Hydrogen fuel cells as a source of power have piqued the interest of the distribution and warehousing sector. The energy is renewable and sustainable, and it offers a viable alternative to lead-acid batteries for powering forklifts.
Federal government tax credits to promote the growth of fuel cells may have come to an end, but this in no way seems to have affected the rate at which the technology is being accepted. When companies such as Wal-Mart and Sysco register success with the implementation of fuel cell technology, then it can only be good news for this clean source of energy.
By last year, Wal-Mart had installed hydrogen fuel power in seven of its distribution centers in North America. The technology powers Class 2 and Class 3 electric lift trucks used by the retail giant. Two years ago, Sysco had reported favorable results by switching from diesel engines to fuel cells for powering its refrigerated trucks used for delivering perishable food items.
In 2009, Central Grocers chose fuel cells over lead-acid batteries for their fleet of 220 forklifts at a new distribution center in Illinois. The company envisages savings of around $1.5 million from this decision.
The material-handling industry is set to play an important role in enabling this technology getting a foothold across sectors. Fuel-cell trucks perform as well as battery-powered trucks when compared for attributes such as braking distance, maximum travel and lift speed.
Hydrogen-fuel-cell-powered forklifts offer several advantages, such as shorter refueling times compared to charging lead-acid batteries. Fuel cells that are a part of the truck design eliminate the removal of cells for charging and contribute as a counterweight.
Quick refueling that takes a few minutes and longer-lasting fuel cells as compared to lead-acid batteries result in improved productivity and efficiency. Constant voltage and power-output capacity enable fuel-cell-driven forklifts to operate at constant speeds. Fuel cells perform admirably even in subzero temperatures.
Another big advantage is that a fuel-cell system has a lifetime of 10 years, with fuel cell stacks refurbished every three years. Fresh lead-acid batteries, on the other hand, have to be obtained every three years. An operation with a fleet size of at least 40 forklifts is sufficient to justify the expense for setting up refueling infrastructure.
The cost of shifting to hydrogen fuel cells depends upon the following factors:
- The size of the fleet and type of forklifts
- Labor costs
- Time to refuel and number of refuels in a day
- Cost of hydrogen fuel-cell power pack
- Life of the fuel-cell power pack
Hydrogen supply during the phase of evaluating the value proposition of fuel cells is an important consideration for warehouses. Gas suppliers provide supply and fueling solutions that can be adapted to the requirements of a warehouse.
For extensive operations, liquid hydrogen is made available to the site. In the absence of hydrogen suppliers in an area, warehouses can generate hydrogen through the simple process of electrolysis.
The use of hydrogen in fuel-cell vehicle technology is slated for further growth. Along with lithium-ion batteries, the technology could soon provide economic and environmental benefits at warehouse locations where it is deployed.
