Engine manufacturers are launching new solutions to reduce emissions from port cargo handling plants, with hydrogen being a prime candidate
SECTOR ANALYSIS: RACE FOR REDUCED EMISSIONS IS ON
Hydrogen is emerging as a front runner as engine manufacturers and terminal operators strive for engines that reduce emissions from port cargo handling plant. As the below company profiles illustrate, there are a range of pilot schemes, developments and initiatives to power port cargo handling equipment with hydrogen. Key to these is industry collaboration, spanning engine makers, hydrogen technology producers, ports and equipment manufacturers. The benefits of hydrogen are highlighted by a whitepaper from Hyster, Raising the Bar, which says: “Compared to lithium-ion battery power, hydrogen fuel cells possess key differences, along with an important similarity. Fuel cells do not need to be recharged. Instead, operators refuel a tank of hydrogen, more similar to the process and time spent refuelling an Internal Combustion Engine (ICE) than lengthy battery charging. But while diesel-powered vehicles produce GHG emissions during operation, equipment powered by hydrogen fuel cells only emits water and heat.” There is likely to be an increasing amount of port equipment engines fuelled by hydrogen, as the supply chain strengthens. “Major companies are joining forces to build a regional hydrogen network to produce and distribute hydrogen fuel at scale,” says the report. But hydrogen is not the only cleaner fuel on the cards – there has also been a focus on using bio diesel options for port equipment engines. Rolls-Royce highlights the advantages of deploying HVO – a reduction of CO2 emissions by up to 90 per cent compared to fossil diesel.
COLLABORATION, INNOVATION, R&D AND RETROFITS
Cummins: US-headquartered Cummins has struck a letter of intent with Taylor Machine Works Inc to integrate its hydrogen engines into the company’s product line. Taylor Machine Works plans to integrate the Cummins 6.7-litre and 15-litre hydrogen engines as part of its “Beyond Clean Lifting” commitment to a sustainable future. This effort includes battery electric trucks, hydrogen fuel cell trucks, and now hydrogen internal combustion engines (H2ICE) for the heavy lift, including port operations, market. Taylor Machine Works says that hydrogen combustion engines will “create a zero-carbon fuelled solution that provides cost effective equipment for high load factor, high utilisation applications”. Adding H2ICE to the mix of zero carbon solutions will also reduce the load required from “already stressed” utility grids. Commonalities with traditional internal combustion equipment will provide solutions that are dependable and easy to service and maintain. Antonio Leitao, Vice President Off- Highway Engine Business, Cummins, says of the plans: “We see hydrogen internal combustion engines as a solution to help drive sustainability improvements in our industry. Hydrogen power will help both OEMs and end-users looking to making carbon emissions reductions on their paths to zero.” Cummins engines power a large portion of more than 100 different models of lift trucks manufactured by Taylor Machine Works.
Nuvera: US-headquartered fuel cell engine manufacturer Nuvera is working with Hyster-Yale Group to develop alternatives to diesel port equipment. Two Nuvera E-45 fuel cell engines are powering the first real-world pilot of a hydrogen fuel cell-powered container handler at the Port of Los Angeles. The Hyster-Yale Group fuel cell-powered Hyster top-pick container handler is part of a project funded by the California Air Resources Board (CARB) and managed by the Center for Transportation and the Environment (CTE). The machine is being operated by Fenix Marine Services, a terminal operator owned by CMA CGM Group. Elsewhere, Nuvera’s E-60 fuel cell engine will power an empty container handler that Hyster is developing for Hamburger Hafen und Logistik AG (HHLA) in Hamburg, to run on hydrogen fuel produced locally at the HHLA Hamburg Green Hydrogen Hub. Nuvera’s E-45 fuel cell engine will also power a zero-emissions terminal tractor that is being developed by Hyster along with yard truck brand Capacity, for HHLA. Nuvera’s E-series fuel cell engine has been used within Port of Valencia’s ground-breaking Hyster Hydrogen Fuel Cell ReachStacker.
