Forschungs- & Entwicklungsinformationsdienst der Gemeinschaft - CORDIS


SHEL Berichtzusammenfassung

Project ID: 256837
Gefördert unter: FP7-JTI
Land: Spain

Periodic Report Summary 2 - SHEL (Sustainable Hydrogen Evaluation in Logistics)

Project Context and Objectives:

SHEL project, “Sustainable Hydrogen Evaluation in Logistics” is a collaborative demonstration project funded by the FCH JU. The overall purpose of the project is to demonstrate the market readiness of the technology and to develop a template for future commercialization of hydrogen powered material handling vehicles for demanding high logistic operations.

The project will demonstrate 10 fuel cell forklift trucks (FLT) and associated hydrogen refueling infrastructure across four sites in Europe. Real time information will be gathered to demonstrate the advantage of using fuel cells to current technologies and fast procedures will be developed to reduce the time required for product certification and infrastructural build approval. Moreover, to ensure the widest dissemination of the results, the project will build a comprehensive State Holder Group of partners to pave the way for wider acceptance of the technology. In addition, during the demonstration studies will be carried out to:

1. Determine predicted hydrogen cost for hydrogen generated from renewable zero carbon resources. Pathways to include:

- Hydrogen generated from waste streams (industrial and commercial).
- In-situ generation of hydrogen from electrolysis powered from renewable energy.
- Purification of industrial hydrogen off-gas.

2. Determine the CO2 savings potential of such vehicles in four different likely early market applications (such as Distribution Centres, Light Logistics, Industrial Complexes or Sea Ports).
3. Develop simulation models and an on-board vehicle monitoring system to aid the gathering of real time information for a detailed well-to-wheel analysis.
4. Develop design improvements for Hydrogen refuelling infrastructure which will achieve:
5. Reduced time for site approval
6. Continuous rapid fill for FC FLT (taking < 5minutes).
7. Improved ease of operation for site operators.
8. To test and evaluate Fuel Cell system performance (to include real data gathered from the demonstration) for:

- A total cost of fuel cell system under €4,000.
- A system lifecycle over 5,000 hours.
- A system efficiency greater than 40%

Project Results:

During the 2nd period, the consortium faced several challenges appeared during execution of the Project. Comparing to the period 1, were the new challenges were undertaken successfully, in this period the events arising in the project, triggered the Consortium decide to terminate the project. Thus, the first event that shook the project was the close down of ICHET on midnight, 31st December 2012. From this date, all ICHET operations were ceased, and all ICHET property was reverted to the Ministry with the Ministry assuming responsibility for all equipment and projects.

In this scene, the main difficulty came from UNIDO-ICHET that in the beginning of 2012 purchased four fuel cell systems to be integrated into the forklift trucks to be used in two different demo sites (Felixstowe Port in UK and Petkim Petrochemical Complex in Turkey). UNIDO-ICHET bought also a hydrogen refuelling station to be installed in Petkim´s facility. These four fuel cell systems were completely integrated in CUMITAS trucks as planned in the DoW at the end of 2012 and the refuelling station was started building by the supplier in order to be ready by March 2013. However, as mentioned in above paragraph, the problem was that these equipments belonged to MENR.

Although CIDETEC did received an extra-official information confirming the willingness of MENR to donate the equipment to SHEL consortium via the remaining Turkish partner within SHEL, the situation with the Turkish Ministry went into at a deadlock, and it was not yet clear when the proper hand-over of the equipment would take place. As this uncertainty situation was not compatible with the need to build a solid timeframe for the demonstrations within the current duration of the project, a reduced continuation plan was proposed in which the demonstrations in Turkey and UK would be removed.

The second event was related to the Mid Term Review held in January 2013 were two major commitments were defined in order to face the difficulty after ICHET shutting down:

• A scenario with 5 HFLTs demonstrated in two sites during a full year trial.
• A contingency plan for each demo site.

