FIAMM, Nuvera to develop hybrid battery/ fuel cell forklift power US/Italian-based fuel cell systems developer Nuvera Fuel Cells is to combine forces with lead-acid battery manufacturer FIAMM SpA in Italy to develop a 7 kWe-class hybrid battery/fuel cell power pack for industrial materials handling vehicles. The companies intend to build and market the innovative hydrogen-fueled, zero-emission power pack for European forklift trucks starting in 2005.
The hybrid power pack will consist of Nuvera's H2eβ’ power module, FIAMM batteries, a fuel system, battery management system, and balanceof-plant components. Claimed advantages over conventional battery systems include lower operating costs, lower capital costs over 10 years and reduced maintenance. Productivity will be improved due to high-performance, steady-state operating conditions and the extended range from the fuel cells and their 'always on' capabilities, which eliminates the need to swap batteries for recharging and reduces operator downtime.
Nuvera and FIAMM will engage in a twoyear, three-phase product development effort to yield commercially available products as early as 2005. The initiative will include product design for manufacturablity, prototype demonstrations and validation of business models. After commercialization, FIAMM will receive exclusive rights to market and sell the hybrid power packs in Europe. Other potential off-road applications for the hybrid system include industrial hauling equipment, baggage tractors, tow tractors and belt loaders.
Nuvera has also recently unveiled a number of developments to improve the efficiency, power density and manufacturability of its gasoline fuel processors and automotive PEM fuel cell stacks. In conjunction with the US Department of Energy and a leading European automaker, it has demonstrated a 75 kWe/liter gasoline fuel processor that is claimed to exceed all of the US FreedomCAR goals set for 2004, except the 30 s startup requirement. The new Starβ’ fuel processor is capable of processing up to 200 kWth of California grade gasoline at greater than 80% efficiency. Nuvera claims the combination of small size, improved performance and manufacturability makes this system particularly suited for integration into a light-duty FCV. In addition, a laboratory prototype, developed with further DOE funding, has demonstrated startup in less than 60 s. This system utilizes no electrical heaters during startup, which is critical to keeping drive-cycle efficiencies high.