DP World has completed initial testing of its hydrogen fuel cell rubber-tired gantry (RTG) crane at the Port of Vancouver. The RTG is now undergoing field testing as DP World assesses the feasibility of electrifying its global fleet of 1,500 RTG cranes.
Traditionally powered by diesel, RTG cranes are essential for cargo handling but are significant contributors to greenhouse gas emissions. At DP World’s Vancouver terminal, 19 RTG cranes account for 50% of diesel consumption and generate over 4,200 tonnes of CO2 annually.
The adoption of hydrogen technology promises to dramatically reduce or even eliminate this impact, according to DP World’s statement.
Doug Smith, CEO of DP World in Canada, said: “This pilot not only marks an important step in DP World’s commitment to decarbonizing its operations, but it also sets a new benchmark in sustainable logistics. Real-world testing ensures our solutions are reliable and effective and could open the door to electrifying our global fleet of RTGs.”
DP World launched its pilot project in October 2023. The first phase included retrofitting a diesel RTG with an integrated solution consisting of a Hydrogen-Electric Generator (HEG), battery energy storage system, hydrogen storage module, regenerative energy capture, and integrated control and safety systems.
The RTG has now entered its second phase, a one-year field trial to track performance parameters such as hydrogen consumption, energy generation, and regenerative energy capture rates.
This data will allow the team to compare the zero-emission hydrogen electric RTG to a traditional diesel-powered RTG in terms of productivity, reliability, maintainability, costs and environmental benefit.
DP World partnered with TYCROP Manufacturing Ltd., H2 Portable and HTEC for this pioneering project. H2 Portable, together with TYCROP, designed a Hydrogen-Electric Generator (HEG) utilizing a dual fuel cell and battery energy storage system, while HTEC provided the hydrogen storage system and hydrogen supply.
To operate, the RTG crane stores up to 135 kg of compressed gaseous hydrogen in 15 pressurized tanks. Hydrogen is fed to the fuel cell system, which charges a high-voltage battery that powers the crane’s electric drive. The bidirectional power system recovers energy when lowering containers, significantly reducing energy demand and enhancing operational efficiency.
Scott Mason, President and CEO of TYCROP, said: “During factory acceptance testing, the system ran continuously for 16 hours, lifting and lowering a 40-ton load 105 times — and emitted only steam, rather than 400 kilograms of CO2 from a comparable diesel unit.”
If the field trial is successful, DP World will consider converting its 25 diesel-powered RTG cranes in Vancouver and Prince Rupert in a bid to meet its zero-emissions objectives. There are additional plans underway to trial an electric terminal tractor at the Port of Vancouver, and the company is in the process of acquiring a fleet of electric vehicles.
