Dubai-based DP World has moved to the second stage – a one-year field test – following the successful completion of the first stage of initial testing of its rubber-tired gantry (RTG) crane, which runs on hydrogen fuel cell.
The tests, which are expected to significantly contribute to decarbonising DP World’s global port operations, are being carried out at the Port of Vancouver in Canada. The Dubai port and logistics company is now assessing the feasibility of electrifying its global fleet of 1,500 RTG cranes, traditionally powered by diesel.
DP World’s green shift
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 per cent 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.
The pilot project was launched in October 2023. In the first phase, a diesel RTG was retrofitted 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.
During factory acceptance testing, the system ran continuously for 16 hours, lifting and lowering a 40-ton load 105 times, emitting only steam instead of 400 kilograms of CO₂ from a comparable diesel unit.
The RTG has now entered its second phase of 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.
Doug Smith, CEO of DP World in Canada, commented: “As one of the world’s foremost port and terminal operators, we are dedicated to advancing sustainable practices that will drive industry-wide change. This pilot not only marks an important step in DP World’s commitment to decarbonising 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.”
The RTG crane stores up to 135 kg of compressed gaseous hydrogen in 15 pressurised 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.
DP World partnered with TYCROP Manufacturing, H2 Portable and HTEC for this pioneering project. H2 Portable, together with TYCROP, designed a Hydrogen-Electric Generator (HEG) utilising a dual fuel cell and battery energy storage system, while HTEC provided the hydrogen storage system and hydrogen supply.
Scott Mason, President and CEO, TYCROP, added: “Through our work with DP World, H2 Portable and HTEC, we achieved a major milestone in zero-emission power. This accomplishment highlights what can be done when industry and government collaborate to drive innovation.”
George Rubin, Managing Director of Commercial Operations, H2 Portable, added that their Advanced Power system “exceeded key benchmarks in early field operations” and demonstrated how hydrogen-based technology can deliver meaningful performance benefits.
Depending on the field tests, 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. It also plans to trial an electric terminal tractor at the Port of Vancouver.
The Port of Vancouver was selected for the pilot due to its thriving hydrogen and fuel cell ecosystem and strong support from the Province of British Columbia.
