Industrial Vehicle Technology - June 2020
HYDROGEN VS ELECTRIC
2020-07-10 04:52:27
“POWERING LIFT-TRUCKS WITH HYDROGEN FUEL CELLS IS A MORE ATTAINABLE OPTION THAN EVER” Kevin Paramore, emerging technology commercialisation manager, Yale Materials Handling Corporation
LIFT-TRUCKS ARE ALMOST THE ORIGINAL ELECTRIC VEHICLE, WITH MANY MODELS POWERED FOR DECADES BY LEAD-ACID BATTERIES. BUT NOW, EVEN WITH THE NEW BENEFITS OFFERED BY LITHIUM-ION, THERE IS A FRESH CHALLENGER TO BATTERY ELECTRIC DOMINANCE - INCREASINGLY AFFORDABLE HYDROGEN FUEL-CELL SOLUTIONS
More and more organisations are seeing for themselves the considerable benefits of integrating fuel cell technology into their lift -truck fleets. This is due to lower operational costs, reduced emissions and improved reliability. Such advantages have contributed to fuel cell popularity and availability.
“Powering lift -trucks with hydrogen fuel cells (HFC) is a more attainable option than ever,” says Kevin Paramore, emerging technology commercialisation manager, Yale Materials Handling Corporation. This has been due to fast refuelling, reduced burden on operators to charging and maintenance, and a variety of hydrogen supply options.
A steady, cost-effective supply of hydrogen is critical to the success of any hydrogen-powered operation, and is an important consideration in the implementation of hydrogen fuel cell-powered lift trucks. “In today’s market, hydrogen can either be delivered or generated on-site,” says Paramore. “Options for delivery range from gaseous hydrogen shipped via tube trailers for lower-volume usage to liquid state hydrogen for higher-volume applications.
“Operations contemplating hydrogen can work with suppliers to evaluate whether fuel cell technology makes sense for their facility, including conducting demos, pilots and trial programmes. This allows the selection of a best-fit hydrogen fuel supply option, each with variable infrastructure, permitting and installation requirements, which can differ greatly based on fleet size, method of hydrogen delivery and anticipated demand.”
“HYDROGEN FUEL CELLS CAN BE RAPIDLY REFUELLED IN AS LITTLE AS THREE MINUTES, SIMILAR TO AN INTERNAL COMBUSTION POWERED LIFT TRUCK” Steven LaFevers, vice president emerging technology, Hyster
Advantages
Environmental benefits are clear: water and heat are the only byproducts and no harmful emissions are produced. However, this accounts for only half the story. Convenience, efficiency and extra productivity are also important factors to consider, as is the space freed up on a vehicle that is otherwise used for batteries. Also, there is no degradation of performance during a shift as compared with lead-acid batteries, which tends to diminish towards the end of a charge. However, large-scale 24/7 operations benefit most of all and much of that benefit is derived from the speed of refuelling without disruption to production or loss of working space.
“Currently, many electric lift trucks use lead-acid batteries. Once the battery charge expires, the battery must be removed and taken to a charging room, and a freshly charged battery must be installed,” says Steven LaFevers, vice president, emerging technology, Hyster. “This equates to 20 minutes of lost productivity every four to eight hours. Hydrogen fuel cells can be rapidly refuelled in as little as three minutes, similar to an internal combustion powered lift truck. In multi-shift operations with two or more battery replacements per day, the quick refuelling of hydrogen fuel cells saves time and helps increase operator efficiency. Furthermore, since lift -truck operators can refuel hydrogen themselves, operations can keep business moving and make more efficient use of labour resources.” Fuel cell technology is proven to operate well around-theclock (‘stop and go’) and in extreme temperatures, which means productivity gains and operational savings. Performance/ power is consistent and maintenance for both forklift and battery is reduced compared with conventional forklifts. “The more hours a logistics company is operational the more HFC forklifts are a relevant option,” says Sabrine Skiker, EU policy manager, Hydrogen Europe. “Proven Life of the fuel cell is
10 years, best economic lifetime, with availability of >97%.”
“In general, deploying hydrogen fuel cells can enable a cleaner workplace and offer productivity and financial advantages over other power sources,” says Yale’s Paramour. “As more companies prioritise green supply chain management, materials handling operations not only face challenges to reduce total cost of operations and increase efficiency, but to minimise environmental impact. Fuel cell-powered lift -trucks offer a realistic, long-term solution that addresses these challenges.
“WE BASE OUR FORK TRUCKS WITH FC AROUND THE SPACE AND WEIGHT OF THE NORMAL LEAD-ACID BATTERY IT REPLACES” Craig Walby, director of products, Toyota Material Handling Europe
Informing design
Skiker sees no technological design challenge presented by a HFC because the fuel cell pack is very compact and can fit easily into each type of forklift . However, the weight of the forklift may need casting added to counterbalance the absence of a heavy battery or ICE system.
“We base our fork trucks with FC around the space and weight of the normal lead-acid battery it replaces,” says Craig Walby, director of products, Toyota Material Handling Europe.“This allows for easier integration of fuel cells across a range of our trucks. Many of our customers are running fleets of mixed truck types so its important to be able to supply them with a fleet. Further down the line when fuel cell/hydrogen is more mainstream, we can certainly envisage completely new truck concepts, but at this stage the market is quite small and we want to transfer the benefit of fuel cells/hydrogen to the customer. The easiest way to do this is on our existing trucks.”
