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Hydrogen Safety in Class 8 Fuel Cell Electric Trucks: Addressing the Real Challenges

Authored with the assistance of Nikola’s Head of Propulsion Engineering and Nikola’s Head of Environmental Health and Safety

As the trucking industry in the U.S. shifts towards more sustainable energy and fueling options to help combat climate change, hydrogen has emerged as a promising alternative to standard diesel Class 8 semi-trucks. Electric semi-trucks have made significant progress in the last decade, opening the door to hydrogen-powered vehicles, especially in the commercial marketplace.

Hydrogen is a powerful, clean fuel source that’s been used in transportation for much longer than most realize. Like any new technology, it comes with its own considerations, particularly about safety. However, advancements in hydrogen storage and distribution, alongside decades of research, have proven its safety and efficiency relative to traditional diesel, gasoline, and other electrified vehicles.


The key focus for hydrogen fueling stations is ensuring consistent training and support for local municipalities. This helps maximize the efficiency and readiness of hydrogen infrastructure in communities.


When Nikola introduced its first hydrogen fuel cell electric Class 8 semi-truck in the U.S. in 2023, the trucking industry welcomed the innovation with both enthusiasm and careful consideration. As with any groundbreaking product, especially one as substantial and advanced as a hydrogen-powered semi-truck, questions about safety naturally arise. Similar to other fuel sources, the use of hydrogen comes with a set of unique considerations. However, these conversations are also helping to expand the dialogue around developing a more robust hydrogen refueling network across the U.S.

Hydrogen as Fuel Isn’t New

Hydrogen was first identified by British scientist Henry Cavendish in 1766 during a demonstration to the Royal Society of London, where he sparked hydrogen gas to yield water, disproving the belief that water was an element. The concept of using hydrogen as fuel dates back almost 200 years to the discovery of combining hydrogen and oxygen together to produce both water and electricity by Swiss chemist Christian Friedrich Schoenbein in 1838. In 1845, Sir William Grove, an English scientist and judge, and often called the “Father of the Fuel Cell,” created a “gas battery.” By the early 1900s hydrogen was already being used in gas furnaces to heat homes .


Throughout the early 20th century, scientists and engineers continued to experiment with hydrogen as fuel. In the 1950s, hydrogen fuel cells powered both NASAs space program and 20-horsepower tractors in Great Britain. NASA first used hydrogen fuel cells in 1965 with Project Gemini with the Gemini V. Today, NASA remains the primary user of hydrogen fuel, relying on liquid hydrogen to propel rockets and power fuel cells.

Because of amount of hydrogen used in NASA mission, NASA has published several guides on hydrogen safety, including the Safety Standard for Hydrogen and Hydrogen Systems. The guide is a central agency document containing guidelines for safely storing, handling, and using hydrogen in gaseous, liquid, or slush form, whether used as a nonpropellant or propellant.

Acceleration of Hydrogen Fuel Cell Use

Unlike traditional diesel engines, the only emission from hydrogen fuel cells is water. Those fortunate enough to see a hydrogen fuel cell truck in person may notice a small amount of water under the truck —that’s it. No fumes, no loud gear shifting, no plumes of diesel smoke. Both battery-electric trucks (BEV) and hydrogen fuel cell electric trucks (FCEV) are designed to reduce the carbon footprint of the transportation sector.

Though the use of hydrogen fuel cell is steadily increasing, this modern fuel technology is still in its early stages.


Because the trucking industry is responsible for a significant portion of tailpipe carbon emissions, the adoption of Class 8 trucks with alternative fueling options such as battery-electric and hydrogen fuel cell electric vehicles will only increase.


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Hydrogen fuel cell electric trucks, like Nikola’s, not only have longer ranges than traditional battery-electric trucks, but compared to traditional diesel trucks, they are also considered easier to maintain and better for drivers’ health with lower vibrations, quieter powertrains, and no harmful emissions.

However, barriers to the adoption of hydrogen fuel cell electric trucks begin with the lack of infrastructure for high-pressure hydrogen fueling across the U.S. Hydrogen refueling stations, like those operated by Nikola’s HYLA brand, are currently scattered across North America, with a greater concentration in California, thanks to state incentives.

But, as they say, this won’t stop the (hydrogen) train from leaving the station. From Class 8 trucks and passenger cars to forklifts, trains and airplanes, hydrogen fuel is here, and it’s here to stay.

One Quirky Thing About Hydrogen: Training

Hydrogen is the most abundant element in the universe. Like any fuel, hydrogen is flammable under the right conditions. However, many experts in the field agree that the single biggest challenge surrounding its use as a fuel is the need for consistent and standardized training for its safe handling. Individuals who work with traditional fuels have been trained for a century on how to manage those fuels and their vapors, while hydrogen safety training is still a relatively new subject.

Unlike diesel fuel, when hydrogen leaks and ignites, the flame may be invisible, and water is not always be the best extinguishing agent. Additionally, hydrogen is odorless, making leaks more difficult to detect without specialized equipment. Understanding this new fuel requires specialized knowledge and training.

