The Innovation Platform’s Maddie Hall interviewed Dr Sunita Satyapal, the Director of the Hydrogen and Fuel Cell Technologies Office at the U.S. Department of Energy, to discuss the potential of hydrogen technologies and the current initiatives of the Office in advancing this field.
As the need for energy solutions becomes increasingly apparent, hydrogen fuel cell technologies have emerged as a promising avenue for energy security. These technologies hold the potential to transform transportation, industrial processes, and power generation.
To fully realise their benefits, significant advancements in development, production, and deployment are required. The U.S. Department of Energy plays a crucial role in this transition, leading innovative initiatives that advance hydrogen technologies. Through targeted funding, strategic partnerships, and a focus on research and development, the Department is setting the stage for a hydrogen-powered future.
The Innovation Platform’s Maddie Hall spoke with Dr Sunita Satyapal, the Director of the Hydrogen and Fuel Cell Technologies Office at the U.S. Department of Energy, to discuss the department’s ongoing efforts and the strategic vision for hydrogen in creating a secure energy landscape.
Can you provide an overview of the key projects undertaken by the Hydrogen and Fuel Cell Technologies Office?
The Hydrogen and Fuel Cell Technologies Office manages hundreds of projects encompassing the entire pipeline of projects. Our research focus includes hydrogen production, delivery, storage, fuel cell technologies, safety codes and standards, as well as workforce development and community engagement.
In addition, we engage in system development and integration activities, which involve demonstrating pre-commercial technologies to mitigate risk. By integrating technological advancements, such as electrolysers, with renewable energy sources and nuclear power, we are demonstrating hydrogen systems at scale.
Over a decade ago, we established a strategy to create national lab-led consortia, providing essential funding to support these initiatives. One notable initiative is the Million Mile Fuel Cell Truck Consortium, which aims to ensure the commercial viability of hydrogen fuel cell trucks, especially for heavy-duty vehicles intended for long-haul transportation. Achieving a million miles over their operational lifetime is a critical requirement, emphasising the need for durable systems with a long lifespan in addition to extended driving ranges.
Why is the development of hydrogen fuel cell technology so crucial? Can you share some potential applications and success stories of technology so far?
Since 2004, our funding has led to the issuance of over 1000 US patents stemming from the research and development projects we have supported. This encompasses approximately 30 commercial technologies, including catalysts, membranes, and electrolysers, along with an additional 65 technologies that we anticipate could be commercialised in the near future.
One notable success story that is interesting to highlight is our early investment in hydrogen fuel cell forklifts, which operate with zero emissions in warehouse environments. Today, there are about 70,000 commercial hydrogen fuel cell forklifts in operation at major companies such as Amazon and Walmart, illustrating how government funding can foster market breakthroughs.
Another exciting new initiative we are undertaking in collaboration with the Department of Defense is the H2 Rescue fuel cell truck. The truck is designed for disaster relief and recently set a Guinness World Record for the longest distance travelled by a hydrogen-powered vehicle (travelling 1,806 miles on a single tank of hydrogen). Emitting only water vapour, this alternative to diesel trucks can provide 25 kilowatts of power for up to 72 hours without refuelling, giving it significant potential for providing power in critical situations.
What barriers are you working to overcome in developing hydrogen and fuel cell technologies?
First and foremost, cost remains one of the greatest challenges. We are actively pursuing initiatives to reduce these costs. For hydrogen production, our goal is to reach $1 per kilogramme of hydrogen within a decade, specifically by 2031. Currently, the cost of hydrogen produced from renewable sources through electrolysis ranges from $5 to $7 per kilogramme. Lowering costs across all aspects of the technology – production, delivery, storage, and fuel cells – is one of the most significant barriers we need to overcome. Government funding plays a crucial role in achieving this, as it enables private sector investment, which has, in turn, benefited commercialisation and market success.
Additionally, a key challenge lies in securing demand for hydrogen. It is essential not only to focus on boosting production but also to enhance deployment and stimulate market demand across various sectors. Ultimately, we must scale up these technologies to achieve genuine commercial viability.
How do hydrogen and fuel cell technologies contribute to the US goals for reducing greenhouse gas emissions and achieving energy security?
The U.S. National Hydrogen Strategy and Roadmap incorporated open public comments and substantial stakeholder input, and it charts the potential for the US to produce 50 million metric tons of hydrogen by 2050, with interim targets established for 2030 and 2040.
What innovations or advancements are you most excited about in the near future? How do you envision the role of hydrogen and fuel cells evolving in the US energy landscape by 2030 and beyond?
Choosing a favourite among so many initiatives is like picking a favourite child; however, we are enthusiastic about all aspects of our work. Each area, such as hydrogen production and innovations in electrolysis, is making great progress, especially as we wrap up our ongoing projects. Furthermore, emerging fields such as geologic hydrogen – often referred to as natural hydrogen – hold considerable promise. The Hydrogen and Fuel Cell Technologies Office coordinates efforts across the Department of Energy (DOE), as well as other agencies, through the Hydrogen Interagency Task Force; we are also collaborating with other agencies to explore geologic hydrogen opportunities.
Regarding end uses, fuel cell technologies are generating significant interest, especially in heavy-duty transportation, where long driving ranges and rapid fuelling capabilities are critical. We have observed significant advancements in the fuel cells we have funded. Notably, we recently launched the L’Innovator programme, which is focused on accelerating the transfer of DOE lab technologies into the commercial sector. This programme aims to connect resources with market-ready products by collaborating with industry partners and providing funding to ensure that new technologies meet market demands and have a clear path to commercialisation.
Through the Million Mile Fuel Truck Consortium, our research has produced a catalyst that has exceeded our expectations. This catalyst achieves an impressive output of 2.5 kilowatts per gram of platinum, and it is characterised by specific performance metrics and cost objectives. We are currently offering this technology, along with its associated intellectual property, for licensing to the industry. This advancement has the potential to significantly enhance related technologies.
One of our previous initiatives established an innovator pilot in collaboration with National Lab technology to mitigate risk. Our investment of $2m catalysed an impressive $160m from the private sector toward the establishment of manufacturing facilities for catalysts and fuel cells, demonstrating the effectiveness of our support.
The outlook for the industry is incredibly positive, and the market is experiencing significant growth, particularly in electrolyser installations. Since 2021, we have documented a 25-fold increase in these installations – we have recorded 4.5 gigawatts that are either planned or currently underway in the United States, compared to just 0.17 gigawatts in 2021.
In conclusion, the combination of significant advancements in hydrogen technologies, robust policy support, substantial investment, and dedicated research positions the US hydrogen industry to emerge as a global leader. As these elements come together, the potential for growth and innovation in this sector will pave the way for an energy future, benefiting both the economy and the environment.
This article is based on an interview conducted with Dr Sunita Satyapal on 10 January, 2025, before she retired from the Department of Energy as Director of the Hydrogen and Fuel Cell Technologies Office.
Please note, this article will also appear in the 22nd edition of our quarterly publication.
