Metal hydride hydrogen storage and supply systems for electric forklift with low-temperature proton exchange membrane fuel cell power module

Abstract A novel hydrogen storage system for a RX60-30L 3-tonne electric forklift (STILL), equipped with a GenDrive 1600-80A fuel cell power module (Plug Power) has been developed. The system combines a compressed H 2 composite cylinder (CGH2) and a liquid-heated-cooled metal hydride (MH) extension tank which is thermally integrated with a power module. The MH extension tank comprises a MH bed formed according to an advanced solution to provide easy activation of the MH material and fast H 2 charge/discharge. The system has the same hydrogen storage capacity (∼19 Nm 3 H 2 or 1.7 kg) as the separate CGH2 tank charged at P = 350 bar, but at a lower H 2 charge pressure (≤185 bar). A 15 min cycle refuelling provides the forklift with full-load operation (according to VDI-60 protocol) during >3 h, or 2 to 4 working shifts in a real industrial environment. The work also presents a hydrogen refuelling station (dispensing pressure up to 185 bar) with integrated MH compressor which has been developed for forklift refuelling.