Techno-economic analysis of a hydrogen fuel cell hybrid system and corresponding optimum matching design for hydrogen fuel cell forklifts

Conventional forklifts face serious issues, with internal combustion engine models causing indoor pollution, and lead-acid battery variants having slow charging and reduced power output as the charge diminishes. To address these drawbacks, this paper introduces a 2.5-tonne fuel cell forklift designed for Hong Kong's bustling logistics, warehousing, and transportation needs. It presents the development of dynamic simulation and cycle condition models, incorporating life cycle cost and average efficiency functions. Simulations reveal that selecting a 50-cell stack (rated at 11.8 kW) is the most cost-effective option, reducing hydrogen consumption by 2.3% using Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) optimisation. Cycle conditions do not alter the stack's optimal working voltage. However, the stack's voltage is influenced by stack and hydrogen prices, requiring an optimal design based on Hong Kong's actual costs. This study provides a theoretical foundation for future fuel cell forklift design through techno-economic analysis.