- Email: [email protected]
Fuel cell forklifts for Walmart Canada distribution center
NEWS / editorial purchase of up to 20 vehicles with specifications similar to the prototype that will be presented at the Hannover Fair. Proton Power’s PM200 fuel cell will improve the range of vehicle operation (from 160 to 300 km/100 to 190 miles), enabling the vehicles to have a wider application within large fleets. It will also provide an onboard electrical supply, which will boost the ease of maintenance work. This would improve the vehicle’s suitability for everyday back-to-base applications, while also supporting auxiliary functions such as airconditioning and heating. ‘There are strong initiatives, such as NOW, in Europe towards the adoption of electric vehicles, and there is also considerable interest in the US and Canada,’ says Thomas Melczer, CEO of Proton Power. ‘We aim to use our fuel cell range extender to help electric vehicle manufacturers such as Smith break further into these markets.’ Proton Power Systems is a developer and manufacturer of fuel cells and fuel cell hybrid systems for motive and stationary power supply. Proton Power is gaining access to a broad range of markets through partnerships with leading OEMs such as Skoda Electric [FCB, May 2009] and Smith Electric Vehicles, in addition to contract manufacturers such as Deutsche Mechatronics [FCB, August 2009]. Proton Power Systems Plc, UK. Web: www.protonpowersystems.com Proton Motor Fuel Cell GmbH, Puchheim, Germany. Tel: +49 89 1276 26520, www.proton-motor.de Smith Electric Vehicles: www.smithelectricvehicles.com Smith Electric Vehicles US Corporation: www.sev-us.com NOW GmbH: www.now-gmbh.de
mobile applications
Oorja launches Model 1 DMFC as onboard battery charger for forklifts
C
alifornia-based Oorja Protonics, a leading developer of powerful direct methanol fuel cell (DMFC) technology, has added the 4.5 kW OorjaPac™ Model 1 to its product line. The company is targeting forklift operators and fleet managers, with a claimed operating cost of $0.18 per kWh for the Model 1. The system eliminates the need for battery charging stations for class 1 and 2 forklifts.
March 2010
The OorjaPac addresses the low vehicle runtime and operational cost challenges facing materials handling fleet managers. OorjaPac continuously trickle-charges the onboard battery in such vehicles, regardless of whether it is operating or parked, which ensures the battery never reaches a state of deep discharge. Thus battery charge and power are maintained at high levels, and the battery is not subject to the heat damage caused during recharging. This significantly increases productivity by eliminating the labor and equipment costs associated with swapping batteries. The OorjaPac system operates on liquid methanol. The 11 gallon (42 liter) methanol fuel tank is sufficient to power two 8 h shifts. Methanol is a widely available and easy to handle energy source. It can be produced from natural gas, and from landfill gases and biowaste. The process of fueling the OorjaPac is as simple as refueling a car. ‘Oorja is leading the commercialization of fuel cells in forklifts by using inexpensive, abundant, and easy-to-handle methanol instead of volatile and expensive hydrogen for material handling operations,’ says Sanjiv Malhotra, founder and CEO of Oorja Protonics. ‘A single refuel of the new Model 1 takes less than one minute, and can last two eight-hour shifts. We’ve seen payback in as little as six months, with companies seeing full payback in 12–15 months.’ Oorja Protonics has previously won two orders for its Model H units, to power materials handling vehicles at Super Store Industries’ facility in Lathrop, California [FCB, July 2009 and January 2010]. And Nissan North America in Smyrna, Tennessee has deployed OorjaPac DMFCs for materials handling applications [FCB, October 2009]. Oorja Protonics Inc, Fremont, California, USA. Tel: +1 510 687 9501, www.oorjaprotonics.com
Fuel cell forklifts for Walmart Canada distribution center
W
almart Canada will open its first sustainable refrigerated distribution center in Balzac, Alberta later this year. The center will include a pilot of fuel cell technology, as well as many other sustainable features. The company expects to open the cutting-edge distribution center in fall 2010, and is investing C$115 million (US$111 million) in its construction.
