SUSTAINABLE HEAVY-DUTY INITIATIVES FOR FUTURE TECHNOLOGY

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Project

Zero Emissions for California Ports (ZECAP)

This project aimed to validate the commercial viability of zero-emission hybrid fuel cell-electric yard trucks in real-world cargo-handling operations at the Port of Los Angeles. GTI Energy and its technology partners deployed two hybrid fuel cell-electric yard trucks, operated by TraPac, for 12 months. The project was designed to reduce technical and scheduling risks while maximizing vehicle uptime and data collection. Yard trucks are the largest source of emissions among cargo-handling equipment but are challenging to electrify due to their demanding duty cycles and operating conditions. The project demonstrated that fuel cell-powered yard trucks are a safe, reliable, and practical zero-emission solution, supporting the ports’ Clean Air Action Plan goals.

Vehicles/Equipment Funded:

Two Capacity Trailer Jockey Series TJ9000 gliders configured with:
  • BAE Systems HDS200 powertrain. This system is capable of a peak propulsion power of 200 kW (270 hp) and peak torque of 5,200 Nm (3,800 ft-lbs). During deceleration, the system employs regenerative braking and captures energy in the battery pack for later use.
  • Ballard Power Systems FCveloCity®-HD85 proton exchange membrane fuel cell providing up to 85kW power.
  • 9.1 kg of onboard hydrogen storage at 350 bar and 85 kWh NMC batteries at 600 VDC.
  • HTEC’s stationarily-placed mobile tube-trailer hydrogen fueling system stored up to 182kg of hydrogen at 450 bar and provided up to 2 kg/min fill without pre-cooling of the hydrogen. The station was refilled via tanker delivery.

Lessons Learned:

  • Yard trucks have extremely constrained packaging space.
  • Hydrogen infrastructure permitting is very complex.
  • Operational efficiency and reliability of fueling is critical.
  • The operators liked the comfort and performance of the trucks.

Status Updates:

  • The equipment was decommissioned after project completion
  • Capacity developed next-generation vehicles based on lessons learned.
  • TraPac continues evaluations of other H2-powered port equipmen

Technology:

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Vehicles / Equipment Status:​

Infrastructure Status:

View Final Report

Project Facts​

  • DATES: Spring 2019 – Spring 2023
  • GRANTEE: GTI
  • PARTNERS: REV Group (Capacity), BAE Systems, Ballard Power Systems, ZEN Clean Energy Solutions, Hydrogen Technology Energy Corporation, Frontier Energy, TraPac
  • GRANT NO.: G17-ZNZE-08

Grant Amount​

  • CARB Contribution: $5,788,335
  • Matching Funds: $6,267,078
  • PROJECT TOTAL: $12,055,413

Partners

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