{"id":9096,"date":"2025-09-02T09:20:29","date_gmt":"2025-09-02T01:20:29","guid":{"rendered":"https:\/\/ascendas-asia.com\/?page_id=9096"},"modified":"2025-09-02T09:24:18","modified_gmt":"2025-09-02T01:24:18","slug":"hydrogen-fuel-cells-reduce-co2-emissions","status":"publish","type":"page","link":"https:\/\/ascendas-asia.com\/vi\/customer-stories\/hydrogen-fuel-cells-reduce-co2-emissions\/","title":{"rendered":"Hydrogen Fuel Cells Reduce CO2 Emissions"},"content":{"rendered":"

Hydrogen Fuel Cells Reduce CO2<\/sub> Emissions<\/h1>\n
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Shipping and seaport infrastructure are significant sources of greenhouse gas (GHG) emissions. According to the International Maritime Organization, maritime transport creates over 900 million tons of CO2<\/sub>\u00a0<\/span>annually. Global economies rely on shipping to get their products to the consumer, with up to 90% of all foreign goods flowing through ports on container ships, but the toll on the environment is substantial. And those living near busy seaports are exposed to dangerous levels of air pollution caused by emissions from diesel engines on the commercial vehicles at the port.<\/p>\n

For example, large industrial vehicles called\u00a0<\/span>container handlers<\/i>\u00a0<\/span>load and unload the containers from the container ships. Each container handler emits up to 144\u00a0tons of CO2<\/sub>\u00a0<\/span>per year, and a large port can have hundreds of these machines on site. Swapping the diesel engine in just one container handler for a green alternative would have the same effect as removing 32 gas-powered passenger cars from our roads.<\/p>\n

From passenger cars to long-haul trucks, locomotives, and heavy equipment, internal combustion engines (ICEs) are being replaced with greener alternatives. Battery-powered electric vehicles have captured much of the spotlight, with an increasing number of options available to consumers in both car models and charging locations. But at ports, the ICEs are diesel engines in heavy-duty industrial vehicles such as yard trucks, forklifts, and container handlers. Batteries and the required charging infrastructure don\u2019t work for many of these operations.<\/p>\n

That\u2019s where fuel cells can help.<\/td>\n

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Enabling Electrification<\/h3>\n<\/div>\n<\/div>\n
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Fuel cells are well-suited for locations with heavy equipment that must run for long shifts with minimal downtime for refueling. Refilling a hydrogen fuel cell takes about the same amount of time as it does to fill a similar-sized gas tank, whereas recharging a battery for heavy-duty e-vehicles would take hours. Fuel cells offer the power density and range needed for the vehicle to make it through an 8-hour shift. One company focusing on fuel cell technology for commercial vehicles is\u00a0<\/span>Nuvera<\/a>.<\/p>\n<\/div>\n<\/div>\n

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One of Nuvera\u2019s E-Series Fuel Cell Engines. Image credit: Nuvera Fuel Cells.<\/p>\n<\/figcaption><\/figure>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

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An Electric Alternative That Doesn\u2019t Require Recharging<\/h3>\n<\/div>\n<\/div>\n
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A fuel cell produces no exhaust other than heat and water. With no moving parts, its design is simple in principle: a membrane is sandwiched between two electrodes. When the hydrogen fuel meets the anode, it is split into a proton and an electron. The proton passes through the membrane to the cathode, where it meets oxygen. The electron takes a longer route between electrodes, traveling through an electrical circuit. The flow of electrons creates the power for the motor. At the cathode, the protons, electrons, and oxygen combine to form water.<\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n

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Using modeling and real-time simulation enables Nuvera\u2019s engineers to iterate on their design quickly and allows for experimentation without putting a real engine at risk.<\/em><\/p>\n<\/blockquote>\n<\/div>\n<\/div>\n

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The science is simple, but perfecting the recipe for a high-performance power source is hard. Many factors govern the multiple reactions inside a fuel cell, and a software control system must account for them all to squeeze the most power and efficiency out of the device. The control system makes constant corrections based on feedback.<\/p>\n

\u201cOne of the greatest design challenges is maintaining proper hydration to the cells,\u201d says Pierre-Fran\u00e7ois Quet, Nuvera\u2019s chief engineer. \u201cNot enough water and protons don\u2019t pass through; too much and the cells flood.\u201d<\/p>\n<\/div>\n<\/div>\n

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Their system manages hydration by changing the coolant temperature and by manipulating airflow to increase or decrease evaporation. To design the software that controls their fuel cell engine\u2014which typically includes hundreds of fuel cells stacked together with coolant flowing between them, plus a coolant pump and an air compressor\u2014Nuvera uses MATLAB<\/span>\u00ae<\/sup>\u202fand Simulink<\/span>\u00ae<\/sup>. A plant model of the fuel cell engine\u2014which comprises equations governing the electrical and chemical reactions and the temperatures and pressures of water and gases and coolant\u2014is also implemented in Simulink, Quet says. With this simulation in place, Nuvera writes algorithms to refine things like coolant flow in order to eke out the best performance. Once the algorithm is finalized, Simulink translates it into code that will run on a processor embedded in the actual fuel cell engine.<\/span><\/td>\n\"Top-loading<\/span><\/p>\n

