Fuel cell yard trucks powered by Ballard complete 12-month trials

Ballard Power Systems has collaborated with global industry partners to design, assemble and deliver two zero-emission hydrogen fuel cell-powered terminal tractors - or yard trucks - for operation at the Port of Los Angeles (POLA), U.S.

Vehicle development was undertaken as part of Zero Emissions for California Ports (ZECAP) - a pioneering project to test and verify the performance of heavy-duty yard trucks. This included evaluating the trucks' safety, reliability, efficiency, and capacity to meet stringent operational requirements in demanding, real-world cargo-handling applications - while reducing emissions at POLA.

The project opted to use a Ballard 85kW proton-exchange membrane fuel cell engine, supplemented by lithium-ion battery technology. The onboard vehicle energy storage consisted of 9.1kg of hydrogen at 350bar pressure, in addition to 85kWh of battery capacity with plug-in charge capability for off-shift or service charging.

With the ambition to scrutinize and validate the commercial viability of zero-emission yard trucks for operational service, the project team oversaw 12 months of testing at POLA, with 14-hour daily shifts supported by an on-site hydrogen fueling station.

Fueling quickly at the start of every day, the trucks have enough hydrogen fuel for busy operations during a long shift which involves moving heavy containers from docks to port gates. The activity recorded during daily duty cycles provides crucial data and insightful information to validate the long-term viability of the vehicles.

 
With approximately 1,000 yard trucks operating at POLA on a 24-hour basis, emitting around 80,000 tons of CO₂ every year, the ZECAP project has been critical in developing viable and sustainable solutions to address the port's emissions issues and in generating increased awareness of how hydrogen can be used as a clean energy source, with fuel cell vehicles being the perfect technology solution in supporting POLA's net zero goals.

Ballard's ZECAP project partners included GTI Energy and Frontier Energy, with support from SoCalGas, who collected the data that demonstrated that fuel cell-powered yard trucks are safe, reliable, and operationally preferable to diesel equipment.

"The continued development and demonstration of advanced technologies (zero-emission and near zero-emission) is necessary in order to meet California’s long-term GHG emission reduction goals, protect public health, and reach attainment with increasingly more stringent federal air quality standards. Thanks to the work of ZECAP at POLA our understanding of next-generation fuel cell yard trucks - in terms of safety, reliability and overall operation - is significantly enhanced, which means that these zero-emission solutions are a step closer to full commercialization; in-turn stimulating the adoption of other decarbonized heavy-duty vehicles."

 

Bart Sowa R&D Manager, GTI Energy

The $12m project was funded by the California Air Resources Board (CARB), with the initiative hoping to contribute technical understanding and strategic planning towards the ultimate goal - to replace all 1,000 diesel-powered yard trucks that operate at POLA with zero-emission alternatives. Introducing a fully decarbonized fleet would decrease noise pollution for nearby residents and significantly improve air quality for staff at the busy port - reducing annual CO₂ emissions by approximately 80,000 tons.