Techno-economic analysis of PSA separation for hydrogen/natural gas mixtures at hydrogen refuelling stations

Logistics of hydrogen is one of the bottlenecks of a hydrogen economy. In this study, a pressure swing adsorption (PSA) system is proposed for the separation of hydrogen from natural gas, co-transported in the natural gas grid. The economic feasibility of hydrogen supplied by a PSA system at a refuelling station is assessed and compared with other alternatives. The adsorbent material is key to the design of a PSA system, which determines the operation performance and cost. It is concluded that a refuelling station with hydrogen supplied by a PSA system is economically feasible. The final hydrogen price including hydrogen supply, compression, storage, and dispensing is compared with two other hydrogen supply methods: on-site electrolysis and tube-trailer transported hydrogen. Currently, PSA supplied hydrogen is a more economical option. On-site electrolysis can become a more economical option in the future with improved cell efficiencies and reduced electricity prices. Tube-trailer transported hydrogen is highly influenced by the distance travelled. The findings of this study will help with more efficient distribution of hydrogen.     

Quantitative analysis of a successful public hydrogen station

Reliable hydrogen fueling stations will be required for the successful commercialization of fuel cell vehicles. An evolving hydrogen fueling station has been in operation in Irvine, California since 2003, with nearly five years of operation in its current form. The usage of the station has increased from just 1000 kg dispensed in 2007 to over 8000 kg dispensed in 2011 due to greater numbers of fuel cell vehicles in the area. The station regularly operates beyond its design capacity of 25 kg/day and enables fuel cell vehicles to exceed future carbon reduction goals today. Current limitations include a cost of hydrogen of $15 per kg, net electrical consumption of 5 kWh per kg dispensed, and a need for faster back-to-back vehicle refueling.     

Manufacturing competitiveness analysis for hydrogen refueling stations

Fuel cell electric vehicles (FCEVs) have now entered the market as zero-emission vehicles. Original equipment manufacturers such as Toyota, Honda, and Hyundai have released commercial cars in parallel with efforts focusing on the development of hydrogen refueling infrastructure to support new FCEV fleets. Persistent challenges for FCEVs include high initial vehicle cost and the availability of hydrogen stations to support FCEV fleets. This study sheds light on the factors that drive manufacturing competitiveness of the principal systems in hydrogen refueling stations, including compressors, storage tanks, precoolers, and dispensers. To explore major cost drivers and investigate possible cost reduction areas, bottom-up manufacturing cost models were developed for these systems. Results from these manufacturing cost models show there is substantial room for cost reductions through economies of scale, as fixed costs can be spread over more units. Results also show that purchasing larger quantities of commodity and purchased parts can drive significant cost reductions. Intuitively, these cost reductions will be reflected in lower hydrogen fuel prices. A simple cost analysis shows there is some room for cost reduction in the manufacturing cost of the hydrogen refueling station systems, which could reach 35% or more when achieving production rates of more than 100 units per year. We estimated the potential cost reduction in hydrogen compression, storage and dispensing as a result of capital cost reduction to reach 5% or more when hydrogen refueling station systems are produced at scale.     

Safety aspects of future infrastructure scenarios with hydrogen refuelling stations

Hydrogen is currently gaining much attention as a possible future substitute for oil in the transport sector. Hydrogen is not a primary energy source, but can be produced from other sources of energy. A future hydrogen economy will need the establishment of new infrastructures for producing, storing, distributing, dispensing and using hydrogen. Hydrogen can be produced in large-scale centralized facilities or in small-scale on-site systems. Large-scale production requires distribution in pipelines or trucks. A major challenge is to plan the new infrastructures to approach an even safer society regarding safe use of hydrogen. The paper will, on the basis of some scenarios for hydrogen deployment, highlight and discuss safety aspects related to future hydrogen economy infrastructures.     

Current standards and configurations for the permitting and operation of hydrogen refueling stations

The literature lacks a systematic analysis of HRS equipment and operating standards. Researchers, policymakers, and HRS operators could find this information relevant for planning the network's future expansion. This study is intended to address this information need by providing a comprehensive strategic overview of the regulations currently in place for the construction and maintenance of hydrogen fueling stations.A quick introduction to fundamental hydrogen precautions and hydrogen design is offered. The paper, therefore, provides a quick overview of hydrogen's safety to emphasize HRS standards, rules, and regulations. Both gaseous and liquid safety issues are detailed, including possible threats and installation and operating expertise.After the safety evaluation, layouts, equipment, and operating strategies for HRSs are presented, followed by a review of in-force regulations: internationally, by presenting ISO, IEC, and SAE standards, and Europeanly, by reviewing the CEN/CENELEC standards. A brief and concise analysis of Italy's HRS regulations is conducted, with the goal of identifying potential insights for strategic development and more convenient technology deployment.     