EDITORIAL
F
uel cells are touted as ‘clean’ power systems, especially those using hydrogen, but in many applications their energy source is at least partially derived from a fossil fuel. Completely ‘green’ hydrogen can of course be generated using electrolysis in combination with renewable energy technologies such as solar photovoltaic (PV) or wind energy. For example, last month we saw that Honda is using a prototype solar hydrogen vehicle fueling station at the Los Angeles headquarters of Honda R&D Americas [FCB, February 2010]. But there is increasing interest in running fuel cells on gases derived from other processes, either as ‘waste’ or as a byproduct. Some applications are better suited to such an approach, in particular large stationary systems. The front page story in this issue, on Bloom Energy's SOFCs, is a prime example. And in Finland, Wärtsilä is having some success running a 20 kW solid oxide fuel cell on gas originating from a nearby landfill. The varying composition of the methane-rich landfill gas has been a challenge, leading to the development of an efficient control system, as well as impurity removal techniques. Meanwhile, Ohio-based Technology Management Inc is field-testing a 1 kW SOFC system, which is targeted for distributed energy applications in developing nations. TMI has engineered the SOFC to run on a wide range of locally available fuels, including methane, ethanol, digester biogas, ammonia, vegetable oils, used cooking oil, corn oil, soybean oil, biodiesel, and jatropha oil. This flex-fuel capability allows farmers to grow or make their own fuel. Such applications are not limited to SOFCs. NedStack is to deliver a 1 MW hydrogen fuel cell power plant to a Solvay chlor-alkali plant in Belgium, which would be the world’s largest PEM fuel cell installation. It will use byproduct hydrogen from chlorine production, so it utilizes a fuel that might otherwise be regarded as waste. Molten carbonate fuel cells are also prime candidates for biogas operation, as reported in our January issue. In Germany, MTU Onsite Energy will supply a HotModule power plant to an automotive supplier; this MCFC unit will use biogas from a nearby corn silage biogas plant. And in California, FuelCell Energy has sold a fourth DFC300 MCFC power plant to the City of Tulare. This will produce electricity at the regional wastewater treatment facility, running on methane as a renewable byproduct of wastewater processing.
Steve Barrett
Fuel Cells Bulletin
3
NEWS The new center is expected to be one of the most energy-efficient distribution facilities of its kind in North America. It will be an estimated 60% more energy-efficient than Walmart’s traditional refrigerated distribution centers. The announcement was made at the recent Walmart Canada Green Business Summit in Vancouver, a high-profile event that brought together more than 300 of Canada’s largest corporations, non-governmental organizations (NGOs), academics, and government leaders to share the business case for sustainability. ‘We’ve set the ambitious goal of building the most sustainable distribution center possible, while at the same time delivering a compelling return on investment,’ explains Andy Ellis, senior vice-president of supply chain for Walmart Canada. ‘The center will be a living lab that demonstrates sustainable operations, products and technologies, while showing that environmental sustainability can go hand-in-hand with business sustainability.’ Walmart Canada will test the use of hydrogen fuel cells for the first time, by replacing traditional lead-acid batteries in the center’s entire materials handling fleet. The fuel cell supplier was not named by Walmart Canada, but two years ago Plug Power provided GenDrive™ power systems for a forklift fleet at a Walmart facility in Ohio [FCB, December 2007]. Or the fuel cells may come from Hydrogenics, which is based in Mississauga – the same Toronto suburb as Walmart Canada. Fuel cells in materials handling applications increase productivity and reduce operational costs because they last longer, do not need to be changed, and can be refueled in just three minutes. The hydrogen for the Balzac fleet will come from Quebec, where it is produced almost entirely using hydroelectric power. Other sustainable features at the facility include lighting exclusively with low-energy LED lighting, using solar thermal panels to heat hot water, and a 225 kW wind turbine to generate electric power. Energy efficiency measures include an innovative refrigeration system, upgraded seals throughout the building, and a white roof membrane that reflects most of the incident sunlight to reduce heat gain and demand on the electric grid. Walmart Canada: www.walmart.ca Plug Power: www.plugpower.com
Linde MH delivers fuel cell forklifts to Linde Gases
I
n Germany, Linde Material Handling has delivered two fuel cell forklift trucks to the Linde Gases Division of The Linde Group. The fuel cell powered lift trucks – powered by PEM fuel cell modules supplied by Canadian-based Hydrogenics – are now in use at the Linde Gases facility in Pullach. Linde MH has incorporated the new fuel cell trucks into its product range. The trucks are now offered as standard and with immediate effect, as a ‘customized option’. Linde MH was previously part of The Linde Group, but it is now part of the KION Group, a global materials handing giant which also includes the Still brand. Both of the fuel cell lift trucks at Linde Gases are based on the 3 tonne electric counterbalanced truck, the Linde E30. In addition, the enhanced beverage industry version offers an optimized view over the load. In place of the usual 80 V battery, the trucks have a fuel cell and a tank, which stores 1.6 kg of hydrogen gas at 350 bar (5000 psi). The vehicle power system is hybridized with supercapacitors, which act as a buffer and cover performance peaks, such as pulling away or lifting. The trucks bear the CE Mark, and are permitted for use on public roads. The performance of the trucks is no different to the equivalent battery-powered model. These particular vehicles are tailored specifically to Linde Gases’ requirements. Linde MH has developed the fuel cell forklifts over the last two years with long-term partner, the Canadian fuel cell manufacturer Hydrogenics. Linde’s contractual partner, Gruma Nutzfahrzeuge GmbH, has been involved with the project from the beginning and is responsible for all issues related to servicing and maintaining the trucks. One of the trucks is used by Linde Gas to transport gas bottles between production halls and the truck embarkation point, which involves crossing a public road. The second truck operates in the gas bottle filling area. Both trucks replace diesel trucks with a 3.5 tonne load capacity, which were previously used for this purpose. Refueling of the fuel cell trucks is quick and safe at the Linde hydrogen center fueling station, and is comparable to refueling a conventional truck.
