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March 13, 2025 – A compact methanol engine built in Valladolid, Spain, is redefining what’s possible for electric vehicles. Developed by Horse Powertrain—the joint venture equally owned by Renault and Geely—the D20 methanol generator uses axial flux motors to deliver a power-to-weight ratio that could make long-distance EV travel far more practical without relying on massive batteries or frequent charging stops.
The D20 is not your typical internal combustion engine. Weighing only 170 kilograms, it produces up to 141 horsepower and achieves a thermal efficiency of 47%. Horse Powertrain claims that to recharge a 40 kWh battery pack, you’d need just 20 liters of methanol—a figure that would slash refueling time for drivers who want to cover hundreds of miles without stopping for a charge. The generator’s electrical efficiency hits 96.4%, meaning only 2.1 kWh of methanol is needed to generate 1 kWh of electricity.
What makes the D20 truly stand out is its axial flux motor design. These motors are 46 times shorter than traditional radial flux motors and deliver 63% more power. Mounted directly on the crankshaft, they create a pancake-shaped package that measures just 50 cm long, 55 cm wide, and 27.5 cm high—small enough to fit in a carry-on suitcase. That compactness allows automakers to install the engine either horizontally or vertically, opening up new possibilities for vehicle packaging.
Fortune Zhao, Chief Technology Officer at Horse Powertrain, told reporters that the D20 serves as a platform for “next-generation propulsion,” emphasizing that the combination of axial flux technology and methanol combustion is unprecedented in mass-market automotive applications. “We’ve achieved power density and size that were previously thought impossible for a production-ready range extender,” Zhao said.
The D20 is tailor-made for range-extended electric vehicles (REEVs), a segment that is gaining traction as drivers look for ways to travel long distances without the anxiety of finding a charger. Horse Powertrain’s companion RGEV Medium 2.0 platform promises up to 750 kilometers of all-electric range and over 1,000 kilometers when the methanol generator is used. That’s a significant leap over plug-in hybrids (PHEVs), which typically offer only 50 to 100 kilometers of electric-only range. For daily commutes, the D20-equipped REEV can run purely on battery, while the methanol generator kicks in for road trips.
Value Add: Industry Context and Expert Insight
While methanol-fueled generators are not yet common, analysts see the D20 as a potential bridge technology. “The beauty of methanol is that it can be produced from renewable sources like biomass or captured CO2, and it’s a liquid fuel that can be distributed with existing infrastructure,” said Dr. Elena Vasquez, a senior researcher at the International Institute for Sustainable Fuels. “Horse Powertrain’s axial flux approach solves the space and weight issues that have held back previous range extenders.”
The timing of the D20’s debut aligns with Spain’s push to become a hub for automotive innovation. Horse Powertrain’s factory in Valladolid currently employs over 2,200 people, and the company has hinted at plans to scale up production for automakers in Europe and Asia. Competitors like Stellantis and BMW are also exploring small combustion generators for EVs, but none have yet matched the D20’s compactness and efficiency.
Challenges remain: methanol infrastructure is sparse outside of China and a few European ports, and the fuel’s energy density is lower than gasoline, meaning larger tanks. But Horse Powertrain expects the D20 to attract interest from fleet operators and automakers targeting markets where charging infrastructure is still developing.
Looking Ahead
As the electric vehicle industry races to improve range and reduce costs, the D20 methanol engine offers a pragmatic alternative to massive battery packs. With its axial flux motor and ultra-lean combustion system, it could help bridge the gap between today’s hybrids and tomorrow’s fully electric fleets—especially in regions where cold weather, towing, or long-distance driving make full battery EVs less practical.
Horse Powertrain is expected to showcase the D20 at upcoming auto shows and begin supplying samples to automakers by late 2025. If the numbers hold up in real-world testing, the Spanish-made methanol engine might just be the breakthrough that makes range anxiety a thing of the past.
