360ES-PEM
Volvo bus on the road

Commercial Field Test: Volvo DD 9800

A real-world analysis of the 360ES-PEM-H2+O2 system, demonstrating significant gains in fuel efficiency, range, and power for commercial fleets.

Executive Summary

Unit

Volvo DD 9800 No. 507 (2023)

Engine

D13C, 12.8 L

System Installed

360ES-PEM-H2+O2

Objective

Increase range and usable power, improve combustion quality, reduce carbon deposits, and validate repeatable operational benefits for commercial fleets.

Verified Field Results (Test Run)

Fuel Economy Improvement

Before

7.06 MPG

(3.0 km/L)

After 360ES-PEM

8.47 MPG

(3.6 km/L)

+20%

Relative Fuel Efficiency Improvement (+1.41 MPG)

Test Segment: Real-world route validated by odometer

Odometer Start: 1,287,622.8 km (800,090.6 mi)

Odometer End: 1,315,968.8 km

Total Distance Covered: 28,346 km

Activated vs. Deactivated Comparison

MetricWithout H₂With H₂% Improvement
Efficiency (km/L)3.03.6+20%
Consumption per 100 km (L)33.3327.78-16.67%
CO₂ Emissions (kg/100 km)89.3374.44-16.67%

System Description & Safety

Safety Features & Components

  • ‣PEM electrolysis cell producing controlled H2+O2
  • ‣Dosing valves, backflow prevention, filters
  • ‣Sensors for water level, cell temperature, line pressure/flow, and leak detection

Control and Protections

  • ‣Microcomputer reads RPM, MAP/MAF, intake temperature, and throttle position
  • ‣Real-time per-second adjustment of electrolysis rate and H2+O2 dosing
  • ‣Automatic shutdowns for low/high water level

How It Works: The Physical Mechanism

H₂ Promotes Ignition

Hydrogen increases flame speed and stabilizes ignition in locally lean mixtures, reducing unburned fuel.

O₂ Complementary Comburent

As the oxidizing agent, injecting localized O2 increases immediate oxidizer availability in the air-fuel mixture, accelerating reaction rates and improving thermal efficiency per cycle.

Microcomputer Dosing

The system doses H2+O2 by the second according to engine regime and load, concentrating its effect where gain is highest (steady cruise, moderate loads).

Net Operational Outcomes

More Complete Combustion

Faster Burn

Reduced Soot/Carbon

Cleaner Engine

Increased Usable Torque

More Power

Lower Thermal Load

Cooler Operation


Effects on Torque Response and Component Life

  • Increased torque per cycle due to higher effective cylinder pressure from more complete combustion.
  • Improved transient response, requiring less throttle to maintain or regain speed on grades.
  • Reduced thermal stress, leading to lower oil and coolant temperatures under sustained operation.
  • Preserved injector geometry means fewer carbon deposits, extending effective injector performance and maintenance intervals.

Projected Range Increase

Example with a 1,000 L tank

Baseline: 3.0 km/L (7.06 MPG)

Base km

3,000 km

With 360ES-PEM

3,600 km

Difference

+600 km

Improvement

+20%

"For Unit 507, each liter of diesel yields 0.6 km more, meaning a 1,000 L tank provides 600 additional kilometers without refueling."

Operational KPIs for Pilots and Rollout

  • MPG measured in windows of 40-60 min runs (3+ ON/OFF cycles per vehicle).
  • Miles per tank vs. actual distance between fuel-ups and gallons recorded.
  • Delta torque and response via onboard telematics during acceleration and steady cruise.
  • Oil and coolant temperature averages during sustained operation.
  • Visual inspections for carbon deposit reduction at 30, 60, 90 days with photos.
  • System logs: H2 production, O2 dosing, alarms, and events.

Conclusion

The 360ES-PEM-H2+O2 installation on Unit 507 demonstrates a practical capture of hydrogen’s combustion advantages. This means each liter of diesel becomes 20% more autonomy, with a direct impact on operations, competitiveness, and fleet sustainability. The system delivered a reproducible gain under realistic field conditions, supported by both lab evidence (NASA) and this field validation.


Key benefits observed and validated include:


  • Increased Per-Cycle Torque: More power when it's needed.

  • Extended Tank Range: An increase of 150-224 extra miles per tank.

  • Improved Throttle Response: Less throttle required to maintain or regain speed.

  • Reduced Carbon Deposits: Preserved injector geometry and extended maintenance intervals.

Coupling field results to NASA technical reports provides a robust narrative for operations teams and commercial decision-makers, setting realistic performance expectations and a clear commercial pathway for adoption.

Reference: NASA Technical Report

Next: Consumer Field Test

See how the 360ES-PEM system delivered a 55% fuel efficiency improvement on a high-performance Range Rover Sport.

Read Consumer Field Test

Next: Commercial CNG Test

Discover the 20-30% efficiency gains on a Shacman X3000 CNG truck.

Read Commercial CNG Test