Exide Technologies and Ballard to Develop Fuel-Cell and Lead-Acid Battery Hybrid System for Forklift Trucks

10 October 2007

The Mark1020 ACS ranges in size from 300 Watts to 5 kW.

Exide Technologies has signed an agreement with Ballard Power Systems to develop an on-board hybrid hydrogen fuel-cell and lead-acid battery energy system for the forklift truck market. Exide plans to meet all of its hydrogen fuel-cell needs for the forklift truck market exclusively with Ballard fuel cells over the next five years.

Ballard’s work in the materials handling market has, to this point, been based on using its Mark9 SSL fuel-cell stack as an alternative to lead-acid batteries. (Earlier post.) This new program will utilize Ballard’s Mark1020 ACS hydrogen fuel-cell stack in combination with Exide’s Element valve regulated lead-acid batteries.

Design of the Element advanced valve-regulated battery. Click to enlarge.

The program illustrates the flexibility of fuel cells and batteries, while opening a new channel to the materials handling market. The hybrid fuel-cell battery system also is anticipated to provide incremental revenue opportunities for both companies.

The new Mark1020 ACS features a simplified, lower-cost design that uses 33% fewer parts than Ballard’s previous generation air-cooled fuel cell. It incorporates new, lower-cost materials, and reduces precious metal content significantly.

The Mark1020 ACS operates without the need for external humidifiers, thereby reducing both part count and cost. By dropping operating pressure of the fuel cell stack, Ballard has removed the need for an air compressor, again reducing system cost and improving reliability. The stacks have a wide operating range of -40 to +46°C.

While Ballard's customers have used the Mark1020 ACS technology primarily for stationary telecommunications backup power, this product is also suitable for motive power applications.

Initial prototypes of the hybrid hydrogen fuel cell battery system will be delivered to the US Department of Defense.

Proton Power Systems plc recently introduced a triple-hybrid forklift system that combines a fuel cell, battery and supercapacitors. (Earlier post.)