Hyster\u00ae<\/sup>\u00a0top-loading container handler. Image credit:\u00a0Hyster-Yale Group.<\/p>\n<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

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The control algorithms also account for many operating conditions. In simulation, Nuvera tests the system in low and high ambient temperatures, and in low- and high-humidity environments.<\/p>\n

In order to experiment with their algorithms in a more realistic setting, Nuvera does hardware-in-the-loop testing: They load their engine model onto a custom computer made by Speedgoat that is tailored to have the same inputs and outputs as the physical engine, and can simulate its operation in real time. The same embedded computer that runs the fuel cell engine is connected to the Speedgoat box and is programmed from C code generated from Simulink.<\/p>\n

This setup adds rigor while enabling Nuvera\u2019s engineers to iterate on their design quickly. It also allows for experimentation without putting a real engine at risk.<\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n

A Different Kind of Hybrid<\/span><\/h3>\n

Virtually all fuel cell vehicles are electrically hybridized, powered by both fuel cells and batteries. In some cases, fuel cells provide a trickle charge to keep the battery charged, while in other configurations both the fuel cell and battery power the motors through an electrical bus. Batteries are also employed to accept a vehicle\u2019s regenerated power, such as when a forklift brakes or lowers a load.<\/p>\n

Quet\u2019s team first had to build a model of the lithium-ion battery in Simulink, based on data provided by the manufacturer and collected in-house. They also wrote algorithms that could estimate the battery\u2019s state of charge based on things they could measure\u2014its voltage and current. They then used Simulink to program the control algorithm. The system needs to maintain an ideal level of battery charge, so there\u2019s always enough energy for peak load and enough capacity to reabsorb energy. The Nuvera team also designed the optimal size for various system components by testing the algorithms in a range of simulated forklift and load scenarios.<\/p>\n

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Best of Both Worlds<\/h3>\n<\/div>\n<\/div>\n
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Fuel cells share strengths with both batteries and ICEs. Like batteries, they\u2019re scalable and quiet, and they don\u2019t produce harmful emissions. But fuel cell vehicles also offer the long range and quick refueling time found in gasoline and diesel-powered ICE vehicles. Hydrogen can be stored at pressure in a fuel tank that enables it to contain much more energy than a battery of the same dimensions, so instead of stopping to recharge or swap out a battery, you can operate the vehicle for as long or longer than a battery-powered equivalent and spend a few minutes filling the fuel tank.<\/p>\n<\/div>\n

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One use of Nuvera\u2019s fuel cell engines is in forklifts made by their parent company, Hyster-Yale Group. Nuvera has also integrated two of its E-45 fuel cell engines into a Hyster\u00ae<\/sup>\u00a0<\/span>container handler that will be used at the Port of Los Angeles, similar to the model shown in the photograph. By replacing the diesel engine with a fuel cell\u2013powered electric drivetrain in this vehicle alone, 128 metric tons of CO2<\/sub>\u00a0<\/span>can be avoided annually. Diesel engines in commercial and industrial vehicles are a source of carbon emissions and criteria pollutants that diminish air quality. Nuvera works with other manufacturers to use fuel cells to electrify buses, trains, and specialty vehicles to help reduce their emissions significantly.<\/p>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/div>\n<\/td>\n

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Hyster\u00ae\u00a0\u00a0<\/span><\/sup>fuel cell\u2013powered forklift. Image credit:\u00a0Hyster-Yale Group.<\/p>\n<\/figcaption><\/figure>\n<\/div>\n<\/div>\n

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Fuel cells are scalable and quiet, don\u2019t produce harmful emissions, and offer the long range and the short downtime found in gasoline and diesel-powered ICE vehicles.<\/p><\/blockquote>\n<\/div>\n<\/div>\n<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n

Get Quote<\/span><\/a>\u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0 \u00a0Download a FREE Trial<\/span><\/a><\/span><\/p>","protected":false},"excerpt":{"rendered":"

Hydrogen Fuel Cells Reduce CO2 Emissions Shipping and seaport infrastructure are significant sources of greenhouse gas (GHG) emissions. According to the International Maritime Organization, maritime transport creates over 900 million tons of CO2\u00a0annually. Global economies rely on shipping to get their products to the consumer, with up to 90% of all foreign goods flowing through […]<\/p>","protected":false},"author":43,"featured_media":0,"parent":3677,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"content-type":"","footnotes":"","_links_to":"","_links_to_target":""},"class_list":["post-9096","page","type-page","status-publish","hentry"],"yoast_head":"\nHydrogen Fuel Cells Reduce CO2 Emissions - TechSource Systems & Ascendas Systems Group<\/title>\n<meta name=\"description\" content=\"Hydrogen fuel cells significantly reduce CO\u2082 emissions in commercial vehicles. 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