Analysis Series, Chapter 3: Compressed Natural Gas (CNG)

by | Aug 18, 2022 | Forklift Fleet Management | 0 comments

Chapter 3: Compressed Natural Gas (CNG)

The process of producing CNG is quite simple. It is composed of methane which is a natural gas which is then filtered and compressed. The comparisons of utilizing CNG as a power source for lift trucks are much stronger when compared to other fossil fuels such as LPG, Diesel or Gas, as opposed to AC electric. Here are a few key areas where CNG may outperform fossil fuel competitors:

Advantages of CNG Lift Trucks over AC and other IC Lift Trucks

  • No significant infrastructure investment. Often the supplier will bear the cost.
  • No capacity limitations (as opposed to AC electric lift trucks).
  • Produces significantly less emissions and pollutants compared to petrol (40% less Co2) which Help mitigate greenhouse gases.
  • Safer than other fuels in the event of a spill/leak (lighter than air, and disperses quickly when released).
  • Considered to be safer than gasoline-powered vehicles.
  • Due to the absence of any lead or benzene content in CNG, the lead fouling of spark plugs is eliminated.
  • Lower maintenance costs – compared to other fuel powered vehicles (less caustic and cleaner, therefore engine will generally longer).
  • Increased life of lubricating oils, as CNG does not contaminate or dilute the crankcase oil.
  • Less likely to auto-ignite on hot surfaces, since it has a high auto-ignition temperature (540c).
  • Quick refueling, taking less than 5 minutes (opposed to electric).

Disadvantages of CNG Lift Trucks over AC and other IC Lift Trucks

  • High fuel burn rate; requires more fuel to be burn to produce the same about of energy.
  • Possible limitations to competitive supplier base for competitive pricing (CNG).
  • Requires a greater amount of space for fuel storage than conventional gasoline powered vehicles, as it is stored as a gas at high pressure. 
  • Less power than petrol/diesel/LPG.
  • High pressure poses greater risk.
  • Not as widely available, cost outlay usually higher due to converting LPG to CNG.
  • Hazardous pollutants/emissions.
  • Significantly lower residual value (approximately $3500 less on 6000# capacity models)

Notes/Assumptions

  • Data assumes 3,500 annual lift truck operating hours.
  • PM interval for CNG/LPG lift truck is 300 hours. PM tech-time for IC lift trucks is 1.5 hrs. PM tech-time for AC lift trucks is 1 hr.
  • PM interval for AC lift truck is 500 hours.
  • Rate of $80/hour used. Add $25 to PM on IC lift trucks for parts.
  • Please use $100/hour of additional downtime cost as industry average – not factored in any numbers.

Continue to Chapter 4…

Read The Full Series:

Chapter 1: The Concept of Total Cost of Ownership (TCO)

Chapter 2: AC Technology Compared to Internal Combustion

Chapter 3: Compressed Natural Gas (CNG)

Chapter 4: Trends in Materials Handling

Chapter 5: Voltage Levels Used in Electric Lift trucks Today

Chapter 6: Battery and Charging Systems

Chapter 7: Electric Braking and Energy Regeneration

Chapter 8: Emissions and Corporate Responsibility: A Major Problem for IC Lift Trucks

Conclusions & Final Recap

HCO Innovations is publishing this eight-part series as an in-depth comparative analysis and discussion on Compressed Natural Gas (CNG) Internal Combustion (IC) motors and Alternating Current (AC) Eletric lift truck engines, Comparison Analysis of CNG (IC) vs. AC Electric Lift Trucks, by Will Van Ness, VP of Fleet Management at HCO Innovations. 

Comparison Analysis of CNG (IC) vs. AC Electric Lift Trucks (AC)

The materials handling industry continues to evolve at a rapid pace, particularly in the area of motive power propulsion. Tremendous technological advancements have been made over the past decade to directly address the rising cost of petrol (fossil fuels) along with stricter emission standards. Today’s MHE acquirers have more choices than ever when it comes to motive power propulsion and with the success seen amongst fleets utilizing alternative fuel sources such as lithium ion (LION) and Hydrogen Fuel Cell (HFC), the choices will most likely increase as time goes on. For the purpose of this discussion document, our focus will be on comparing AC Electric (AC) to Internal Combustion powered lift trucks (IC), specifically compressed natural gas (CNG).

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What is compressed natural gas (CNG)?

Compressed natural gas (CNG) is a cleaner and more environmentally friendly alternative to gasoline and diesel fuel. It is composed of mostly methane gas stored at high pressure, which enables it to be used as a fuel for vehicles and other applications.

How is CNG produced?

CNG is primarily produced by compressing natural gas, which is extracted from underground reservoirs or harvested from biogas sources. The natural gas is then compressed to a pressure of up to 3,600 pounds per square inch (psi) for efficient storage and transportation.

What are the advantages of using CNG?

Using CNG as a fuel offers several advantages. It is a cleaner-burning fuel compared to gasoline and diesel, resulting in reduced emissions of harmful pollutants. CNG also has a higher octane rating, leading to improved engine performance and longevity. Additionally, it is typically less expensive than traditional fuels and can help reduce dependence on imported oil.

Are CNG vehicles widely available?

While the availability of CNG vehicles varies by region, they are becoming increasingly more common. Many automakers offer CNG options for their vehicles, including sedans, trucks, and buses. Additionally, there are conversion kits available that can convert gasoline-powered vehicles to run on CNG.

How does the infrastructure for CNG refueling compare to traditional gasoline stations?