Perkins: Perkins has launched a collaboration to develop and produce an advanced multi-fuel ‘drop-in’ hybrid integrated power unit. The power unit will be able to directly replace its diesel equivalent in terms of power density and response, enabling a wide range of off-highway industrial OEMs to accelerate their transition to lower-carbon intensity or zero carbon fuels such as hydrogen, methanol, bio-ethanol and other eFuels and harness electrification. The design will support several fuel types with the initial demonstration deploying hydrogen. Project Coeus - Perkins’ collaboration with electric engineering specialist Equipmake and Loughborough University’s Mechanical, Electrical and Manufacturing Engineering School – will develop a 7-litre Perkins® 1200 Series industrial power unit with hybrid-electric components and advanced controls to enable operation on hydrogen fuel. The 45-250 kW hybrid powertrain system will be configured with factory-installed ECM sensors, radiators, cooling packs, filtration, control systems and after treatment hardware in a complete, integrated package that minimises OEM development timelines and reduces engineering and assembly costs. Supported by UK Government funding of £11.14 million, the three and a half-year project will be led by Perkins’ global engineering headquarters in Peterborough, UK, with Equipmake providing epowertrain technology and Loughborough University supporting through advanced engine analytics and emissions control.
Rolls-Royce: Germany headquartered Rolls-Royce Power Systems has taken a step towards a more climate friendly future with the approval of its mtu Series 1000, 1100, 1300 and 1500 engines for sustainable fuels. Used within industrial applications including port cargo handling equipment, the engines have been released for use with EN15940 paraffinic diesel fuels following bench testing. Sustainable synthetic fuels include BtL (Biomass to Liquid), HVO (Hydrotreated Vegetable Oil) and PtL (Power to Liquid) such as e-diesel. Rolls-Royce explains that to convert from conventional diesel fuel made from fossil petroleum to synthetic fuels of the EN15940 standard, no adaptation of existing engines is necessary. “The use of sustainable fuels enables our industrial customers to significantly reduce greenhouse gas emissions – without compromising performance compared to conventional diesel,” said Dr Lei Berners-Wu, Vice President Global Industrial, Power Systems, Rolls-Royce. Port operator Duisburg has developed a partnership with Roll-Royce as part of the goal for Duisburg Gateway Terminal to be carbon-neutral. Most of the electrical energy required to power the port’s operations will be generated on demand on site using hydrogen. The power installation will comprise two cogeneration plants based on mtu Series 4000 hydrogen engines (2 MW total installed capacity) and three mtu fuel cell systems (1.5 MW total installed capacity). The applications to be powered by electricity generated with hydrogen include the unloading, storage and handling of containers.
Scania: The Swedish manufacturer has developed an inline engine platform set that it says offers major CO2 emissions improvement. “This is our most fuel-efficient engine ever, with more torque, more power and up to 50 per cent longer base engine lifespan. A game-changer for power solutions,” says Joel Granath, Senior Vice President and Head of Power Solutions, Scania. Scania explains that the enhanced gas exchange system, reduced internal friction, and increased turbocharger efficiency all have a positive impact on the fuel-efficiency of the engines, that have been developed for industrial applications. For the 13-litre engine, this means up to seven per cent improvement in fuel consumption compared to the current generation at the same power output, translating to four litres of diesel saved per engine hour at full load. The engines are compatible with biodiesel blends and HVO. The 13-litre engine has a power range from 368 kW to 450 kW and delivers up to 11 per cent more power and 21 per cent more torque than the current generation. The 11-litre engine has a power range from 202 kW to 368 kW.
Volvo Penta: A hydrogen dual fuel generator set for port operations that deploys a Volvo Penta Stage V D8 industrial engine was launched in September last year. The Sweden headquartered engine manufacturer has partnered with NENS Power, CMB.TECH and e-power® International to develop the 250kVA generator. Applying CMB.TECH’s hydrogen dual fuel technology, it can operate in either full diesel mode or in dual fuel mode, where hydrogen can replace up to 80 per cent of the diesel consumption, thereby reducing CO₂ emissions. NENS Power is trialling the generator in various locations to accumulate the necessary experience and validation for this new product. The aim is to bring the hydrogen dual fuel generator set to market. “This pilot is an exciting development in our stepwise approach to adopting renewable fuels such as hydrogen in our combustion engine production portfolio. We will be able to gain collaborative insights into operations, accessibility, and various other elements that will improve future endeavours in the domain of power generation on top of off-road applications,” says Anders Wernersson, Product Manager, Volvo Penta Industrial. This collaboration follows a partnership agreement between Volva Penta and CMB.TECH to accelerate the development of dual-fuel hydrogen-powered solutions for both on land and at sea applications. Announced in October 2022, the collaboration covers pilot projects and small-scale industrialisation of a hydrogen dual-fuel solution for selected customers.
