4.5 Forklifts
Fuel cell powered forklifts are one of the largest sectors of fuel cell applications in the industry. Most fuel cells used for material handling purposes are powered by PEM fuel cells, although some direct methanol fuel forklifts are coming onto the market. Fuel cell fleets are currently being operated by a large number of companies, including Sysco Foods, FedEx Freight, GENCO (at Wegmans, Coca-Cola, Kimberly Clark, Sysco Foods, and Whole Foods), and H-E-B Grocers. [10]
Fig. 9 - Toyota’s fuel cell powered forklift
Fuel cell powered forklifts provide significant benefits over both petroleum and battery powered forklifts as they produce no local emissions, can work for a full 8 hour shift on a single tank of hydrogen, can be refueled in 3 minutes and have a lifetime of 8–10 years. Fuel cell powered forklifts are often used in refrigerated warehouses as their performance is not degraded by lower temperatures. Many companies do not use petroleum powered forklifts, as these vehicles work indoors where emissions must be controlled and instead are turning towards electric forklifts. Fuel cell forklifts offer greenhouse gas, product lifetime, maintenance cost, refueling and labor cost benefits over battery operated fork lifts.[11]
4.6 Other implementations
4.6.1 Stationary Electric Power
One characteristic of fuel cell systems is that their efficiency is nearly unaffected by size. This means that small, relatively high efficient power plants can be developed, thus avoiding the higher cost exposure associated with large plant development. As a result, initial stationary plant development has been focused on several hundred kW to low MW capacity plants. [2]
4.6.2 Distributed Generation
Distributed generation involves small, modular power systems that are sited at or near their point of use. The typical system is less than 30 MW, used for generation or storage, and extremely clean. [2]
4.6.3 Auxiliary Power Systems (APU)
Auxiliary power units are devices that provide all or part of the non-propulsion power for vehicles.APU applications may be an attractive market because they offer a true mass-market opportunity that does not require the challenging performance andlow cost required for propulsion systems for vehicles.[2]
4.6.4 Space and Other Closed Environment Power
The application of fuel cells in the space program (1 kW PEFC in the Gemini program and1.5 kW AFC in the Apollo program) was demonstrated in the 1960s. IFCproduced a H2/O2 30 kW unit for the Navy’s Lockheed Deep Quest vehicle. It operates at depths
of 1500 meters (5000 feet). Ballard Power Systems has produced an 80 kW PEFC fuel cell unitfor submarine use (methanol fueled) and for portable power systems. [2]
Comparison with other energy sources
Figure 10 illustrates the practical travel range of a vehicle powered by a fuel cell (FC) compared to lead acid, NiMH or Li-ion batteries. One can clearly see that lead- and nickel-based batteries simply get too heavy when increasing the size to enable larger distances. In this respect, the fuel cell enjoys similar qualities to the IC engine in that it can conquer large distances with only the extra weight of fuel. [14]
Fig. 10 - Comparison in energy consumption
Fuel cells have less emissions than other types of powerplants, and as believe analytics it would be decreased to extra low values by 2050. (Fig. 11)
Fig. 11 – Power Source’s Comparison in terms of emissions and driving range
Conclusion
The potential for fuel cells to provide zero or near-zero emissions has been a significant force in the development of the technology over the past 30 years, and is drawing increasing attention to the technology today.
* Because there is no combustion in a fuel cell, fuel is converted to electricity more efficiently than any other electrical generating technology available today.
* There are no moving parts in a fuel cell stack, making them more reliable and quieter than generators. Even the ancillary systems (fans, pumps, controls, etc.) in a complete fuel cell unit are relatively mature and simple technologies that should prove extremely reliable.
* Unlike batteries that must be disposed of once their chemicals are used up, fuel cell reactions do not degrade over time and can theoretically provide continuous electricity.
* Traditional power plants must be large in order to gain efficiency, but fuel cells can achieve higher efficiencies at any scale, making them perfect for small portable, residential, and transportation uses.
* Because fuel cells are clean and efficient at any size, they can be located almost anywhere, including dense urban areas where both air quality and transmission congestion may be of concern. Fuel cells can offer an alternative to building new power lines, while also reducing American dependence on foreign oil. Fuel cells can provide more reliable power wherever electricity is needed, making the whole electric power grid more robust and reliable. Distributed application of small fuel cells will also enhance security of key infrastructures, such as our communication and water systems.
We are currently in a transition period now, where many fuel cell companies are investing literally hundreds of millions of dollars to gear up for mass manufacturing at the same time they are trying to begin to develop a variety of markets for their product. Currently, there is no hydrogen infrastructure to supply coast-to-coast delivery of hydrogen fuel. Technologies are being developed to provide alternative fuel storage and delivery methods.
References
[1] "Fuel cells", http://www.altenergy.org/renewables/fuel_cells.html
[2] "Fuel Cell Handbook", EG&G Technical Services, Inc., 2004
[3] "Automotive Fuel Cells The Road to Emission Free Mobility", Craig Louie, AFCC Automotive Fuel Cell Cooperation Corp. Burnaby, Canada
[4] "Fuel Cell Power System for Utility Vehicle", M. Graham, F. Barbir, F. Marken, M. Nadal,Program and Abstracts 1996 Fuel Cell Seminar, November 17-20, 1996, Orlando, FL, pp. 571-574.
[5] "Life-cycle analysis of fuel cell system components", M. Pehnt
[6] "Hydrogen and Fuel Cell Vehicles Worldwide". TÜV SÜD Industrie Service GmbH, accessed on August 2, 2011
[7] "Controlled Hydrogen Fleet and Infrastructure Demonstration and Validation Project", Wipke, Keith, Sam Sprik, Jennifer Kurtz and Todd Ramsden. National Renewable Energy Laboratory, September 11, 2009, accessed on August 2, 2011
[8] "Hydrogen Is Down, But Not Out", Squatriglia, Chuck.,Wired.com, Autopia, March 17, 2011, accessed on August 2, 2011
[9] "Mercedes-Benz Fuel Cell Car Ready for Market in 2014", Lienert, Anita. Edmunds Inside Line, June 21, 2011.
[10] "Fact Sheet: Materials Handling and Fuel Cells". Fuel Cell and Hydrogen Energy Association.Accessed August 2nd 2011.
[11] "Early Markets: Fuel Cells for Material Handling Equipment". U.S. Department of Energy Fuel Cell Technologies Program, February 2011, accessed August 2, 2011
[12] "The ENV Bike". Intelligent Energy. Retrieved 2007-05-27.
[13] "APFCT won Taiwan BOE project contract for 80 FC scooters fleet demonstration", (http://www.apfct.com/article_cat.php?act=view&no=26)
[14] "Fuel cell vehicles" (http://batteryuniversity.com/learn/article/fuel_cell_vehicles)
[15] "Modeling and control of fuel cell systems and fuel processors", J.T. Pukrushpan, 2003
AS-84.3210
Mini-seminar report