Hydrogen fuel cell “more efficient than diesel engines”

Loop Energy, a designer and manufacturer of hydrogen fuel cells for commercial mobility, unveiled its landmark 120kW fuel cell system at IAA Transportation 2022 in Hannover, Germany.

The announcement marks a milestone for Loop Energy as it believes this new product is a significant achievement in advancing the global hydrogen industry and the transition of commercial transport industries by achieving fuel cost parity with diesel by up to eight years earlier than previously possible.

The 120kW fuel cell system, the S1200, builds on Loop Energy’s existing technology, to provide an additional efficiency gain of 20% when it generates electricity. The S1200 is designed to deliver up to 60% in net system efficiency. This efficiency enables an electric vehicle powered by a Loop Energy fuel cell to deliver up to 54% fuel-to-wheel efficiency compared to the typical fuel-to-wheel efficiency delivered by a diesel engine powered vehicle of 20% to 25%.

Loop Energy believes the S1200 and its next-generation technology will significantly benefit commercial vehicle manufacturers, fleet operators and associated industries, as well as the global clean energy transition as governments seek to reach net zero emissions by 2050.

Loop Energy says it has achieved this efficiency gain because of its patented eFlow fuel cell architecture. Specifically, Loop Energy uses a signature trapezoid plate with narrowing channels for its bipolar plates, which increases gas velocity down the plate to deliver superior performance for fuel efficiency, and power output.

For fleet managers, operators of commercial vehicles and the wider hydrogen infrastructure market, that means less hydrogen fuel used per kilometre, lowering the total cost of ownership (TCO) of hydrogen-electric commercial vehicles.

Fuel costs make up roughly half of the TCO for heavy-duty hydrogen vehicles, which makes advancement in fuel efficiency a significant factor in creating a tipping point for commercial transition from diesel to clean fuels.

Loop Energy’s presence at IAA Transportation 2022 also signifies its commitment to the European continent, where it plans to expand its presence and customer base. Loop Energy already has offices in Italy and the UK, and is actively engaged with OEMs across the region. Loop Energy is also active in Asia, with its new manufacturing facility in Shanghai.

The S1200 opens up a new market for Loop Energy as the product is specifically designed for medium- to heavy-duty commercial vehicles, which is a step up in power range and scope compared to its other fuel cell products.

The S1200 is delivered as a complete fuel cell system which simplifies and quickens integration for vehicle OEMs, and makes it a ready-to adopt solution for heavy-duty transportation and power system applications.

Loop Energy President & CEO, Ben Nyland, said: “With the launch of our new fuel cell system, we are proud to be leading the way in making transport electrification economically viable. The S1200 brings world-leading fuel efficiency levels for medium- to heavy-duty vehicles, crucially making the total cost of ownership lower and bringing fuel cost parity forward by four to eight years.”

“We are keen to work with OEMs, governments and the wider hydrogen industry to help meet zero-emission targets. We strongly believe that energy transition must happen now, and hydrogen fuel cell technology is in prime place as an alternative to diesel-powered vehicles.”

Canadian Minister of Environment and Climate Change, The Honourable Steven Guilbeault, said: “Very happy to see Canadian companies such as Loop Energy leading in the global clean energy sector. They are creating sustainable jobs for workers, while contributing to our global climate objectives and a better future for everyone.”

Hyster supplies fuel-cell trucks to Hamburg port

Hyster has entered into a non-binding Memorandum of Understanding to provide Hamburger Hafen und Logistik AG (HHLA) with two Hyster electric container handling vehicles, including the first-ever empty container handler powered by fuel cell technology in a real-world application. In addition, this will be the first Hyster terminal tractor supplied in Europe. Both units will be powered by Nuvera fuel cells and run on hydrogen fuel produced locally at the HHLA Hamburg Green Hydrogen Hub.

Fuel cell-powered clean port equipment from Hyster is a key component of the ‘Clean Port and Logistic’ programme and subsequently HHLA’s H2LOAD project aiming to achieve climate neutrality across the HHLA group by 2040. The initial agreement is for two hydrogen-powered vehicles. The delivery of the terminal tractor is planned for late 2022, with the empty container handler to follow in early 2023.

“The ‘Clean Port and Logistics’ programme, a joint initiative of HHLA and other European companies, aims to operationalise and test the next-generation hydrogen-powered port equipment in order to reduce emissions in port handling and the associated logistics chains,” says Georg Böttner, head executive board projects, HHLA.

“The results of this programme will be the basis for a possible scaling up of further zero-emission hydrogen-powered port equipment, which is a part of our ‘H2Load’ project that was selected by the German government as one of the Important Projects of Common European Interest. This initiative is a further step as we help lay the foundation for a strong hydrogen economy not only in Hamburg, but elsewhere in Germany and Europe.”

The hydrogen fuel cell-powered equipment from Hyster will be deployed at HHLA Container Terminal Tollerort (CTT) in Hamburg. It is planned to equip CTT with a refuelling infrastructure and connect the terminal to the future Hamburg hydrogen grid. A possible phase two of the H2LOAD project includes the rollout of hydrogen fuel cell equipment and infrastructure to several HHLA locations in Central and Eastern Europe.

“Our goal is to provide the innovative technologies customers need to help meet emissions reduction targets,” says Jan Willem van den Brand, director, global market development, big trucks, Hyster. “But developing the technology is just the start. Ultimately, our commitment to HHLA is about delivering hydrogen fuel cell-powered equipment at scale to help make their hydrogen-focused vision a reality.”

