An Evaluation of Opportunities Arising from Hydrogen Retrofitting of Commercial Vehicles in Urban Areas: A Case Study

This article investigates the feasibility of hydrogen-based retrofitting solutions for light commercial vehicles operating in urban freight transport. The analysis is based on a mission-driven methodology applied to a representative urban case study in the city of Rome, using synthetic route profiles and vehicle specifications derived from manufacturer datasheets. Three representative urban delivery missions are defined, characterised by cumulative daily distances of approximately 190–200 km and associated energy requirements in the range of 54–57 kWh. These mission profiles are first used to assess a commercially representative battery electric vehicle configuration, for which the usable onboard battery energy is estimated at 41.6 kWh. The results show that, under the considered operating conditions, the battery electric configuration is not able to complete the planned routes without intermediate recharging. On this basis, a fuel cell hybrid electric vehicle retrofit configuration is evaluated, combining a 35 kWh battery, a 45 kW fuel cell system and 3.5 kg of onboard hydrogen storage at 350 bar. The resulting estimated driving range is approximately 293 km, which is sufficient to satisfy the defined mission requirements. This study is framed as a technical feasibility assessment and does not aim to provide optimisation or experimental validation. The proposed methodology can be applied to other urban contexts by adapting route characteristics and daily mileage requirements.