Since the Mid Term Review Consortium tried to sort out the new challenges, trying to fix all open issues related to the starting of the re-scheduled demonstrations on time –i.e., in June 2013- as well as the contingency plan. However, 3 months later than the Mid Term Review the above mentioned challenges still remain opened leading to a new scenario where the 5 HFC FLTs could not be demonstrated during at least the specified full year trial, assuming that the end date already agreed for the project could not be further delayed.

Thus, the Consortium decided that it would not be possible to reach the goals of the project demonstration activities as expected on due time.

Although the project went into a deadlock, the Consortium was able to make progress in some of the project activities and some of the planned objectives for the 2nd period were reached. Therefore, the objectives achieved during the 2nd period of the project are highlight below:

- The Project Steering Committee was held.
- Dissemination of the project has been done in several International Conferences.

Potential Impact:

The overall aim of the SHEL project was to demonstrate the market readiness of the technology and to develop a template for future commercialization of hydrogen powered fuel cell based materials handling vehicles for demanding, high intensity logistics operations.

The consortium brought together a strong cluster of partners from Europe’s hydrogen and fuel cell sector with key industrial partners (a major industrial gas company (AP), a Fork Lift truck OEM (Cumitas) and a leading logistic company (CEGA) who on successful completion of the demonstration can move towards full scale commercialisation. The project would directly support the development and testing of a Fuel Cell prototype Fork Lift Truck developed by Cumitas (supported by UNIDO-ICHET ) and the development of a low cost modular hydrogen refuelling unit designed to support rapid site certification.

The project was fully compliant with the technical content and scope of the topic ‘Demonstration of fuel-cell materials handling vehicles and infrastructure’ and aimed to achieving the impacts required by the work programme as detailed below.

• The deployment of 10 FLT across 4 sites in Europe, would give the participant partners in-depth field experience (both technical and operational) to accelerate medium term (3 to 5 years) commercialisation across the EU member states. Each site has been selected to be representative of current identified niche market opportunities:
• This proposed large-scale demonstration of second-generation pre-commercial products would confirm system specifications, lifecycle costs and training needs for product installation and use, and demonstrate public acceptance. The evaluation of a mixture of fuel cell retrofitted and OEM FLTs will demonstrate both of the important routes to market, providing detailed operational information on service intervals and operational match between the technology and user requirements including handling and ease of use, including training requirements.
• The development of a monitoring system for real-time data analysis and a simulation model for detailed analysis of the existing demonstration current duty cycle of forklift trucks and material handling equipment on site would pave the way for future commercial installations by enabling the preparation of full operational protocols for deployment of fuel cell vehicles including CO2 reduction analysis (comparing existing and FC FLT alternatives); training procedures; safety protocols and real-time data on preventive maintenance.
• The demonstration benchmarks would prove performance versus the call’s technical requirements (an expected outcome).
• The proposed development of a low impact hydrogen refuelling system for FLT operations would demonstrate a flexible, low cost refuelling station capable of delivering low cost hydrogen from multiple sources. The project would provided detailed models for medium to long-term hydrogen integration, specifically: 1) distributed hydrogen distribution model most suitable for short to medium term commercialization; 2) an on-site generation model for hydrogen generation from embedded renewable energy generation) and low cost hydrogen storage. 3) the use of waste hydrogen from petrochemical sites.
• Fostering education and public acceptance were pivotal topics to be addressed in order to achieve a spread of hydrogen applications to the broader public. Sites were selected with high public presence to promote greater public awareness and acceptance.
• One of the barriers to successful commercial introduction of fuel cell powered materials handling systems was the current regulatory environment. The SHEL project would identify and improve the speed of certification from the relevant European Agencies, promoting international standards and developing procedures for certification within the European member states.

However, due to the enforced end of the project, only the following impacts have been reached:

• A certification report detailing methodologies / procedures for simplified hydrogen infrastructure approvals have been developed. This roadmap will permit a successful commercial introduction of FC FLT due to elimination of regulatory barriers.

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