Hyster-Yale Group, Inc. acquired Nuvera Fuel Cells, Inc. in 2014. Founded in 2000, Nuvera specializes in fuel cell stacks and fully integrated systems called fuel cell engines, as well as hydrogen production and dispensing systems. This acquisition has enabled Hyster-Yale to integrate advanced fuel cell technology into their material handling equipment, especially at ports where battery-based solutions are less optimal due to continuous power requirements and duty cycles, which typically consider shifts and refueling time.
One of Nuvera’s early success products was warehouse forklifts with 24-hour operational capability, ideal for maintaining clean air inside warehouses. Fuel cell forklifts proved more advantageous over both battery and propane power solutions. Nuvera’s fuel cell engines were installed in Hyster-Yale forklifts, eventually leading to the acquisition with hopes of expanding the fuel cell-based lineup.
Nuvera’s fuel cells are designed to power a variety of applications, including buses, trucks, marine vessels, and off-road vehicles. The Nuvera E-Series Fuel Cell Engines, featuring open flow field architecture and metal bipolar plates, are known for their high performance and durability in extreme environments. Currently, Nuvera offers 45 kW and 60 kW fuel cell engines, with a 125 kW engine expected by the end of the year. These fuel cell engines can replace internal combustion engines in the same spaces.
In addition to Hyster-Yale, Nuvera collaborates with other vehicle producers to integrate these engines. This includes providing engineering support and working closely in development to ensure long-term functionality. Application engineering services are a crucial part of Nuvera’s business.
As Gus Block, Director of Corporate Development, has recently noted, “Ports are incredibly important in this context. Shipping ports are ground zero for the emerging hydrogen economy. Most equipment on the port side is primarily diesel-driven, including rubber-tire gantries and container handling equipment, not to mention the vehicles going in and out of the port. Vessels also need to be decarbonized within the same timeframe for zero emissions. Hydrogen will play a crucial role in this transition, and ports will be central to the hydrogen infrastructure, serving various needs.”
The Zero-Emission Technologies for Freight Operations at Ports project deployed the Hyster brand fuel cell electric top loader. This was developed under the California Air Resources Board’s Advanced Technology Demonstration Program, awarded in 2017.
The project partners included the Port of Los Angeles, the Center for Transportation and the Environment, and several others. The Hyster top loader carries about 30 kg of hydrogen onboard. It is powered by two 45 kW fuel cell engines and a 130 kWh battery driving a 220 kW peak electric traction motor. The hydrogen fueling system is a mobile refueler with a capacity of 120 kg of hydrogen, taking about 15 minutes to refuel the vehicle.
There were two demonstration periods totaling six months: the first was in 2022, and the second ended just recently in April 2024. The time between demonstrations was primarily due to switching fuel suppliers due to pricing and availability. This common challenge in early demonstrations underscores the critical importance of reliable and cost-effective hydrogen supply. Establishing a reliable hydrogen supply in ports, as planned by ARCHESH2, the California hydrogen hub, will enable moving hydrogen deployments forward. In total, the top loader accumulated 38 operational days and moved 986 containers, with efficiency ranging from 1.2 to 3.6 kg of hydrogen per hour.
Hyster is broadening its array of fuel cell-powered port vehicles, including a new version of the top loader, an empty container handler, a reach stacker, a terminal tractor, and a rubber-tired gantry crane. A rubber-tired gantry crane powered by a Toyota fuel cell was recently presented.
At the 2024 ACT Expo, Nuvera showcased a trailer-based mobile version of the HydroCharge fuel cell genset and EV charger, based on the 60 kW fuel cell engine. This equipment might provide charging options at ports, warehouses, parking lots, malls, construction zones, and mining sites. There are a number of competitors developing similar products. Nuvera’s entry is not alone but comes prepared with powerful features. The Level 3 DC fast charger offers 250 to 920V direct current output. Other outputs include 3-phase AC power with options for 208 or 415V alternating current power, along with 10 kW of 120 or 240V single-phase power.
Nuvera’s broad presence in the warehouse fuel cell forklift market has enabled the company to pursue diverse and larger applications of fuel cell technology in recent years. A combination of manufacturing its own fuel cell stacks, installing them into reliable engines, and later into vehicles, affords Nuvera and Hyster-Yale partnership a strong hold on the market value chain.
