Fuel cell and Li-ion capacitor power system for construction industry
This project is funded by Norway Grants „Green ICT“ programme
The purpose of the project is to develop and assemble in co-operation with Beyonder AS and Nordic Batteries AS a 10,000 W proton exchange membrane (PEM) fuel cell based portable generator, UP10K Pro, which will provide clean energy to a number of industries that require uninterrupted power supply, but is mainly targeted to the construction and mining industry.
The generator uses compressed hydrogen gas as fuel and is a zero-emission solution, therefore it is perfect to replace polluting and heavy diesel generators. The UP10K Pro will include a lithium-ion capacitor (LiC) pack, whereby the solution will be able to provide a high power for a short period of time for an application that requires high amounts of energy over a limited period of time, such as to perform heavy lifts or to start up heavy machinery. Therefore, this solution will be suitable for many applications in the construction and mining industry, such as forklifts, cranes, and lighting. The peak power of the solution is 100 kW.
Beyonder AS (BYO) is responsible for the development and production of LiC cells. Nordic Batteries AS (Nordic Batteries AS) is responsible for the packing of BYO's cells into a battery pack. PowerUP Fuel Cells OÜ (PUFC) is leading the project and is responsible for the development and production of the whole generator system.
Project update 2022
During the last quarter of 2022 Beyonder has finalized this project’s first version of high-power energy storage cells, which will soon be ready for shipment to Nordic Batteries to be included in the first proof of concept battery module in combination with a fuel cell system prototype from PowerUP.
Partners will continue to optimize this first version to improve its properties further for the final product, for example in terms of process optimization to ensure reproducibility of the cell quality and thereby cycle life. Furthermore PowerUP turned the common attention towards the development of a first joint prototype called H.U.L.C.
After increasing the efforts by not only doubling up the number of project meetings, but also creating a technical task force with additional separate meetings, we already have successfully identified first specs that are applicable for the first proof of concept.
Key for the first prototype will be the development of a unique control structure to combine the different components.
At the end of 2022 all the partners and PowerUP are looking back towards a very challenging but successful year. We want to thank all supporters and our partners for working closely together towards this common goal of a green energy providing solution for the future of the construction and mining industry.
Project update Q1 / 2023
The technical taskforce has made significant progress regarding the system integration. The success of proving the system integrity on a first prototype will make the process of upscaling it to the final product specs much easier.
First integration steps have already been taken into account during the assembly of the first battery prototype that happened in February 2023. Nordic Batteries and Beyonder have successfully optimized their first build to be ready for a connection with the first fuel cell system prototype developed by PowerUP and the control architecture that has been developed in the recent period by all the partners in cooperation.
As Beyonder and Nordic Batteries have completed and tested their first prototype of a battery with Li-Ion capacitors and PowerUP has PEM fuel cells with reasonable power output for a first fuel cell system prototype, then all partners are soon ready to deliver the technology needed to be implemented. All partners are looking forward to achieving hands-on experience while assembling the H.U.L.C. first of its kind.
Project update Q2-Q3 / 2023
The project has made a great step towards the first prototype. Beyonder has improved powerful energy storage battery cells while Nordic Batteries is ensuring they work well together in a pack. They also have been tested to make sure they're safe and work in extreme conditions. Now that the manufacturing of these special batteries has been completed, we are waiting to see how well they perform in tests. This information will help our project partners to make even better batteries in the future. Nordic Batteries and Beyonder are also working on improving the design of a battery pack to work in a combination with fuel cells. All partners are working collectively to ensure the markets needs are met with the product under development. We are adjusting it based on the latest battery designs and fuel cell developments. PowerUP has made good progress in creating electrical components that make these batteries work efficiently together with fuel cells. This control system will help the batteries to provide power and convert it to different types as needed. The project is moving along as planned. While we are not ready to patent our work yet, we have plans in place to protect our ideas. In summary, this project is making strides in improving battery-fuel cell hybrid technology and its applications, all while keeping an eye on safety and market needs.
Project update Q4 2023/ Q1 2024
The Project has achieved yet another significant milestone during an in-person workshop attended by personnel from all project partners on October 17th and 18th, 2023. PowerUP's engineers traveled from Estonia to Kongsberg, Norway, bringing along their Fuel Cell technology to be combined with the battery technology from Beyonder and Nordic Batteries, in order to assemble the pioneering H.U.L.C. (Hydrogen technology Unified with Lithium Capacitor technology) prototype.
Following a successful assembly of the first unified prototype on the 17th, the team of six proceeded to conduct rigorous testing on October 18th. The smaller scale energy management system was tested to provide uninterrupted power from two different innovative power sources for a load up to 6kW. Any additional or peak loads were managed and supported by the Lithium Capacitor battery, integrated into a sophisticated bi-directional DC/AC structure.
Subsequent to the successful initial test with a table saw, the team proceeded to push the prototype to its maximum capabilities. Also the choice of a table saw for the initial test was deliberate, as the primary focus of the final product lies within the construction and mining industries. This assembly and the following efforts from the partners have transformed the first H.U.L.C. prototype into a compelling proof of concept, setting the stage for its expansion and further development within the project.
From November 2023 to January 2024, PowerUP and partners advanced in the product development and started the creation of a more sophisticated second H.U.L.C. prototype that will also feature a specially designed housing to underline the market placement and intended use cases. Tests, conducted on the first H.U.L.C. prototype were evaluated, yielding valuable insights and providing important feedback to the next prototype version. While our partners were focused on Li-ion capacitor optimization and battery pack design, PowerUP was responsible for power electronics and total system integration. The progress includes successful safety and performance tests on the battery cells, successfully tested PCB designs and industrial simulations. Dissemination efforts involved the planning of workshops, media creation, and stakeholder seminars. More news about the events will be shared soon.
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