Alstom Achieves a Groundbreaking Milestone by Completing the First-Ever Hydrogen-Powered Shunting Locomotive Journey, Ushering in a New Era of Clean Rail Transport Technologies

In a world-first for the transport and railway industries, French multinational Alstom, a global expert in smart and sustainable mobility solutions, has completed the first-ever trip using a shunting locomotive converted from diesel to hydrogen fuelled drive. The historic trip was accomplished in Salzgitter, Germany, and represents an important step towards greener, more sustainable transport technologies. This locomotive’s conversion is a part of cooperation that focuses on the decarbonization of shunting activities and minimizing the carbon footprint of the rail industry.

The project, which has garnered attention for its innovative approach to reducing greenhouse gas emissions, was carried out in partnership with several organizations, including VPS Verkehrsbetriebe Peine-Salzgitter GmbH (VPS, a subsidiary of Salzgitter AG), WTZ Roßlau gGmbH, and the renowned Fraunhofer Institute for Surface Engineering and Thin Films. The city of Salzgitter has also played a key role in the success of this project by providing funding support, contributing a significant 1.5 million euros from the 50 million euros allocated by the state of Lower Saxony for structural aid. This funding is crucial in advancing the development of environmentally friendly technologies in the region.

François Muller, Vice President Services for Central and Northern Europe at Alstom said: “With this research project, we are once again pioneering the use of hydrogen in rail transport. We are expanding the spectrum of vehicle modernisation with a doubly sustainable approach – thanks to this solution, our customers can switch to emission-free operation without having to replace their existing fleet. This is a particularly worthwhile option in shunting traffic due to the long service life of the vehicles.”

Modernisation Solution: A Step Toward Decarbonization

The modernisation of the shunting locomotive, showcased at Alstom’s Salzgitter facility, represents a key step forward in the decarbonisation of shunting traffic in industrial settings. Shunting locomotives, which are primarily used for moving railcars in yards and industrial areas, have traditionally been powered by diesel engines, which contribute significantly to carbon emissions. By converting these locomotives to hydrogen-powered engines, Alstom is making a bold move toward a cleaner, greener future for the railway industry.

The newly converted hydrogen-powered locomotive operates by utilizing direct, CO2-free combustion of hydrogen fuel. This shift from diesel to hydrogen is not only environmentally friendly but also highly innovative. The engine’s operation produces zero emissions, effectively eliminating harmful carbon dioxide (CO2) emissions that would have otherwise been generated by the diesel-powered alternative. Hydrogen fuel is seen as a promising solution to reduce the reliance on fossil fuels in the transportation sector, as it produces only water vapor when combusted, making it an ideal alternative to traditional diesel-powered locomotives.

Frank Klingebiel, Mayor of the city of Salzgitter: “Our former Minister President Stephan Weil called Salzgitter the transformation capital of Germany – and rightly so! Salzgitter AG is investing billions to switch to low-CO2 steel production by 2033 with the SALCOS project. In addition, Volkswagen is currently building its first battery cell plant here and is also investing billions in Salzgitter as a business location.
At our Hydrogen Campus, we are developing the technologies of tomorrow in the areas of factory transformation, green hydrogen and hydrogen storage. We are further expanding the district heating supply with our own Salwe project. And in the joint project to decarbonise shunting traffic, the city is not only on the sidelines but is also an active player with a financial contribution of 1.5 million euros!”

The project will enter its industrial test phase at the Salzgitter Group’s steel production facilities, where the converted locomotive will be put through rigorous testing to assess its practical viability. The test operation will run until October 2025, and the partners involved in the project are eager to gather valuable insights regarding the daily performance of hydrogen-powered shunting locomotives. The outcomes of these trials will help to determine the suitability of hydrogen technology for widespread use in industrial operations and inform future developments in the railway sector.

The Environmental Impact: A Massive CO2 Reduction

The environmental benefits of converting diesel-powered shunting locomotives to hydrogen drive are profound. In Germany alone, there are approximately 1,000 diesel-powered shunting locomotives in operation, with another 4,000 across Europe. These diesel locomotives have an average service life of between 50 to 70 years and emit a staggering 150 tonnes of CO2 annually, contributing significantly to the carbon footprint of the transportation sector.

