Performance of electric forklift with low-temperature polymer exchange membrane fuel cell power module and metal hydride hydrogen storage extension tank

•Electric forklift equipped with commercial fuel cell module and MH H storage tank.•Heavy duty tests according to VDI2198 protocol and light duty tests were performed.•Forklift refuelling time not longer than 15 min.•Forklift energy consumption with fuel cell module and MH extension tank is 9.56 kWh/h.•Energy consumption during typical light duty operation at customer side is 3.87 kWh/h.

We present test results of a commercial 3-tonne electric forklift (STILL) equipped with a commercial fuel cell power module (Plug Power) and a MH hydrogen storage tank (HySA Systems and TF Design). The tests included: (i) performance evaluation of “hybrid” hydrogen storage system during refuelling at low (<185 bar) dispensing pressures; (ii) comparison of the forklift performances during heavy-duty operation when changing the powering in the series: standard battery – fuel cell power module (alone) – power module with integrated MH tank; and (iii) performance tests of the forklift during its operation under working conditions. It was found that (a) the forklift with power module and MH tank can achieve 83% of maximum hydrogen storage capacity during 6 min refuelling (for full capacity 12–15 min); (b) heavy-duty operation of the forklift is characterised by 25% increase in energy consumption, and during system operation more uniform power distribution occurs when operating in the fuel cell powering mode with MH, in comparison to the battery powering mode; (c) use of the fully refuelled fuel cell power module with the MH extension tank allows for uninterrupted operation for 3 h 6 min and 7 h 15 min, for heavy- and light-duty operation, respectively.