Project: “Development and commercialisation of fuel cell hybrid power systems for clean and efficient material handling vehicles”

HyLIFT-FLEX will develop and commercialize fuel cell hybrid systems that enable zero emission and efficient propulsion of materials handling vehicles. _x000D_ _x000D_ Hydrogen and fuel cell technology holds the potential to make fossil independent and zero emission transportation possible. Hydrogen can be produced from unlimited renewable energy sources by using electricity to split water. Hydrogen is stored onboard vehicles where a fuel cell converts it to electricity that powers the vehicle. _x000D_ _x000D_ One of the earliest commercial markets for hydrogen fuel cells are materials handling vehicles where the technology combine the best features of today’s battery propulsion technology and LGP/diesel powered combustion engines. Hydrogen and fuel cells can deliver a silent and zero emission electric power delivery for material handling vehicles like batteries whilst still having the fast refuelling and consistent power delivery as a combustion engine powered vehicle. _x000D_ _x000D_ Hydrogen and fuel cells can thus enable electric propulsion of larger and heavy duty used material handling vehicles that today use LGP/diesel. The emission reduction potentials by use of hydrogen instead of fossil fuels are significant, e.g. the annual CO2 emissions from 1 forklift are corresponding to that of 8 cars. Also particle emissions can be totally eliminated. As the fuel cell utilizes the hydrogen fuel at a energy efficiency twice that of combustion engines, fuel cells are competitive on a total cost of ownership basis in material handling vehicles due to savings in fuel costs, enabling a payback time on less than 3 years. _x000D_ _x000D_ HyLIFT-FLEX focuses on two early commercial sub market segments within material handling vehicles, namely towing tractors for aviation vehicle purposes and 2,5-5 tons forklifts. The annual world market for the mentioned target segments are respectively 150.000-170.000 units (forklifts) and 6-10.000 units (aviation vehicles). The segments hold sufficient volume potential to reach high-volume production and price reduction enabling use in other material handling vehicles where the total world market potential are in the range of 1 million units annually and a market value of more than €23 billion. The worldwide annual sales of fuel cells for material handling vehicles is expected to reach 30.000 units in 2015 corresponding to a market value of up to €416 million. _x000D_ _x000D_ A commercial use of hydrogen and fuel cells in materials handling vehicles can also ease and advance use hereof in road vehicles, thus enabling fossil independent and zero emission transportation in general. _x000D_ _x000D_ The HyLIFT-FLEX project will address the research and development obstacles for a commercial use of hydrogen and fuel cells in materials handling vehicles. The project has three CO tasks and objectives:_x000D_ 1) Conduct R&D of a 3rd generation Fuel Cell Hybrid System for material handling reaching commercial targets on price, life time and energy efficiency _x000D_ 2) Conduct field testing at potential end-users to validate reaching of commercial targets_x000D_ 3) Prepare, plan and secure a following market introduction no later than 2012. _x000D_ _x000D_ The HyLIFT-FLEX project participants constitute a consortium that is among the world leaders in all disciplines and sectors required for developing and commercializing fuel cells for material handling vehicles, covering the entire value chain and combining the newest R&D knowledge with years of industrial experience._x000D_ _x000D_ H2 Logic A/S (R&D performing SME) (DK)_x000D_ H2 Logic will act as system integrator and developer of the fuel cell system in the project. H2 Logic has since 2003 accumulated ended R&D projects for €5,3 million and by summer 2009 ongoing product R&D activities for €5,0 million. The ambition of H2 Logic is to become among the world leading top3 within supply of fuel cell systems for materials handling vehicles. H2 Logic has collaboration agreements with some of the major forklift worldwide. _x000D_ _x000D_ MULAG Fahrzeugwerk Heinz Wössner GmbH (SME) (DE)_x000D_ MULAG will act as the vehicle OEM in the HyLIFT-FLEX project providing knowledge about the end-user and functioning as a potential later sales channel for the developed fuel cell hybrid system. MULAG has since 1953 been one of the leading German manufacturers of airport ground support vehicles. For MULAG the goal of the project is to ensure R&D of a towing tractor with an integrated fuel cell hybrid system.

Acronym HyLIFT-FLEX (Reference Number: 5099)
Duration 01/02/2010 - 31/07/2012
Project Topic HyLIFT-FLEX will develop & demonstrate a 3rd generation fuel cell hybrid power system for commercial use in electric material handling vehicles, eliminating emissions and increasing fuel utilization, whilst ensuring same fast refuelling and long range as diesel and LPG offers today.
Project Results
(after finalisation)
The 2 project participants had jointly developed a Hydrogen tow tractor for airport applications, and the vehicle has been proven at 4 different demonstration sites._x000D_H2 Logic A/S has developed a 10kW flexible fuel cell system, than can easily be integrated in a normal battery powered vehicle._x000D_MULAG GmbH has updated Comet 3 vehicle to work with fuel cell._x000D_The project has been a succes. MULAG & H2 Logic continue the cooperation, and have initiated the HyLift-Demo & HyLift-Europe project under the FCH-JU (JTI).
Network Eurostars
Call Eurostars Cut-Off 3

Project partner

Number Name Role Country
3 H2 Logic A/S Coordinator Denmark
3 Svenska Rotor Maskiner AB Observer Sweden
3 MULAG Fahrzeugwerk Heinz Wössner GmbH Partner Germany