Fuel cell mobile lighting: A fuel cell market transformation project

We report the results of a project aimed to introduce proton exchange membrane (PEM) hydrogen fuel cell technology into aviation ground support equipment (GSE) and rental construction equipment. The purpose of the project was to design, build, field-test and then commercialize fuel cell equipment that is superior to its diesel counterpart. The commercializing of this hydrogen-based technology will help to start the process of displacing diesel fuel use in aviation GSE and in mobile construction equipment. We describe a hydrogen fuel cell mobile lighting tower (H₂LT) that combines hydrogen stored as a high pressure gas, PEM fuel cell technology, and advanced lighting into a single unit with uses in aviation and construction. We assembled a project team of 15 institutional partners combining new technology expertise (hydrogen, fuel cells), equipment mass manufacturing capability (mobile light towers, lighting) and influential end-users to field test the H₂LT in real-world use in diverse environments. Seed funding provided by Boeing enabled additional funding from the U.S. Department of Energy (DOE) and a preponderance of in-kind contributions from the industrial partners. Prototype units were constructed and field tested in the entertainment industry, at the San Francisco International Airport, at the NASA Kennedy Space Center, with the California Department of Transportation (Caltrans), and with the Connecticut Department of Transportation. The goals of these approximately year-long field tests were to assess operation of the H₂LT technology in a wide variety of potentially corrosive environments (cold, wet, hot, humid, salty air) performing a wide variety of tasks, to reduce diesel emissions at these locations, and to help promote hydrogen PEM technology in new influential markets. The H₂LT proved to be exceptionally durable in these diverse environments, demonstrating the compatibility of PEM fuel cells and high-pressure hydrogen storage with the construction equipment application. Results from the field tests are discussed, including system performance (efficiency, duration, durability) and the efficacy of refueling the system by different methods (H₂ stations, mobile refueling). The H₂LT system is compared directly to a comparable diesel-fueled light tower with regard to size, performance and emissions savings. Overall, end users were pleased with the performance of the H₂LT, noting the lack of emissions and exceptionally low noise level. Recommendations for improvement were also collected and will be discussed. Two types of lighting used on the H₂LT (plasma, LED) were characterized by U.C. Davis in collaboration with Caltrans. LED lighting was found to be the most energy efficient and robust lighting technology for the highly mobile H₂LT application. The technical “lessons-learned” are reviewed, along with the plans for commercialization of the H₂LT technology by Multiquip Inc. Finally, the benefits to the industrial participants of the project organization are described.