Linde Material Handling GmbH, Aschaffenburg, Hydrogenics: www.hydrogenics.com
4
Fuel Cells Bulletin
Germany. Tel: + 49 6021 990, www.linde-mh.de
Hydrogenics Corporation, Mississauga, Ontario, Canada. Tel: +1 905 361 3660, www.hydrogenics.com
Hydrogenics fuel cells to power UNIDO boat in Turkey
C
anadian-based Hydrogenics has been awarded a contract to supply the United Nations Industrial Development Organization (UNIDO) with six HyPM™ HD8 PEM fuel cell power modules, for a boat project coordinated by the International Centre for Hydrogen Energy Technologies (ICHET) in Istanbul, Turkey. Hydrogenics will also supply carbon composite hydrogen storage tanks and components, other auxiliaries, and spare parts for two years of operation to ICHET, which is overseeing the integration. This contract follows on from the award last year of a contract for four HyPM HD12 fuel cell power modules for a passenger boat application. They were ordered by the engineering organization BELBIM AS for Istanbul’s Municipal Transit Authority. UNIDO-ICHET participated in the deal as a hydrogen and fuel cell consultant. ‘Hydrogenics has slowly worked to pave a presence in fuel cell powered water mobility applications, starting with our Venice water taxi project several years ago,’ says Daryl Wilson, president and CEO. ‘As in other important end markets, our efforts are now bearing fruit, and we look forward to working with ICHET on this integrated hydrogen system.’
Hydrogenics Corporation, Mississauga, Ontario, Canada. Tel: +1 905 361 3660, www.hydrogenics.com UNIDO International Centre for Hydrogen Energy Technologies: www.unido-ichet.org
small stationary
CFCL wins more European orders for BlueGen mCHP
A
ustralian-based Ceramic Fuel Cells Ltd has announced several recent orders from utilities in Germany and The Netherlands, for its BlueGen solid oxide fuel cell product for residential micro combined heat and power (mCHP) applications.
March 2010
mobile applications
Oorja launches Model 1 DMFC as onboard battery charger for forklifts
C
alifornia-based Oorja Protonics, a leading developer of powerful direct methanol fuel cell (DMFC) technology, has added the 4.5 kW OorjaPac™ Model 1 to its product line. The company is targeting forklift operators and fleet managers, with a claimed operating cost of $0.18 per kWh for the Model 1. The system eliminates the need for battery charging stations for class 1 and 2 forklifts.
March 2010
The OorjaPac addresses the low vehicle runtime and operational cost challenges facing materials handling fleet managers. OorjaPac continuously trickle-charges the onboard battery in such vehicles, regardless of whether it is operating or parked, which ensures the battery never reaches a state of deep discharge. Thus battery charge and power are maintained at high levels, and the battery is not subject to the heat damage caused during recharging. This significantly increases productivity by eliminating the labor and equipment costs associated with swapping batteries. The OorjaPac system operates on liquid methanol. The 11 gallon (42 liter) methanol fuel tank is sufficient to power two 8 h shifts. Methanol is a widely available and easy to handle energy source. It can be produced from natural gas, and from landfill gases and biowaste. The process of fueling the OorjaPac is as simple as refueling a car. ‘Oorja is leading the commercialization of fuel cells in forklifts by using inexpensive, abundant, and easy-to-handle methanol instead of volatile and expensive hydrogen for material handling operations,’ says Sanjiv Malhotra, founder and CEO of Oorja Protonics. ‘A single refuel of the new Model 1 takes less than one minute, and can last two eight-hour shifts. We’ve seen payback in as little as six months, with companies seeing full payback in 12–15 months.’ Oorja Protonics has previously won two orders for its Model H units, to power materials handling vehicles at Super Store Industries’ facility in Lathrop, California [FCB, July 2009 and January 2010]. And Nissan North America in Smyrna, Tennessee has deployed OorjaPac DMFCs for materials handling applications [FCB, October 2009]. Oorja Protonics Inc, Fremont, California, USA. Tel: +1 510 687 9501, www.oorjaprotonics.com
Fuel cell forklifts for Walmart Canada distribution center
W
almart Canada will open its first sustainable refrigerated distribution center in Balzac, Alberta later this year. The center will include a pilot of fuel cell technology, as well as many other sustainable features. The company expects to open the cutting-edge distribution center in fall 2010, and is investing C$115 million (US$111 million) in its construction.
