Fuel cell power plant

Diesel Progress North American Edition - Fuel cell-powered forklifts at work in auto plant

While it might be a decade or more before fuel cell vehicles roll off assembly lines, fuel cell-powered forklifts are already being used, at least in prototype form, in a General Motor's car plant in Oshawa, Ontario, Canada. General Motors of Canada Ltd. and Hydrogenics Corp. are demonstrating two 5000 lb. lift capacity, Hyster E55Z, Class I sit-rider, electric counter-balanced lift tracks in which the batteries have been replaced with hybrid fuel cell propulsion systems.

According to GM and Hydrogenics, commercially viable hydrogen-powered industrial vehicles are closer to the market than many people think. "We believe that one of the first commercial uses for hydrogen powered-vehicles will be in industrial vehicle fleets, such as forklifts, where dedicated on-site refueling stations can meet immediate refueling needs," said Pierre Rivard, president and CEO of Hydrogenics.

Fuel cell-powered forklifts are ideal for indoor facilities, such as factories and warehouses, because they produce no significant exhaust emissions, are quiet and offer significant operational advantages over battery-powered forklifts such as longer life and greatly reduced recharging times.

The project is partially funded by Sustainable Development Technology Canada, a foundation created by the Canadian government to develop and demonstrate clean technologies that address climate change as well as clean air, water and soil quality. Also participating are the Canadian Transportation Fuel Cell Alliance and FedEx Canada. Deere & Co. and NACCO Materials Handling Group assisted in integrating the fuel cell systems into the forklifts.

The fuel cell power pack includes the fuel cell power module, an ultracapacitor storage unit, hydrogen storage, thermal management and power electronics and controls. Hydrogenics' HyPM 10 Proton Exchange Membrane (PEM) fuel cells are used. The compact power pack is only 33 in. long x 40 in. wide x 24 in. high. The low-pressure fuel cell is rated 10 kW net continuous power at 39 to 58 Vdc with a maximum system efficiency of 56%. The HyPM 10 fuel cell is fueled by hydrogen.

The low-pressure design ensures quiet operation while maintaining high performance, the company said.

The four-wheel forklift features regenerative braking. In this hybrid system, electrical energy is stored in Maxwell Technologies' Boostcap ultracapacitors that are integrated into the Hydrogenics' power pack. "In fuel cell vehicles, ultracapacitors have demonstrated a higher recovery of energy from braking than batteries, are considerably lighter, have a longer economic life and are more environmentally friendly in their manufacture and disposal," said Rivard. "When paired with fuel cells in stop-and-go mobility applications such as forklifts, ultracapacitors provide burst power for lifting and acceleration and enable regenerative braking."

A small 12-volt battery is also included to "start" the fuel cell.

Because the forklifts had previously been powered by heavier batteries, the biggest issue in the modification was weight. The fuel cell power pack itself was relatively easy to integrate into the machine since it was smaller and lighter than the lead acid battery system. But as the battery provides part of the counterbalance, additional weight had to be added to provide sufficient stability for the forklift.

The fuel cell is supplied with hydrogen from a Hydrogenics HyLyzer hydrogen refueling station that is also part of the demonstration project. The HyLyzer produces hydrogen by the hydrolysis of water using electricity.

Depending on the size of the HyLyzer, the unit can produce up to 65 kg of hydrogen daily. The HyLyzer refueling station is designed to be compact with easy connection points, so it can be transported easily from site to site. It can produce a variable amount of hydrogen, depending on requirements, and it can refuel a forklift in less than two minutes, much less than batteries can be changed or recharged.

The forklift's 4 lb. hydrogen storage capacity is sufficient for up to eight hours of operation.

"Demonstration projects like this are critical to the development of fuel cell technology," said David Paterson, GM Canada's VP for corporate and environmental affairs. "With predictable duty cycles, lift trucks are an ideal application from which to learn, and a large plant like ours, where external elements are not a factor, is an ideal place in which to conduct a trial like this."

Working demonstrations of the forklifts and refueler will take place also at FedEx operations within the Greater Toronto Area, and potentially other locations.

The modular design of HyPM fuel cells allows scaling up for higher power requirements through a variety of configurations, such as series and parallel systems. Potential applications for the HyPM technology include vehicle propulsion, auxiliary power units (APU), stationary applications including backup and standby power units, combined heat and power units and portable power applications such as for the construction industry and the military.