Notice

Red Diesel Replacement competition: Phase 2 successful projects

Updated 22 April 2024

Phase 2 of the Red Diesel Replacement (RDR) competition funds projects to demonstrate an end-to-end low-carbon solution to replace red diesel-using technologies on construction and mining or quarrying sites. This is designed to accelerate deployment of such technologies across UK industry, contributing to achieving net zero by 2050.

The following 6 projects will receive combined grant funding of around £25.7 million for Phase 2, leveraging around £14.2 million in private investment.

DEPOWER 2

• Project owner: Danfoss Scotland Limited
  
• Location: Edinburgh
  
• Amount being awarded: £4,941,809.00

Project description

A major barrier to electrification of construction equipment is cost associated with large, expensive batteries and suitable charging infrastructure due to the current high power consumption of these machines. Currently excavator hydraulic systems waste around 70% of useful power delivered by the engine. This project aims to accelerate electrification of these machines through improving the energy efficiency of excavators, which will reduce battery size and charging energy required.

Invented, developed and manufactured in the UK, Digital Displacement® is a fundamental advance in hydraulic power, replacing traditional analog mechanisms with innovative digital pump and actuator control systems. The first two tiers of Danfoss’s Dextreme products, Swap and Flex, have been proven to reduce energy consumption by 15% and 30%, respectively. This project will demonstrate the next iteration of the product, Dextreme Max, and aims to reduce energy consumption by up to 50% of traditional excavators, through reducing energy losses and recovering waste energy.

Under Phase 1, a prototype Digital Displacement pump/ motor was developed to enable energy recovery, and proven to reach expected efficiency levels in a test rig. Phase 2 will integrate this into a large battery/ electric excavator, and demonstrate operation in a quarry. The project also aims to prove the components of the technology (machine, controller, system hardware and software) and develop simulation tools to accelerate development.

Demonstration of decarbonised quarrying operations through E-Diesel and hydrogen dispensing technologies

• Project owner: CATAGEN Limited
  
• Location: Belfast
  
• Amount being awarded: £6,274,318.73

Project description

This Phase 2 project will be delivered by a consortium of three NI-based successful RDR Phase 1 recipients; CATAGEN, TEREX and WRIGHTBUS. The project seeks to build on the success of the consortium partners’ Phase 1 projects to produce a robust set of equipment, integrating conventional and novel technologies, for quarrying and recycling industries with net zero carbon emissions and a significant reduction in all engine emissions.

The objective is to develop the solution to pre-production readiness level and demonstrate the full systems approach at 2 trial sites. The benefits of this concept lie in the integration of well-proven equipment with new technology capable of delivering a fully decarbonised, robust solution for the industry.

The scope covers 3 main themes:

1. Evolution of the TEREX crusher and screener for improved energy efficiency through low-carbon power supply.

2. Development of CATAGEN’s e-diesel technology (ClimaHtech E-FUEL) for pilot-scale production.

3. Integration of CATAGEN’s hybrid compression and dispensing technology (ClimaHtech COMPRESSOR) with WRIGHTBUS’s mobile hydrogen bowser to support refuelling of a hydrogen genset and dual-fuel engine at a demonstration site.

The project will model alternative fuels for on-road and off-highway applications, plan future use and developments post-demonstration for commercialisation of the technology. Key learnings and results will be shared through dissemination activities.

Red garnet red diesel generator alternative

• Project owner: AFC Energy Plc
  
• Location: Surrey
  
• Amount being awarded: £4,823,728.13

Project description

AFC Energy has formed a well-to-work consortium to demonstrate the use of green hydrogen to displace red diesel at UK quarry sites. AFC Energy develop modular, scalable hydrogen fuel cell and hydrogen-carrier conversion systems, and are working with; Energy Solutions, a battery energy storage system (BESS) manufacturer; and Brett Aggregates, a quarry operator and cement supplier.

The project will demonstrate the supply chain and technology of AFC Energy’s H-Power S/S+ Series emissions-free hydrogen gensets through one month deployments of green hydrogen-fuelled gensets at two quarry locations. The gensets will displace red diesel generators across the two most commonly deployed power ratings: 30-50kVA and 250kVA. The H-Power S Series is an air-cooled fuel cell generator which will be operated with a BESS with a minimum usable capacity of 45kWh and the H-Power S+ Series is a liquid-cooled fuel cell generator to be operated with a BESS with a minimum usable capacity of 184kWh.

The gensets’ deployment will demonstrate the flexibility and power range of hydrogen fuel cells, BESS and the potential to displace virtually all off-grid diesel generators in construction, mining and quarrying sectors. Demonstration in working quarry sites under identical conditions will enable the cost of ownership, durability and suitability of the emissions-free gensets to be established. Key findings from the project will be shared through dissemination activities.