The hydrogen fuel cell-powered empty container handler is a result of intense collaboration and rigorous application analysis. It will be powered by a single, 60kW Nuvera fuel cell, while the terminal tractor will be powered by a 45kW Nuvera fuel cell. Both trucks will share many of the same components such as drive motor, battery modules, converters, hydrogen tanks and controls. This design approach offers a level of familiarity for operators who have experience with other Hyster big trucks and helps limit complexity, cost of design, manufacturing, service and maintenance.

“We are transforming the way the world moves materials, from busy ports moving shipping containers to the warehouses responsible for bringing goods right to your front door,” says David LeBlanc, president, technology solutions division, Hyster-Yale Group – parent company of Hyster and Nuvera. “This project with HHLA truly exemplifies that. We relish the opportunity to leverage our combined resources to push container handling forward.”

Work underway on ‘next-generation’ HGV hydrogen engine

Ballard Power Systems and MAHLE Group, a Tier 1 automotive supplier, are progressing the development of a new fuel cell engine concept for long-haul trucks, with MAHLE taking delivery of 120kW module at the company’s hydrogen test centre in Stuttgart, Germany.

The new concept engine is a part of the ongoing development of Ballard’s future product platform – which will feature power outputs from 180kW to 360kW – to specifically address the requirements of heavy-duty and long-haul trucks on global markets.

The joint project is a multi-year development program in which Ballard and MAHLE will continuously refine Ballard’s compact, energy-dense fuel cell stack and an integrated engine to meet the quality and performance expectations of the truck industry.

Seungsoo Jung, Product Director, Trucks, Ballard, said: “We are committed to fuel cell technology leadership, and to tailoring our fuel cell solutions to our customers’ needs. We are extremely optimistic about the value of our collaboration with MAHLE—combining their strength in the automotive value chain with our leadership in hydrogen fuel cell technology and products.”

The module incorporates Ballard’s FCgen-HPS Fuel Cell stack, which addresses limited engine space, and maximizes freight and cargo capacity. Based on an earlier high power density design, the technology draws on Ballard’s on-road experience of 100 million km in service and proven fuel cell durability, exceeding 30,000 in vehicle operation as demonstrated in the London bus fleet.

The concept fuel cell module is the central building block in Ballard’s future engine, which MAHLE will now test and integrate with their components, including the balance-of-plant, thermal management and power electronics, and the system assembly.

The new concept engine for heavy-duty vehicles will feature:

High Power for Heavy Payloads: the 120kW module is a building block for systems that can deliver up to 240kW power, to serve the needs of heavy Class 8 and long-haul freight trucks and coaches that require more power and longer range than transit buses or short-range delivery vehicles.

Easier Maintenance for Lower Total Cost of Ownership (TCO): the module design features reduced weight, fewer parts and a more compact design. A key new feature, the “Open Engine Concept Design”, provides better access to parts and the subsystem, for easier maintenance and ultimately, a lower total life cycle cost.

Robust, Reliable Design: For long-haul trucks delivering critical goods, reliability and robustness are essential – and the Concept Engine’s reduced parts count and simplified integration design are key factors in dependable long-term performance.

Trustworthy Durability: The Concept Engine is based on field-proven technologies and designs, and Ballard’s vast experience in heavy-duty transport.

Fuel Efficiency for Economical Operation: Fuel costs are a major component of a Class 8 truck’s TCO. Fuel efficiency is also key for a manageable heat rejection system.

Freeze Start for Cold Weather: Because commercial trucks have to power up and deliver the goods, even in midwinter in the worst mountain roads.

The partnership’s aim is to accelerate the development and commercialization of zero-emission fuel cell systems. Ballard has prime responsibility for system design and the fuel cell stack sub-system, while MAHLE’s scope of responsibility includes balance-of-plant components, thermal management and power electronics for the complete fuel cell system.

 

Caigan launches hydrogen vehicle conversion service

Caigan Vehicle Technologies Ltd. has entered the zero-carbon transport market with an innovative hydrogen fuel cell conversion for internal combustion engine vehicles.

Based in South Lanarkshire, Caigan’s engineers can replace a petrol or diesel engine with a complete hydrogen fuel cell power system to eliminate harmful emissions entirely. This novel approach allows fleet managers to gradually upgrade in order to meet targets without the cost and disruption of replacing all of their vehicles.

The conversion process involves removing the existing engine and fuel system and retrofitting a hydrogen storage tank, a fuel cell to convert the hydrogen gas to electricity, a traction battery and an electric drive motor.

Caigan Managing Director Steve Turner (pictured) said: “Companies and organisations are under growing pressure to reduce their carbon footprint and there won’t be enough electric vehicles to meet demand as deadlines approach. We can design and integrate a hydrogen powertrain with negligible reduction in payload and range when compared to petrol or diesel power. This option allows fleet managers to upgrade their high-value assets and keep them in service instead of coming under pressure to dispose of them before good alternatives are available.

“Hydrogen fuel cell technology isn’t a compromise or a half measure. Fuel cells only emit water vapour and a little heat so harmful tailpipe emissions are zero. The most polluting vehicles can drive into our workshop and drive out with no emissions at all. The latest fuel cell cars actually clean the air as they drive which is a game-changer for the environment.”

As well as the environmental and compliance benefits, Caigan also expect a converted vehicle to have significantly lower running and maintenance costs compared to original specification.

With its focus set on medium-duty (3.5-7.5t) vehicles, Caigan is looking towards local councils, emergency services and similar fleets as ideal candidates for its conversion packages.

Subscribe

Get notified about New Episodes of our Podcast, New Magazine Issues and stay updated with our Weekly Newsletter.