Linde Material Handling launches an unprecedented project in Europe: the hydrogen lighthouse

Cutting edge technology

Linde Material Handling (MH) is now producing green hydrogen to power 21 fuel cell forklifts in its internal fleet.

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This is an unprecedented pilot project in this sector in Germany, and even throughout Europe: using its own infrastructure, Linde Material Handling (MH) now produces green hydrogen to power 21 fuel cell forklifts in its internal fleet. On Thursday, May 11, 2023, the new hydrogen production facility and vehicles were officially put into operation at the plant. Aschaffenburg. The investment is financed by the German Federal Ministry for Digital Affairs and Transport (BMDV), coordinated by NOW GmbH and executed by Project Management Jülich (PtJ). The aim is to gain experience and accumulate knowledge to be able to offer customers comprehensive advice and support on the use of hydrogen in material flow processes.  

"The issue of energy is emerging as one of the main challenges of this decade and beyond," he stated. Stefan Prokosch, Linde Material Handling's Senior Vice President of Brand Management spoke at the inauguration ceremony. "In our search for potential solutions, we identified hydrogen as an option in the energy mix of the future." He noted that this was especially relevant for intralogistics, as, in addition to the potential for climate neutrality, the rapid refueling of industrial forklifts with hydrogen during intensive multi-shift operations offered a significant advantage. "A refueling time of three minutes corresponds to a comparable charging power of around 480 kW," he explained. Furthermore, the energy carrier could act as an energy storage medium with the increasing use of renewable sources in the future, for example, to temporarily store electricity generated by solar or wind power. "We want to have the full range of energy supply options in our portfolio so that we can offer our customers the best possible solution for their specific needs. With this strategy, we can also remain flexible and open to different developments. After all, no one knows exactly where this journey will lead," the brand's top executive explained. 

Demonstrate courage, break new ground 

Some 2,8 million euros have been invested in the planning and construction of the hydrogen infrastructure. The hydrogen production facility was built within eleven months on a 280 square meter area conveniently located within the manufacturing and assembly plant. Around 50 subcontractors were involved in the construction of the hydrogen infrastructure under the direction of the general contractor Covalion, a mark of Framatome, and the construction department of Linde Material Handling. 

“With the commissioning of the plant and the forklifts, we ourselves become producers and users of hydrogen, and in this way, we can continue to expand our technological expertise. Over time, this will also benefit our customers, as the experience we gain in planning, constructing, and operating the plant and in using the fuel cell forklifts will be passed on to them as part of future material flow projects,” stated Prokosch. At the same time, the decentralized, on-site hydrogen infrastructure will serve as a showcase for other interested parties. “We will demonstrate how the use of renewable energy sources can work in practice,” added the brand manager. 

Kurt-Christoph von Knobelsdorff, CEO and spokesperson of NOW GmbH"Flagship projects like this one, undertaken by Linde Material Handling, are of great importance to continue promoting hydrogen and fuel cell technology. They demonstrate what is already possible in the field of intralogistics And they make it clear that the transformation towards climate neutrality has also gained momentum in the non-road sector. Companies leading the way in this area and sharing their experience in networks like the Clean Intralogistics Net are already reaping the benefits today, ensuring their success well beyond tomorrow. 

Michael Kraus, project manager at Framatome (Covalion): “The project has been a challenge, as well as an opportunity to demonstrate our capabilities and experience. Project planning and facility construction took approximately three years in total, and we were able to support Linde Material Handling from our initial meeting through the approval process and the first refueling of the industrial forklifts. We worked closely with the project management team to meet the project-specific requirements and find the best possible solution.”

Cutting-edge technology in discreet containers

The hydrogen infrastructure components consist of several modules. The centerpiece is a PEM (polymer electrolyte membrane) electrolyser, prepared to produce 50 kg of hydrogen per day. In it, purified and deionized drinking water is separated into oxygen and hydrogen with the help of green electricity. In another vessel, the hydrogen is gradually compressed to 450 bar and introduced into high-pressure storage tanks via pipes and valves. A software-controlled valve system regulates the supply line to the dispenser, the gas pump. Here, employees can connect their vehicles in a few simple steps. The refueling process is completed in a short time. The high-pressure storage tank is designed to store up to 120 kg of hydrogen at 450 bar, so that even demand peaks caused by increased refueling processes at shift changes can be covered.

A total of 21 electric counterbalance forklifts with hybrid fuel cell systems, comprising 12 Linde E50s with a five-ton payload capacity and nine Linde E35s with a 3,5-ton payload capacity, have replaced the previously used internal combustion (IC) models. As part of the plant's fleet, they are used to load and unload trucks and supply the assembly lines with large, heavy components such as counterweights, pre-assembled frames, and driver's cabs, among other things. "The vehicles produce no emissions during operation," emphasizes Prokosch. Hydrogen and oxygen from the air react in the fuel cell system of the industrial forklifts. The generated electrical energy charges a lithium-ion battery that powers the forklift; water and heat are the only byproducts. 

The generation and use of hydrogen takes place directly where intralogistics operations take place. In addition to Linde forklifts, other technical solutions offered by the company are also used. For example, the explosion-proof access control system of the Linde:connect fleet management solution ensures that only authorized and trained personnel can use the hydrogen facilities. Furthermore, the explosion-proof "Safety Guard" assistance solution for both the pump and the vehicles automatically reduces driving speed in the vicinity of the refueling station. Last but not least, the "Linde Energy Manager" solution enables intelligent planning and control of energy demand across the entire site, thus avoiding peak electrical loads and optimizing costs.

Hydrogen technology made by Linde MH

Linde MH is considered a pioneer in the use of hydrogen in intralogistics, having developed the first fully operational fuel cell-powered forklift prototype back in 2000. Since 2010, fuel cell forklifts have been integrated into the company's series production, and today, 80% of the product line, including counterbalance forklifts, tow tractors, and pallet stackers, can be ordered with this energy option as a customized hydrogen-powered solution. Through numerous studies and projects, Linde MH and its industry and scientific partners have demonstrated the conditions under which fuel cell forklifts are commercially viable and cost-effective today. This is especially true if an on-site hydrogen infrastructure is already in place or if high-purity hydrogen is produced as a byproduct of the operational process. Fuel cell forklifts are also suitable for multi-shift operation involving heavy use and a high number of annual operating hours indoors, or where there is limited space for battery charging or swapping facilities, which are ultimately intended to be eliminated.

Along with the construction of Linde MH's hydrogen infrastructure in Aschaffenburg, the parent company KION GROUP AG Linde MH continues to move forward with the development and production of its own fuel cell systems. At the LogiMAT trade fair, Linde MH presented its first in-house 24-volt system for warehouse equipment, developed at its Aschaffenburg facility. Funding has already been approved for the development of a 48-volt fuel cell system, and the team is working towards its rapid implementation. “By developing fuel cell and lithium-ion battery systems in-house, we will also have the opportunity in the future to design our own fully integrated hybrid fuel cell systems precisely tailored to the requirements of material handling equipment,” explains Prokosch.