EDITORIAL
F
uel cells are touted as ‘clean’ power systems, especially those using hydrogen, but in many applications their energy source is at least partially derived from a fossil fuel. Completely ‘green’ hydrogen can of course be generated using electrolysis in combination with renewable energy technologies such as solar photovoltaic (PV) or wind energy. For example, last month we saw that Honda is using a prototype solar hydrogen vehicle fueling station at the Los Angeles headquarters of Honda R&D Americas [FCB, February 2010]. But there is increasing interest in running fuel cells on gases derived from other processes, either as ‘waste’ or as a byproduct. Some applications are better suited to such an approach, in particular large stationary systems. The front page story in this issue, on Bloom Energy's SOFCs, is a prime example. And in Finland, Wärtsilä is having some success running a 20 kW solid oxide fuel cell on gas originating from a nearby landfill. The varying composition of the methane-rich landfill gas has been a challenge, leading to the development of an efficient control system, as well as impurity removal techniques. Meanwhile, Ohio-based Technology Management Inc is field-testing a 1 kW SOFC system, which is targeted for distributed energy applications in developing nations. TMI has engineered the SOFC to run on a wide range of locally available fuels, including methane, ethanol, digester biogas, ammonia, vegetable oils, used cooking oil, corn oil, soybean oil, biodiesel, and jatropha oil. This flex-fuel capability allows farmers to grow or make their own fuel. Such applications are not limited to SOFCs. NedStack is to deliver a 1 MW hydrogen fuel cell power plant to a Solvay chlor-alkali plant in Belgium, which would be the world’s largest PEM fuel cell installation. It will use byproduct hydrogen from chlorine production, so it utilizes a fuel that might otherwise be regarded as waste. Molten carbonate fuel cells are also prime candidates for biogas operation, as reported in our January issue. In Germany, MTU Onsite Energy will supply a HotModule power plant to an automotive supplier; this MCFC unit will use biogas from a nearby corn silage biogas plant. And in California, FuelCell Energy has sold a fourth DFC300 MCFC power plant to the City of Tulare. This will produce electricity at the regional wastewater treatment facility, running on methane as a renewable byproduct of wastewater processing.
Steve Barrett
Fuel Cells Bulletin
3
NEWS The new center is expected to be one of the most energy-efficient distribution facilities of its kind in North America. It will be an estimated 60% more energy-efficient than Walmart’s traditional refrigerated distribution centers. The announcement was made at the recent Walmart Canada Green Business Summit in Vancouver, a high-profile event that brought together more than 300 of Canada’s largest corporations, non-governmental organizations (NGOs), academics, and government leaders to share the business case for sustainability. ‘We’ve set the ambitious goal of building the most sustainable distribution center possible, while at the same time delivering a compelling return on investment,’ explains Andy Ellis, senior vice-president of supply chain for Walmart Canada. ‘The center will be a living lab that demonstrates sustainable operations, products and technologies, while showing that environmental sustainability can go hand-in-hand with business sustainability.’ Walmart Canada will test the use of hydrogen fuel cells for the first time, by replacing traditional lead-acid batteries in the center’s entire materials handling fleet. The fuel cell supplier was not named by Walmart Canada, but two years ago Plug Power provided GenDrive™ power systems for a forklift fleet at a Walmart facility in Ohio [FCB, December 2007]. Or the fuel cells may come from Hydrogenics, which is based in Mississauga – the same Toronto suburb as Walmart Canada. Fuel cells in materials handling applications increase productivity and reduce operational costs because they last longer, do not need to be changed, and can be refueled in just three minutes. The hydrogen for the Balzac fleet will come from Quebec, where it is produced almost entirely using hydroelectric power. Other sustainable features at the facility include lighting exclusively with low-energy LED lighting, using solar thermal panels to heat hot water, and a 225 kW wind turbine to generate electric power. Energy efficiency measures include an innovative refrigeration system, upgraded seals throughout the building, and a white roof membrane that reflects most of the incident sunlight to reduce heat gain and demand on the electric grid. Walmart Canada: www.walmart.ca Plug Power: www.plugpower.com
