Green Logistics offering Eco Solutions: Hydrogen Powered Fuel Cell Forklifts

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1 Green Logistics offering Eco Solutions: Hydrogen Powered Fuel Cell Forklifts Petra Schemitsch Schenker Manfred Klell HyCentA A3PS Conference, Vienna, November 15 th

2 Project background E-LOG-Bio-Fleet Leuchtturm der Elektromobilität in einer Logistikflottenanwendung mit Range Extender unter Nutzung von Biomethan mit klimarelevanter Modellwirkung This project is selected for funding by the Austrian Climate and Energy Fund within the program: Technologische Leuchttürme der Elektromobilität 2

3 E-LOG-Bio-Fleet: Project Objectives Development, certification and demonstration of a warehouse tow truck fleet (12 vehicles) with fuel cell range extender Installation, authority approval and demonstration of indoors and onboard biohydrogen refueling of the warehouse truck fleet CO 2 neutral generation of bio-hydrogen using reformed biogas as source of energy Environmental and socio-economic assessment of the innovative and sustainable warehouse logistic application Preparation for enhanced market entry C-H2 Delivery (Tube Trailer) Compression and Filling Station H2 350bar Biogas H2 Reformer Bio-H2 CH2 3

4 E-LOG-Bio-Fleet: Project Structure Accompanying Studies Project Management Pilot Customer Industrial Field Trial Fuel Cell-System Provider Service & Maintenance Fuell Cell Linde Austria Vehicle-System Provider Service & Maintenance Vehicle H2 Infrastructure Provider

5 DB Schenker aims to reduce 20% of CO 2 -emissions by 2020 by defined targets and measures for all business units

6 Avoid - Reduce Compensate: Our 3-step approach to address the CO 2 -issue

7 DB Schenker provides a strong packet of measures for emission reduction New and enhanced vehicle generations Usage of blocktrains Engergy efficient driving Monitoring TEMA Box Automotive engineering Hub systems Energy efficient driving Monitoring Close cooperation with preferred carriers Intelligent link of transport modes Optimized routing and new equipment New engines and aerodynamics 11/2/2011 7

8 DB Schenker provides a strong packet of measures for emission reduction Improvements in aero- and hydrodynamics Advanced machinery Clean shipping reporting Workshops with preferred carriers Building measures save environment Selecting the most efficient technology Integrated lightning concepts Energy monitoring and benchmarking

9 Integration of ELOG-Biofleet in our Green Logistics (Green Terminals) Use of fuel cells as further step of CO 2 -reduction Diesel as strongest CO 2 -emitter by comparison Electricity consumption valuated with the specific CO 2 -energy mix Natural gas has the highest hydrogen and the lowest hydrocarbon portion thus less CO 2 -emissions H2 produced by solar energy emission of 0 Schematic diagram of emission comparison Referring to chart of Mr. Schubert Energieketten / CO 2 -Reduktion 11/2/2011 9

10 Integration of ELOG-Biofleet in our Green Logistics (Green Terminals) Advantages compared to conventional battery operation Refueling with H2 takes only few minutes Improvement of forklift efficiency Doubling of energy density and forklift efficiency Decrease of operating costs because of extended maintenance intervals Reduction of electricity consumption Battery charging time 8-10 hours Drop of efficiency during the discharge Lower energy density High-maintenance 11/2/

11 Battery-electric forklifts Market for electric forklifts represenst world biggest market for electric vehicles Disadvantages of purely battery-electric vehicles with lead acid acumulators: long charging times Decreased performance with decreased state of charge Low energy density High service and maintenance efforts batterytray 11

12 H 2 -Fuel Cell Range Extender Forklifts Significant lower refuelling times a fewminutes, not hours Doubled energy density Constant performance independent of the state of charge of the hydrogen storage Lower operating costs due to extended maintenance intervalls Hydrogen Substitution of fossil energy carriers CO 2 free/ CO 2 neutral zero emission 12

13 Battery tray 4PzS Battery Voltage: 24 V f (discharge current, state of charge, ) Capacity(new): 450 Ah Only80 % fordischarge: 360 Ah F (Temp., No. ofloadcycles, ) Refueling time: > 480 min Weight: 365 kg Dimensions L/W/H: 786/310/630 mm 13

14 H 2 -Fuel Cell Range Extender FC-Range Extender fuel cell system LiFePO 4 -High power battery Nominal system voltage: 26.4 V Peak power: 11.9 kw (450 A, 26.4 V) H 2 -Storage: 27 l, 200 bar 12.7 kwh H2, 6 kwh el (efficiency: 47 %) Refuelingtime: < 3 min Weight: 180 kg Dimensions: equal to 4PzS tray 14

15 ELOG-Biofleet: Target vehicles target vehicle range was selected on the basis of: market share typical fleet size of vehicle types typical operating hours typical energy consumption load profiles, etc. L PzS: 624 x 284 x 627 mm T16-T20 2PzS: 624 x 212 x 627 mm T20-24 AP/SP P30C N PzS: 786 x 310 x 630 mm R PzS: 1223 x 355 x 784 mm R14-20G 4PzS: 1223 x 355 x 784 mm P60z 3PzS: 830 x 414 x 627 mm 15

16 Forklift N20: Low Level Order Picker Load capacity: 2000 kg Service weight (with battery): 1160 kg Travel speed with/without load: 10/12 km/h Lifting speed with/without load: 0.031/0.039 m/s Driving motor: 3 kw Lift motor: 1 kw 16

17 Onsite hydrogen infrastructure Hydrogen production: 0.45 kg H2 /h(purity: %) Feedgas: Bio-CH 4,3 Nm³/h ( mbar Water consumption: 350 l/h Power consumption: 44.2 kwh/day 17

18 Onsite hydrogen infrastructure Indoor Dispenser Refueling time < 3 min Refueling power > 400 kw Supplied pressure Upto350 bar Refueling nozzle Weh TK 17 18

19 Analysis H2-infrastructure EfficiencyBio-CH 4 H 350 bar 47 % CO 2 -emissions: 396 g CO2 /kwh H2 (CO 2 -balanced) 13.2 kg CO2 /kg H2 CostsH 2 : 8.1 /kg H /kwh H2 CGH 2 η CO 2 19

20 Safety and approval issues General 2006/42/EC Machinery directive 97/23/EC Pressure equipment directive(ped) 1999/92/EC ATEX H 2 -powered vehicles/ hydrogen qualityforpem-fc EC 79/2009 hydrogen powered vehicles 406/2010 implementing regulation 79/2009 ISO 14687/2 / SAE J2719 hydrogen quality for PEM-FC Indoor dispensation ÖVGW G97: NGV filling stations- Design, production, installation and operation VdTÜVMerkblattDruckgase514: Requirements for hydrogen fueling stations, Compressed gases 514 NFPA 52: Vehicular gaseous fuel system code 20

21 Thank you for your attention! Petra Schemitsch SCHENKER & CO AG Stella-Klein-Löw-Weg 11 A-1020 Wien Tel.: petra.schemitsch@schenker.at Manfred Klell HyCentA Research GmbH Inffeldgasse 15 A-8010 Graz Tel.: +43 (0) klell@hycenta.at 21