Fuel cell power packs (FCPP) combine hydrogen and oxygen to produce electricity.
Powered by gaseous hydrogen stored at 250-350 bar, the fuel cells can run almost continuously and emit only water vapour and heat, making them an environmentally friendly alternative.
Expanding on its environmental commitment, Crown Equipment Corporation was recently awarded a second $US1 million in grant money from the state of Ohio in the US to conduct fuel cell research.
“Crown is leading the way in researching fuel cell usage in lift trucks for the material handling industry, and this development is a natural support of the company’s ongoing environmental sustainability focus,” says Eric Jensen, Manager of New Technology, Research and Development for Crown, who heads the FCPP project.
Jensen tells Logistics Magazine that Crown is working with multiple suppliers of fuel cells to test the cells with the trucks.
“Crown has committed a considerable amount of its own money to the project, and that commitment could ultimately increase,” he says.
“Crown is also working with the United States Industrial Truck Association, a trade organisation that develops operating standards for the trucks. We hope to supply them with information based on actual experience.''
Crown’s FCPP project has involved the qualification of as many of its trucks as possible with the commercially available fuel cell power packs.
“We are acting as an enabler to allow our customers that want to do a complete transformation to hydrogen-powered warehouse to do so with a full range of trucks," Jensen explains.
Crown is currently collaborating with three providers of hydrogen fuel cell power packs -- Plug Power, Canada's Hydrogenics and Nuvera.
Also collaborating with Crown is Oorja Protonics Inc., a maker of direct methanol, methyl alcohol-powered fuel cells.
While fossil fuels are not directly used in electric fork trucks, Jensen says a 2006 Battelle Study indicates that many users are dissatisfied with operating procedures using current battery technology.
They are looking for cost improvement opportunities and wish to reduce downtime arising from battery changes that can impact productivity.
For lift truck users, one of the biggest fuel cell benefits doesn't come from fuel savings, but from labour savings derived from the elimination of the battery charging cycles.
"Hydrogen refuelling only takes about two minutes while replacing a depleted battery can take as long as 20 minutes three times a day," Jensen points out.
"Then factor in eight hours of charging plus another eight hours for cooling and a three-shift operation can require three batteries per lift truck."
Jensen says the labour savings can be significant enough to make up the difference between the cost of three batteries and the cost of a fuel cell power pack.
Crown estimates labour to be 70% of the cost of operating a distribution warehouse. In addition, battery-changing equipment becomes unnecessary infrastructure with fuel cells.
“The other benefit is the elimination of a battery room dedicated to charging and battery maintenance and storage,” Jensen adds.
“Well-paid personnel and hundreds of square feet of floor space can be involved.”
According to Jensen, a successful FCCP installation requires three things to be in place. “First, a hydrogen supply with storage and dispensing; second, a fuel cell power pack of the proper size; and third, the proper qualified lift truck to match the fuel cell power pack,” he says.
In the US, re-fuelling stations can be installed in warehouse facilities to enable large scale users to easily access high pressure hoses that connect to the FCPP with a standardised fitting. For shorter term trials, mobile re-fuelling tankers are available to supply trucks.
“The main road block to the introduction to Australia is the availability of hydrogen,” says Crown Equipment General Manager - Marketing Craig Kenchington.
“We are currently discussing the opportunities with several of our key customers. Currently several models of Crown lift truck series have been successfully qualified with a FCPP.
Eric Jensen says that customer trials have shown that hydrogen is not for every operation. “This product is best used in large multiple shift operations, using a minimum of 15-20 trucks,” he explains.
“For the smaller lift truck user or the single-shift user, fuel cell-powered vehicles don't make as much sense. For example, single shift operations have the overnight charging alternative.
“There are many economic variables, so a trial is the best way to investigate whether hydrogen fuel cells are viable for your operation.”
Contact your local Crown Fleet Department on 131 604 Australia wide or at aus.marketing@crown.com