • Stationary and mobile power systems, including hybrid generators, emergency backup units, and scalable multi-megawatt hydrogen power plants

Fuel cells versus batteries

Feature IE-DRIVE HD100 Battery alternatives
Maximum net output 100kW The typical power output for a battery electric Heavy Goods Vehicle (HGV) ranges from 330 kW to 490 kW for continuous operation, with peak outputs often exceeding 600 kW
Weight 285kg The weight difference is most dramatic in long-haul trucking. For an 800km range, a fuel cell powertrain can be up to 2 tonnes lighter than a battery-electric equivalent
Range 400-1,000km Battery electric HGVs typically offer a driving range between 300 km and 500 km (approx. 186–310 miles) on a single charge, significantly lower than the 1,000–1,200 km typically achieved by diesel trucks
Refuelling/recharge time <10 minutes The average time depends on whether you are at a depot, a warehouse, or a high-power motorway station but can range between 45 minutes and 8 hours
Cold weather performance -20°C to +40°C Typically lose 20% to 40% of their range in freezing conditions. This drop is caused by slowed internal chemical reactions and the heavy energy drain from cabin heaters and battery thermal management systems

Summary product information

System architecture

Fuel cell system: Fuel cell module package, includes fuel cell stack, low pressure hydrogen management, air compressor module, internal water module and control system. Heat exchanger, exhaust & intake filter packaged separately

Fuel cell stack: IE patented evaporatively-cooled fuel cell stack design – metallic pressed plate, bi-polar design (no separate cooling plates)

System electrical output

Through life power 110kW

Maximum voltage 385V

Physical excluding condenser

Mass 285kg

Fuel cell module dimensions (L x H x W): 1260 x 520 x 700mm

Volume 460 litres

Environment

Operating ambient temp. -20°C to +40°C nominal (-40°C to +65°C derated)

Storage / Shipment -40°C to +85°C

Fuel

Type Gaseous hydrogen to ISO 14687:2 grade D

Peak efficiency 55%

Fuel flow rate at 70kW 4.6kg/h at BoL to 5.6kg/h at EoL

Fuel supply pressure 6 to 10 bar gauge

* Please refer to the datasheet for the full product specification.

Top