FCH2RAIL · Project

Hydrogen Fuel Cell Power System That Replaces Diesel Engines on Trains

transportPilotedTRL 7

Imagine a train that runs on electricity from overhead wires where they exist, but switches to a hydrogen fuel cell — like a giant, clean battery — on stretches without wires. That's exactly what FCH2RAIL built: a modular power unit that slots into existing trains so operators don't need to buy entirely new fleets. They retrofitted a real train and ran it across the Spain-Portugal border, proving it works in everyday conditions. The goal is to give rail operators a drop-in replacement for dirty diesel engines on routes that aren't fully electrified.

By the numbers

TRL7

Target technology readiness level — system demonstrated in operational environment

Consortium partners involved in development

Countries in the consortium (BE, DE, ES, PT)

Industry partners in the consortium

62%

Industry ratio in the consortium

EU countries targeted for train homologation

Total project deliverables

The business problem

What needed solving

Rail operators across Europe are stuck between two bad options: keep burning diesel on non-electrified routes (rising fuel costs, tightening emissions rules) or invest billions in full electrification that takes decades to complete. They need a clean, cost-competitive power source that works with their existing trains and infrastructure — without waiting for wires to be strung across every kilometre of track.

The solution

What was built

The project built a modular Fuel Cell Hybrid PowerPack and integrated it into a real bi-mode train demonstrator, tested cross-border in Portugal and Spain. Key deliverables include the commissioned hydrogen system with fuel cell cooling, the full PowerPack commissioning, a hydrogen refuelling station prototype in service, and a Life Cycle Cost model comparing fuel cell hybrid traction against diesel across different rail sectors.

Audience

Who needs this

Regional rail operators running diesel trains on non-electrified or partially electrified routesRolling stock manufacturers looking to offer hydrogen-powered train variantsNational transport ministries planning rail decarbonisation strategiesHydrogen infrastructure companies seeking anchor customers in transportRail maintenance and retrofit companies expanding into green technology

Business applications

Who can put this to work

Rail transport operators

enterprise

Target: Regional and national rail operators running diesel on non-electrified lines

If you are a rail operator still burning diesel on non-electrified routes — this project developed a modular Fuel Cell Hybrid PowerPack tested to TRL7 that retrofits into existing trains. Instead of scrapping your fleet or waiting decades for full electrification, you plug in a hydrogen unit that takes over when the overhead wire ends. The system was demonstrated cross-border in Portugal and Spain with homologation pursued in 3 EU countries.

Rolling stock manufacturing

enterprise

Target: Train manufacturers and system integrators looking to offer zero-emission options

If you are a rolling stock manufacturer needing to offer decarbonised trains without redesigning from scratch — this project produced a scalable, modular power pack applicable to multiple unit trains, mainline locomotives, and shunting locomotives. The design was validated through commissioning tests and a full demonstrator integration, giving you a proven reference architecture. With 10 industry partners across 4 countries already in the consortium, the supply chain groundwork is laid.

Hydrogen refuelling infrastructure

mid-size

Target: Energy companies and infrastructure providers building hydrogen supply for transport

If you are an energy company investing in hydrogen infrastructure and looking for anchor demand — this project demonstrated a hydrogen refuelling station prototype as part of the rail demonstrator. Rail is ideal because trains follow fixed routes with predictable fuel needs, making station placement straightforward. The project's 16-partner consortium across 4 countries mapped out normative and standards gaps for EU-wide hydrogen rail deployment.

Frequently asked

Quick answers

What does a hydrogen retrofit cost compared to full electrification?

The project built a Life Cycle Cost (LCC) model specifically to prove competitiveness of fuel cell hybrid traction against diesel. While exact cost figures are not published in the available data, the LCC model covers different rail sectors and derives cost reduction potentials — ask for the detailed results.

Can this scale to our entire fleet and different train types?

Yes — the Fuel Cell Hybrid PowerPack was designed to be scalable and modular, applicable to multiple unit trains, mainline locomotives, and shunting locomotives. It also supports retrofit of existing electric and diesel trains, meaning you don't need a new fleet.

What is the IP situation — can we license this technology?

The project was an Innovation Action with 16 partners including 10 industry players. IP is likely shared among consortium members under Horizon 2020 grant agreement rules. Contact the coordinator (DLR) or specific industrial partners for licensing discussions.

Has this been approved by rail safety regulators?

The project pursued homologation in 3 EU countries and conducted a systematic screening of hydrogen and rail-related EU normative and standards gaps. The consortium actively participated in standardisation and norming workgroups, which is critical groundwork for regulatory approval.

How mature is this — lab prototype or something that actually runs on tracks?

This is a real train running on real tracks. The demonstrator was a retrofitted bi-mode multiple unit tested cross-border in Portugal and Spain. Deliverables include photo and video evidence of the integrated system and hydrogen refuelling station in service. The target was TRL7 — system prototype demonstrated in operational environment.

How does it integrate with existing rail infrastructure?

The system is designed as a bi-mode solution: it draws electricity from the catenary on electrified sections and switches to the fuel cell hybrid system on non-electrified sections. An energy management system handles the transition automatically, minimising energy consumption across both modes.

Who built this and can they support deployment?

The consortium of 16 partners across 4 countries is led by DLR (German Aerospace Center) and includes 10 industry partners. With a 62% industry ratio and partners in Germany, Spain, Portugal, and Belgium, commercial support capacity is strong.

Consortium

Who built it

This is a heavily industry-driven consortium: 10 out of 16 partners (62%) are industry players, with 3 research organisations and 3 other entities rounding out the team. Led by DLR, one of Europe's premier aerospace and transport research centres, the consortium spans 4 countries — Germany, Spain, Portugal, and Belgium — giving it cross-border credibility and market access. The low SME count (just 1) suggests this is big-industry territory where established rail and energy companies dominate. For a business looking to adopt or partner, this means the technology has serious industrial backing and the consortium likely has the capacity to support commercial deployment.

DEUTSCHES ZENTRUM FUR LUFT - UND RAUMFAHRT EVCoordinator · DE
Construcciones y Auxiliar de Ferrocarriles, S.A.participant · ES
TOYOTA MOTOR EUROPE NVparticipant · BE
CENTRO DE ENSAYOS Y ANALISIS CETEST SLthirdparty · ES
CAF POWER & AUTOMATION SLthirdparty · ES
INFRAESTRUTURAS DE PORTUGAL SAparticipant · PT
CENTRO NACIONAL DE EXPERIMENTACIONDE TECNOLOGIAS DE HIDROGENO Y PILASDE COMBUSTIBLE CONSORCIOparticipant · ES
Renfe Operadoraparticipant · ES
CAF TURNKEY & ENGINEERING SOCIEDAD LIMITADAthirdparty · ES
FAIVELEY TRANSPORT LEIPZIG GMBH & CO. KGthirdparty · DE
ADMINISTRADOR DE INFRAESTRUCTURAS FERROVIARIASparticipant · ES
CONSTRUCCIONES Y AUXILIAR DE FERROCARRILES INVESTIGACION Y DESARROLLO SLthirdparty · ES

How to reach the team

DLR (Deutsches Zentrum für Luft- und Raumfahrt) in Germany — reach their transport research division

Order a report on this consortium See DEUTSCHES ZENTRUM FUR LUFT - UND RAUMFAHRT EV profile →

Next steps

Talk to the team behind this work.

Want an introduction to the FCH2RAIL team or a detailed technology brief for your rail decarbonisation strategy? Contact SciTransfer — we connect businesses with EU research teams.

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