We won’t delve too deeply into the properties of hydrogen gas, as organizations like the Center for Hydrogen Safety and the International Association for Hydrogen Safety offer well-curated and thoroughly researched resources on safely handling hydrogen. This is new territory and with innovation comes the need for centralized and consistent training as the hydrogen network grows.

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The Hydrogen Safety Training Landscape is in its Infancy

Access to hydrogen training varies across North America, differing not only from state to state but also from county to county. Larger cities often provide more resources and full-time safety training for first responders and often volunteers without formal HAZMAT training on this emerging fueling option.

In Arizona, where Nikola is headquartered, the safety team responding to a hydrogen leak or fire may vary depending on whether the incident occurs in Maricopa or Pinal County. Response teams could include local firefighters, HAZMAT teams, or even Nikola teams specifically focused on hydrogen safety. Similarly, in California, where hydrogen refueling stations are found in smaller towns and counties, any number of first responders may be called to Nikola’s HYLA refueling stations.

It is crucial that personnel operating with hydrogen, as well as those responding to hydrogen emergencies, receive proper training.

Comprehensive hydrogen safety training should include an understanding of:

  1. Properties and hazards of hydrogen fuel
  2. Proper handling and storage
  3. System operation
  4. Inspection and maintenance
  5. Leak detection and response
  6. Emergency preparedness and response
  7. Continuing education and certification

This training should include adherence to safety standards for hydrogen storage and refueling, as well as guidelines for transporting hydrogen. Compliance with these regulations not only ensures the safety of staff and the public but also protects the company from potential legal and financial liabilities.

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Smart Solutions Require Smart Tech

Companies like Nikola are paving the way for hydrogen fuel cell powered semi-trucks. With great power comes great responsibility, and the launch of a new class of products in the market necessitates the development of smart technology to monitor them effectively. Recognizing that hydrogen fuel cell electric trucks are relatively new to the marketplace, Nikola has developed a comprehensive digital product portfolio, standard on every truck, providing both drivers and fleet managers instant access to the health and safety status of their vehicles.

Hydrogen Fuel News. (n.d.). Safety tips for hydrogen fueling stations. Retrieved from https://hydrogenfuelnews.com

Smart tech is not just for entertainment. For Nikola trucks, it helps drivers manage everything from leaks to safety system challenges, enabling quick and efficient responses. Standard features on every Nikola truck include:

• Nikola Human Machine Interface (HMI): Information-packed in-vehicle digital displays for
    drivers
• Nikola DRIVE: An app that enables drivers to control truck features
• Nikola FLEET: An app that allows fleet operators remote access and monitoring of their fleets,
   including a new function to ensure maximum charge before departure
• Nikola VIEW: An app that streamlines warranty issues, parts, and service
• Nikola PULSE: An app that provides real-time monitoring of Nikola vehicles to improve uptime

With our four web apps and a smart display, our trucks are monitored frequently by professionals trained in truck performance and hydrogen safety. Smart tech, combined with hydrogen safety training, is essential for addressing hydrogen safety concerns as the industry grows and evolves to meet the demands of a population interested in zero-emissions transportation.

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Hydrogen Safety – We’re On It

At Nikola, we recognize the need and urgency for hydrogen fuel cell safety as we expand. We are committed to collaborating with communities, counties, partners, states, and governments to provide the training and technology necessary to ensure that hydrogen fuel cell electric trucks not only become the new technology on the market but also the new standard for Class 8 trucks.

Nikola Corporation. (n.d.). Nikola celebrates the commercial launch of hydrogen fuel cell electric truck in Coolidge, Arizona. Nikola Motor Company. Retrieved from https://nikolamotor.com

Hydrogen Fuel News. (n.d.). Safety tips for hydrogen fueling stations. Retrieved from https://hydrogenfuelnews.com

Centre for Financial Accountability. (n.d.). History of hydrogen as a fuel. Retrieved from https://cenfa.org
ATCO. (n.d.). History of hydrogen. Retrieved from https://www.atco.com/en-au/for-business/hydrogen/Hydrogen-History.html
AltEnergyMag. (n.d.). The history of hydrogen. Retrieved from https://www.altenergymag.com
History of hydrogen as a fuel – Centre for Financial Accountability (cenfa.org)
NASA. (n.d.). History of hydrogen as a fuel (Publication No. 19970033338). Retrieved from https://nasa.gov
U.S. Department of Energy. (n.d.). Alternative fuels data center: Fuel cell electric vehicle emissions. Retrieved from https://energy.gov

Reuters. (n.d.). Key issues for development and expansion of hydrogen fueling infrastructure. Retrieved from https://reuters.com
Center for Hydrogen Safety. (n.d.). CHS. AIChE. Retrieved from https://aiche.org
HySafe. (n.d.). International Association for Hydrogen Safety. Retrieved from https://hysafe.org