Looking to the future
There are now more providers and greater competition along the entire fuel cell supply chain and there’s more consolidation among lift truck customers. “This consolidation means bigger fleets with increased opportunity to adopt hydrogenpowered lift trucks,” says Paramore.
Fuelling is not standing still either. “Years ago, using fuel cells at your site required investment in either a hydrogen generation system or a liquid-based system. Now it is possible to simply lease systems or just pay for the fuel consumed,” says LaFevers.
“Fuel cells are already costcompetitive compared with ICE forklifts,” says Skiker. “The HFC forklifts will break even battery forklift around 2023 as highlighted in the Total Cost of Ownership (TCO) trajectory of forklifts.”
There are more power source options for forklifts than ever before. LaFevers comments that part of Hyster’s job as a lift truck OEM is to help educate its customers on the new advanced technologies and improvements to traditional power sources. “We look to match customers with whatever power source matches them best,” he says. “Since Hyster offers access to a broad range of power options, the power selection choice is made purely based on the customers’ interest – not a need to push a particular technology.”
Hydrogen Europe’s stated objective is to promote hydrogen technologies. It currently includes 160 industry companies, 78 research organisations and 21 national associations. Key players of the fuel cell forklift business rank among its membership and include Plug Power.
“We support the hydrogen forklift industry as part of the hydrogen economy, and as a proven hydrogen application which is becoming more cost competitive,” says Skiker.
Toyota Material Handling supports its customers in the dialogue on electric and HFC forklifts as a way to support decarbonising operations and meet zero emissions targets. The company says that 80% of its electric forklifts range can alternatively operate with hydrogen fuel cells so far, and has several customer sites (typically 24/7 operations) upand- running, which are already benefiting from hydrogen fuel cells.
Although interest in the technology is high, the operational sites in EU are still in their infancy. “Many actors need play their part across industry and across government,” says Walby. This means energy industries plus EU initiatives such as the Fuel Cell Joint Undertaking (FCHJU) and local government supporting hydrogen as a central part of decarbonisation.
“Connecting up the dots, the more cross-industry activity in this area, the better,” says Walby. “We need to cooperate to support green hydrogen production, share infrastructure costs, and share project costs connected with distribution of hydrogen. We all need to work, with help from governments, to show hydrogen as an integral part of decarbonising our society, the same way we view wind and solar supporting the generation of green electricity today.”
10 years
The proven lifetime of a hydrogen fuel cell, with over 97% availability
2023
The year by which it is predicted HFC lift-trucks will be more economical than battery electric
80%
The extent of the Toyota Material Handling electric forklift range that can be alternatively powered by HFC
HYDROGEN FC VS LITHIUM-ION
HFC versus lithium-ion is the big ‘compete’ at the moment, says Craig Walby, director of products, Toyota Material Handling Europe. No major additional infrastructure is required for an electric solution. “Couple your building with solar, and you can have green electricity and CO2-netural solutions.”
The energy efficiency of the lithium-ion battery can also be improved compared with traditional fuel cell, and at the same time have a quicker recharge, Walby explains. “Lithium Ion is 30% more energy-efficient than lead-acid, so improves energy use and CO2, so for many companies it’s a good way to make real improvements in operations and CO2, simply.”
However, fast charging requires more electricity to be delivered to the trucks in a shorter time and this can affect ‘peak’ electricity, so for some heavy operations this can be a challenge, but not one that is insurmountable: energy banks can be used as storage, or charging can be staggered with an opportunity of charges at break times.
“Hydrogen does not have this issue of peak,” Walby continues. “The hydrogen is stored in a tank and can be delivered directly to the truck. No grid issues. Solar power can also be harnessed to make on site hydrogen with an electrolyser to convert solar electricity into hydrogen for use at a time when needed, so can in effect can be a way to have on demand power when needed for use on electric trucks.”
MYTH BUSTING
There are several myths that have grown up around HFC lift trucks such as that they are less safe, are only suitable for large fleets or that their only benefits are environmental.
It’s true that the technology has its challenges as well as benefits, but these are surmountable. For example, although hydrogen is more expensive than electricity, as hydrogen becomes more popular, in industrial vehicles as well as in commercial and automotive, costs will come down. And while hydrogen is certainly flammable, it is no more dangerous than ordinary petrol/gasoline that is used widely today, and in fact, because in the event of an accident it rapidly dissipates as a gas, many consider it to be safer.
“New fuelling options – like leasing and pay-as-yougo – can make hydrogen fuel cells a sensible choice for more than just the largest lift truck fleets,” says Kevin Paramore, emerging technology manager with Yale Material Handling.
Nevertheless, it is in the larger fleets of over 50 trucks that the benefits of hydrogen remain easiest to attain. “You need forklifts companies, fuel cell companies, gas companies, infrastructure and permitting for use of hydrogen, ideally government support for deployment and funding, and inside the customer a strong commitment all working as a team,” says Craig Walby, director of products, Toyota Material Handling Europe. “With this we can deliver effective solutions. Typically these fleets also need to be ones that are intensive users, with multiple shifts, where we can eliminate the use of battery change and costs/time associated with this into the customers operational business case.”
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HYDROGEN VS ELECTRIC
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