Direct methanol fuel cells (DMFCs) directly convert methanol into electric current. In comparison to fuel cell systems operated with pure hydrogen or hydrogen-rich gases from reforming processes, the liquid methanol is supplied directly. Apart from the very high energy density of methanol, the DMFC is characterized by easy handling and trouble-free refuelling. DMFCs are attractive for various applications, above all, however, as replacements for accumulators, since DMFC systems permit longer operating times due to the high energy density of methanol.
Development of DMFCs has been a priority in research activities at the Institute of Energy Research (IEF-3) for nine years now. In past years, IEF-3 has further developed DMFC technology from the laboratory stage up to use in small mobile applications. A market analysis indicated that the use of a DMFC energy system in the kW class had the best chance of commercial realization if applied in a fork-lift truck. An advantage of such energy systems is that there is no need for the time-consuming recharging of the lead-acid batteries nor is it necessary to have spare batteries available for multi-shift operation.
This contribution will present the development status of DMFC systems for material handling applications at Research Centre Jülich and the results of a feasibility study. On the basis of these results, the first DMFC system for a fork-lift truck was constructed and tested. By means of optimized system packaging it was possible to integrate it into the space available for the battery tray.