By Kristen Poland

The hydrogen fuel industry could be on the horizon of South Carolina’s future economic prosperity, but before hydrogen-powered cars begin buzzing down the state’s highways, the alternative fuel must first be embraced in more feasible and cost-effective applications.

One such application being explored in South Carolina is fuel cell-powered forklifts, primarily those used in indoor facilities that operate around the clock. Forklifts in these types of operations typically run on batteries.

“We’re very excited about this as a potentially early market for alternative fuels,” said Russ Keller, senior director for alternative energy programs at the S.C. Research Authority. “The size of the material-handling industry is huge and maybe a third of all forklifts are battery only, as indoor facilities can’t use combustion.” 

Two fuel cell-powered forklifts are currently circulating through warehouses of six South Carolina companies. The project allows each of these companies to operate both forklifts at their warehouse facilities for two weeks.

The fuel cell power packs, made by Hydrogenics, are placed in lift trucks supplied by LiftOne, a division of Carolina Tractor. The forklift demonstration project was launched in July as part of the Greater Columbia Fuel Cell Challenge and is sponsored by SC Launch!, a collaboration of the S.C. Research Authority. SC Launch! paid $84,000 to underwrite all hydrogen fueling and infrastructure costs for the six companies participating in the demonstration project.

The four initial participating companies are ISOLA Laminates in Ridgeway, Leigh Fibers in Spartanburg, Michelin North America in Columbia and PBR Columbia in West Columbia. Amcor PET Packaging in Blythewood is the newest site to join the project. The sixth company has asked not to be named.

Keller said the response to the demonstration project thus far has been positive among participants because of the enhanced performance of the fuel-cell powered forklifts. These forklifts have a significantly longer running time than the conventional battery-powered lifts, which lose power after about eight hours.

The fuel cells can be refilled in just three to four minutes (in a process much like refueling a car’s gas tank), while the 3,500- to 4,000-pound batteries take six to eight hours to recharge. Not to mention the additional 15 to 20 minutes and a small crane necessary to exchange a low battery for a fully-charged one. Lastly, because fuel-cells don’t need to be replaced regularly, less storage space is required within the facility.

The major downside to fuel cells is, of course, cost. A single fuel cell power pack can cost anywhere from $35,000 to $50,000 right now as compared to a forklift battery, which costs less than $10,000. However, a company needs to own two or three batteries per forklift, whereas they just need one fuel cell power pack per forklift. 

Keller pointed out that while the upfront investment is greater with fuel cells than batteries, maintenance is cheaper during the lifetime of the fuel cell power pack and the increased productivity makes up for the initial extra cost.

“Fuel cells make more sense. As the market grows, the price will come down,” Keller said.