Linde MH delivers fuel cell forklifts to Linde Gases
I
n Germany, Linde Material Handling has delivered two fuel cell forklift trucks to the Linde Gases Division of The Linde Group. The fuel cell powered lift trucks – powered by PEM fuel cell modules supplied by Canadian-based Hydrogenics – are now in use at the Linde Gases facility in Pullach. Linde MH has incorporated the new fuel cell trucks into its product range. The trucks are now offered as standard and with immediate effect, as a ‘customized option’. Linde MH was previously part of The Linde Group, but it is now part of the KION Group, a global materials handing giant which also includes the Still brand. Both of the fuel cell lift trucks at Linde Gases are based on the 3 tonne electric counterbalanced truck, the Linde E30. In addition, the enhanced beverage industry version offers an optimized view over the load. In place of the usual 80 V battery, the trucks have a fuel cell and a tank, which stores 1.6 kg of hydrogen gas at 350 bar (5000 psi). The vehicle power system is hybridized with supercapacitors, which act as a buffer and cover performance peaks, such as pulling away or lifting. The trucks bear the CE Mark, and are permitted for use on public roads. The performance of the trucks is no different to the equivalent battery-powered model. These particular vehicles are tailored specifically to Linde Gases’ requirements. Linde MH has developed the fuel cell forklifts over the last two years with long-term partner, the Canadian fuel cell manufacturer Hydrogenics. Linde’s contractual partner, Gruma Nutzfahrzeuge GmbH, has been involved with the project from the beginning and is responsible for all issues related to servicing and maintaining the trucks. One of the trucks is used by Linde Gas to transport gas bottles between production halls and the truck embarkation point, which involves crossing a public road. The second truck operates in the gas bottle filling area. Both trucks replace diesel trucks with a 3.5 tonne load capacity, which were previously used for this purpose. Refueling of the fuel cell trucks is quick and safe at the Linde hydrogen center fueling station, and is comparable to refueling a conventional truck.
Linde Material Handling GmbH, Aschaffenburg, Hydrogenics: www.hydrogenics.com
4
Fuel Cells Bulletin
Germany. Tel: + 49 6021 990, www.linde-mh.de
Hydrogenics Corporation, Mississauga, Ontario, Canada. Tel: +1 905 361 3660, www.hydrogenics.com
Hydrogenics fuel cells to power UNIDO boat in Turkey
C
anadian-based Hydrogenics has been awarded a contract to supply the United Nations Industrial Development Organization (UNIDO) with six HyPM™ HD8 PEM fuel cell power modules, for a boat project coordinated by the International Centre for Hydrogen Energy Technologies (ICHET) in Istanbul, Turkey. Hydrogenics will also supply carbon composite hydrogen storage tanks and components, other auxiliaries, and spare parts for two years of operation to ICHET, which is overseeing the integration. This contract follows on from the award last year of a contract for four HyPM HD12 fuel cell power modules for a passenger boat application. They were ordered by the engineering organization BELBIM AS for Istanbul’s Municipal Transit Authority. UNIDO-ICHET participated in the deal as a hydrogen and fuel cell consultant. ‘Hydrogenics has slowly worked to pave a presence in fuel cell powered water mobility applications, starting with our Venice water taxi project several years ago,’ says Daryl Wilson, president and CEO. ‘As in other important end markets, our efforts are now bearing fruit, and we look forward to working with ICHET on this integrated hydrogen system.’
Hydrogenics Corporation, Mississauga, Ontario, Canada. Tel: +1 905 361 3660, www.hydrogenics.com UNIDO International Centre for Hydrogen Energy Technologies: www.unido-ichet.org
small stationary
CFCL wins more European orders for BlueGen mCHP
A
ustralian-based Ceramic Fuel Cells Ltd has announced several recent orders from utilities in Germany and The Netherlands, for its BlueGen solid oxide fuel cell product for residential micro combined heat and power (mCHP) applications.
March 2010