Astrid Paus, Head of Department at the Braunschweig Regional Development Office: “Many good projects have been supported and implemented with the structural aid funds from the state of Lower Saxony. Primary schools and day-care centres have been built, residential buildings are being renovated, and hydrogen campus projects have been funded. The conversion of the shunting locomotive to a hydrogen drive is one of them and is of course something very special with a world premiere. Here, the state’s funding was well invested in innovation, CO2 savings and climate protection. The climate protection potential and the impact of this conversion are huge: imitation is encouraged.”

However, the potential for CO2 savings through the conversion to hydrogen is enormous. By switching from diesel to hydrogen, a modernised shunting locomotive can save up to 3,000 tonnes of CO2 over its remaining service life of 15 to 20 years. This reduction in emissions is equivalent to the annual CO2 output of up to 650 passenger vehicles. To put this into perspective, planting 200,000 trees would be required to offset the same amount of CO2 emissions that a single hydrogen-powered locomotive can save over its operational lifetime.

For VPS, the company operating the newly converted locomotive, the environmental benefits are particularly significant. VPS manages a fleet of 42 locomotives that transport key materials such as ore, coal, pig iron, and steel products within the production network. The conversion of these locomotives to hydrogen could result in substantial reductions in the overall carbon footprint of VPS’s operations, aligning with the company’s sustainability goals and the broader push for greener industrial practices.

A Model for the Future

The success of this pioneering project in Salzgitter could serve as a model for similar initiatives across Europe and beyond. As the railway industry continues to seek innovative solutions to meet stringent climate goals, hydrogen-powered locomotives offer a promising alternative to traditional fossil fuel-based technologies. The completion of this project demonstrates that it is possible to retrofit existing infrastructure to make use of cleaner energy sources, providing an important pathway for the decarbonisation of the transportation sector.

Alstom and its partners are optimistic that the lessons learned from this project will pave the way for a broader adoption of hydrogen-powered locomotives across various sectors. The ultimate goal is to make hydrogen technology a mainstream solution for rail transport, reducing emissions and contributing to a more sustainable future.

As the project progresses toward its conclusion in 2025, the team will continue to gather data and refine the technology, ultimately preparing it for potential widespread implementation. The insights gained from this test phase will not only benefit the partners involved but also set the stage for similar initiatives across the globe, driving the shift towards cleaner and more sustainable mobility solutions in the railway industry.

Dr Johannes Dreier, Managing Director of VPS: “This test deployment of a locomotive with an engine converted to direct hydrogen combustion fits perfectly into the ongoing transformation within the Salzgitter Group.

With the SALCOS® – Salzgitter Low CO2 Steelmaking programme, the Salzgitter Group will gradually switch pig iron production from the blast furnace route to direct reduction, initially predominantly natural gas-based and later increasingly hydrogen-based, over the coming years. As the Group’s central logistics service provider, we are also required to test alternative drive concepts for our locomotive fleet to make our contribution to the decarbonisation of the Group.”

Dr Christian Reiser, Managing Director of WTZ Roßlau gGmbH: “During the intensive development work, we were able to successfully apply our expertise, especially in the field of combustion process development and system application, to the research project. As a result, the future-proof hydrogen engine technology was successfully transferred from the test bench to the real track. We are very much looking forward to the upcoming test operation of the locomotive. Because a green future is our drive!”

Prof Dr Peter Eilts, Head of the Institute for Internal Combustion Engines and Fuel Cells at TU Braunschweig: “The special feature of hydrogen is that it can be burnt with a high excess of air. For the conversion of the shunting locomotives, we are making targeted use of this property to stabilise combustion, increase efficiency and at the same time minimise the formation of nitrogen oxide. We have worked intensively on the design of the exhaust gas turbocharging, as the high excess air poses a particular challenge here. With success!“

The successful conversion of a hydrogen-powered diesel shunting locomotive in Salzgitter is a giant step towards more sustainable transportation. Thanks to the support of main collaborators such as VPS and Fraunhofer Institute, and assistance by local government funding, Alstom is taking the lead in the decarbonisation of industrial rail transport. The project’s environmental consequences are evident, with the potential for enormous reductions in CO2 over the lifespan of the converted locomotives. As the rail sector seeks to fulfill future sustainability goals, this project stands as a light of innovation and a move toward a cleaner, greener future for rail transport.

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