Demonstration of Zero-Emission Technologies for Freight Operations at Ports: Fuel Cell Hybrid Electric Top Loader

Vehicles/Equipment Funded:

• One (1) fuel-cell hybrid electric top loader developed and built by Hyster-Yale Group.
• Two (2) 45-kW fuel cell engines developed and built by Nuvera Fuel Cells, LLC.
• One (1) 250-kW wireless charging system developed and built by WAVE.
• One (1) hydrogen mobile refueler by BayoTech.

Lessons Learned:

• Designing wireless charging systems for heavy-duty vehicles must account for tire wear, which can affect charging alignment.
• Zero-emission components are often pre-commercial and require extensive validation and fine-tuning to meet application needs.
• Permitting hydrogen fueling systems at ports remains a major challenge and requires active collaboration from all project partners.
• The electric top loader (ETL) experienced extended downtime between commissioning and deployment, highlighting the need to align infrastructure readiness with vehicle delivery.

Status Updates:

• Site design and construction was completed, including installation of the wireless charging system and H2 mobile refueler, and the vehicle demonstration began in August 2022.
• Following a successful battery pack replacement and resolution of fuel-cell and communication issues, the ETL began the second demonstration period in February 2024, but experienced intermittent downtime due to maintenance, battery charge, and fueling coordination issues; both were resolved in early April 2024, and the ETL was in service for the rest of the month.
• The ETL was featured in the 2024 State of the Port: hydrogen hub video in February 2024.