Comprehensive hydrogen supply-chain solutions for NRMM (H2-to-Site)

• Project owner: Ryze Hydrogen Limited
  
• Location: Oxford
  
• Amount being awarded: £3,212,280.99

Project description

While there has been considerable progress in the development of hydrogen fuelled construction machinery, there is a lack of hydrogen refuelling infrastructure tailored to construction sites, which poses a barrier to hydrogen adoption as fuel. This project aims to overcome this barrier through demonstration of a hydrogen supply chain and development of associated equipment that is mobile, flexible, and provides hydrogen on-demand at construction sites.

A new suite of production-ready modular hydrogen refuelling technologies will be developed which are flexible to the needs of diverse construction sites. The refuelling technologies to be tested include; bowsers, tube trailers, refueller, a portable compressor, and a second generation fuel cell. Different refuelling equipment configurations will be demonstrated, as part of an end-to-end hydrogen solution, to refuel a range of hydrogen fuelled machines, including backhoe loaders, telescopic handlers and excavators, at a working test quarry.

The project unites a UK hydrogen supplier, Ryze Hydrogen, with a leading construction equipment manufacturer, technology suppliers (iGAS and Wrightbus) and leading global construction firms (Skanska, Mace Dragados and Sizewell C). It will support development and dissemination of standard operating procedures, site safety, equipment standardisation and hydrogen knowledge sharing. The project will also deliver case study reports from project partners on the feasibility for hydrogen use on major construction sites from 2025.

Element1: Leading the construction industry towards zero emissions future

• Project owner: BAM Nuttall Limited
  
• Location: Camberley
  
• Amount being awarded: £4,872,653.62

Project description

Element1 will design and demonstrate an end-to-end solution for the manufacture, supply, distribution, storage, and use of hydrogen as an alternative to diesel on a construction site, powering construction plant and equipment. The project aims to accelerate displacement of diesel-fuelled technologies whilst enabling existing plant to continue in-use over its remaining lifecycle.

The project will adapt and develop dual fuel technology, converting a range of construction plant alongside a hydrogen fuelled generator. The project will also develop a hydrogen manufacturing and supply chain, including off-site production and on-site, off-grid compression, as well as developing innovative on-site storage and distribution solutions, tailored to on-site construction requirements.

The project will demonstrate on an operating construction site for at least a month and aims to address barriers to hydrogen production, supply and use including skills/ training needs, H&S and regulatory issues. The demonstration will support market assessment and business cases for investment and will measure and assess impacts on site productivity and emissions compared to conventional diesel plant with learnings disseminated to wider industry.

BAM and Skanska will provide operating construction sites to demonstrate the solution, with GeoPura supplying hydrogen and a hydrogen powered generator with off-grid hydrogen compressor, Reynolds Logistics addressing hydrogen transport/logistics, GeoPura adapting/developing storage and onsite distribution capabilities to the needs of site-based construction, ULEMCo developing a hydrogen bowser and adapting their dual fuel technology to convert plant provided by Flannery and Plantforce prior to demonstration and assessment, and BRE providing independent assessments and metrics.

Hybrid gas engine 2 (HGE2)

• Project owner: Cage Technologies Limited
  
• Location: Lancaster
  
• Amount being awarded: £1,600,820.44

Project description

Hybrid gas engines (HGE) have a similar performance and efficiency to diesel engines. Their short-term deployment can displace diesel in construction through the use of widely available, cost-effective fuels and support the transition to net zero fuels such as hydrogen and rDME.

The HGE2 project will build on the RDR Phase 1 HGE project, which delivered 3 working prototype gas engine platforms able to use hydrogen, LPG or other gas fuels which were installed in generators and demonstrated using LPG. In HGE2, the technology will be further developed and trialled on construction sites. The platform will be developed to accept rDME; a low-carbon, renewable fuel with similar properties to LPG in terms of storage and transportation. The project aims to address two barriers to adoption of alternative fuel engines in the off-highway sector; certification to meet emission standards to allow commercial supply at scale, and measures to ease safe supply of alternative fuels to the construction sector at the point of use.

HGE2 will be led by CAGE Technologies, responsible for engine R&D and the build and supply of generators for trial. Imperial College London will run emissions testing, engage policy makers on emission regulations for ultra-low emission engines using alternative fuels, and support fuel access onto sites. Calor Gas will focus on the rDME supply-chain, including bottling and supply for engine development and demonstration. HS2 will support all project delivery aspects with a focus on emissions testing, site availability and dissemination. Speedy Hire will manage site trials and liaise with major construction sector partners.