The infrastructure for CNG refueling is less extensive compared to traditional gasoline stations. However, there is a growing network of CNG refueling stations worldwide. These stations often cater to fleets and larger vehicles, but public access stations for passenger vehicles are also being established.

Is it safe to use CNG?

CNG is considered safe when handled properly. CNG vehicles undergo rigorous testing and meet strict safety standards. The fuel tanks used to store CNG are designed to withstand high pressures and are constructed with safety features. Additionally, CNG has a narrow range of flammability and disperses rapidly in the event of a leak.

What are the challenges of using CNG?

One of the main challenges of using CNG is the limited refueling infrastructure, particularly in certain regions. The range of CNG vehicles is often lower compared to gasoline-powered vehicles, which means more frequent refueling may be necessary. Additionally, the upfront cost of purchasing a CNG vehicle or converting an existing vehicle can be higher.

Is CNG a sustainable alternative to traditional fuels?

CNG is considered a more sustainable alternative to traditional fuels. It is a cleaner-burning fuel, emitting lower levels of greenhouse gases and pollutants. Additionally, as natural gas reserves are abundant, using CNG can reduce dependence on finite fossil fuel resources.

Hydrogen Fuel Cells: The Future of Clean Energy.

In today's rapidly changing world, the demand for clean and sustainable energy sources is greater than ever. As we strive to reduce our carbon footprint and combat climate change, finding alternative energy solutions becomes increasingly important. One promising technology that holds the key to a cleaner future is hydrogen fuel cells.

The Basics of Hydrogen Fuel Cells

Hydrogen fuel cells are devices that convert the chemical energy of hydrogen and oxygen into electrical energy. The principle behind fuel cells is simple yet revolutionary. By combining hydrogen and oxygen in a controlled manner, fuel cells generate electricity, with only water and heat as byproducts. This process, known as electrochemical conversion, offers a clean and efficient way to produce electricity.

Unlike conventional batteries, fuel cells do not require recharging. As long as there is a constant supply of hydrogen and oxygen, a fuel cell can continuously produce electricity. This makes fuel cells particularly suitable for applications that require long-duration power, such as vehicles, residential power backup systems, and even large-scale industrial operations.

The Advantages of Hydrogen Fuel Cells

1. Clean Energy: Hydrogen fuel cells produce zero harmful emissions. The only byproduct is pure water, making them a truly clean energy source. As the world shifts towards decarbonizing our energy systems, hydrogen fuel cells play a crucial role in reducing greenhouse gas emissions and improving air quality.

2. High Energy Efficiency: Fuel cells have a high energy conversion efficiency compared to traditional combustion engines. While internal combustion engines waste a significant amount of energy as heat, fuel cells can convert more than 50% of the energy in hydrogen into electricity, resulting in greater overall efficiency and reduced energy waste.

3. Versatility: Hydrogen fuel cells have a wide range of applications. They can be used in transportation, powering electric vehicles with long-range capabilities and quick refueling times. Additionally, fuel cells can provide electricity for residential and commercial buildings, acting as decentralized power sources. They can even be integrated into portable electronic devices, ensuring clean and reliable power on the go.

4. Energy Independence: Hydrogen is one of the most abundant elements on Earth. It can be produced from various sources, including water electrolysis, natural gas, and renewable resources like solar and wind power. This accessibility and diversity of sources give us the opportunity to achieve energy independence and reduce reliance on finite fossil fuels.

5. Durability and Scalability: Fuel cells are designed to be durable and require minimal maintenance. They have a longer lifespan compared to batteries, which need regular replacement. Moreover, fuel cell systems can be easily scaled up or down to meet specific power requirements.

The Role of HCO Innovations in Advancing Hydrogen Fuel Cells

At HCO Innovations, we recognize the immense potential of hydrogen fuel cells as a key player in the clean energy transition. We provide comprehensive services to support the adoption and optimization of fuel cell technologies.

Our expert team at HCO Innovations specializes in warehouse optimization and forklift fleet management. Although it may seem unrelated, the efficient management of warehouse operations and material handling plays a significant role in the adoption and advancement of hydrogen fuel cells.

By optimizing warehouse layouts and implementing tailored solutions, HCO Innovations helps businesses reduce operational costs and improve efficiency. We leverage advanced cost-tracking software and a collaborative "boots on the ground" approach to deliver exceptional return on investment.

Why is this relevant to fuel cells, you may ask? Well, the adoption of hydrogen fuel cell technology requires efficient supply chains, streamlined logistics, and optimized warehouse operations. HCO Innovations ensures that businesses have the infrastructure and processes in place to support the use of fuel cells in their operations.

For instance, our warehouse layout evaluation service helps identify potential bottlenecks and inefficiencies in the material handling process. By reorganizing the layout and strategically placing hydrogen fueling stations, businesses can seamlessly integrate fuel cells into their operations.

Additionally, our safety assessments ensure that all necessary safety measures are in place when working with fuel cells. We provide training and guidance to help companies handle and store hydrogen safely, thereby minimizing the risk associated with fuel cell technology.

Furthermore, our turnkey maintenance solutions help businesses maintain the longevity and efficiency of their fuel cell systems. By implementing proactive maintenance schedules and conducting regular inspections, we ensure that fuel cell systems operate at their optimal performance levels.

At HCO Innovations, we are proud to be at the forefront of the clean energy revolution, supporting the adoption and optimization of hydrogen fuel cells. Through our expertise in warehouse optimization and our commitment to sustainable solutions, we help businesses reduce their environmental footprint and embrace the future of clean energy.

If you want to learn more about how HCO Innovations can help your business optimize warehouse operations and adopt hydrogen fuel cell technology, contact us today or visit our website for more information.

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