Sustainability of hydrogen refuelling stations for trains using electrolysers

Hydrogen has the potential to become a powerful energy vector with different applications in many sectors (industrial, residential, transportation and other applications) as it offers a clean, sustainable, and flexible alternative. Hydrogen trains use compressed hydrogen as fuel to generate electricity using a hybrid system (combining fuel cell and batteries) to power traction motors and auxiliaries. This hydrogen trains are fuelled with hydrogen at the central train depot, like diesel locomotives. The main goal of this paper is to perform a techno-economic analysis for a hydrogen refuelling stations using on-site production, based on PEM electrolyser technology in order to supply hydrogen to a 20 hydrogen-powered trains captive fleet. A sensitivity analysis on the main parameters will be performed as well, in order to acquire the knowledge required to take any decisions on implementation regarding electricity cost, hydrogen selling price, number of operation hours and number of trains for the captive fleet.The main methodology considers the evaluation of the project based on the Net Present Value calculation and the sensitivity analysis through standard method using Oracle Crystal Ball. The main result shows that the use of hydrogen as an alternative fuel for trains is a sustainable and profitable solution from the economic, environmental and safety points of view.The economic analysis concludes with the need to negotiate an electricity cost lower than 50 €/MWh, in order to be able to establish the hydrogen selling price at a rate higher than 4.5€/kg. The number of operating hours should be higher than 4800 h per year, and the electrolyser system capacity (or hydrogen refuelling station capacity) should be greater than 3.5 MW in order to reach a Net Present Value of 7,115,391 € with a Return of Investment set to 9 years. The result of the multiparametric sensitivity analysis for the Net Present Value (NPV) shows an 85.6% certainty that the project will have a positive result (i.e. profitability) (NPV> 0). The two main variables with the largest impact on Net Present Value are the electrolyser capacity (or hydrogen refuelling station capacity) and the hydrogen selling price. Moreover, a margin of improvement (higher NPV) could be reached with the monetization of the heat, oxygen by-product and CO₂ emission reduction.     

Dynamic planning and energy management strategy of integrated charging and hydrogen refueling at highway energy supply stations considering on-site green hydrogen production

The layout of electric vehicles charging stations and hydrogen refueling stations (HRSs) is more and more necessary with the development of electric vehicles (EVs) and progress in hydrogen energy storage technology. Due to the high costs of HRSs and the low demand for hydrogen, it is difficult for independent HRSs to make a profit. This study focuses on the dynamic planning of energy supply stations on highways in the medium and long term, considering the growth of EV charging demand and the change in the proportion of hydrogen fuel cell vehicles (HFCVs). Based on the perspective of renewable energy generators (REGs), this study seeks the dynamic optimal configuration and comprehensive benefits of adding HRS and battery to existing EVCS considering the travel rules of new energy vehicles (NEVs). The results show that (1) It is profitable for REGs to invest in HRSs; (2) The economy of investment in batteries by REGs depends on the source-load matching. It is feasible only when the output of renewable energy is difficult to meet the demand. (3) The business model of REGs producing hydrogen on-site and supplying both electricity and hydrogen is feasible.     

Design proposal for hydrogen refueling infrastructure deployment in the Northeastern United States

Fuel cell vehicles (FCVs) are expected to be commercially available on the world market in 2015, therefore, introducing hydrogen-refueling stations is an urgent issue to be addressed. This paper proposes deployment plan of hydrogen infrastructure for the success of their market penetration in the Northeastern United States. The plan consists of three-timeline stages from 2013 to 2025 and divides the designated region into urban area, suburban area and area adjacent to expressway, so that easy to access to hydrogen stations can be realized. Station is chosen from four types of stations: off-site station, urban-type on-site station, suburban-type on-site station and portable station, associated with growing demand. In addition, on-site station is used as hydrogen production factory for off-site station to save total investment. This deployment plan shows that 83% of urban residents can reach station within 10 min in 2025, and that more than 90% people especially in four major cities: Boston, New York City, Philadelphia, and Washington, D.C. can get to station within 10 min by Geographic Information System (GIS) calculation.     

Life cycle assessment of hydrogen supply chain with special attention on hydrogen refuelling stations

The controversial and highly emotional discussion about biofuels in recent years has shown that greenhouse gas² (GHG) emissions can only be evaluated in an acceptable way by carrying out a full life cycle assessment (LCA) taking the overall life cycle including all necessary pre-chains into consideration. Against this background, the goal of this paper is it to analyse the overall life cycle of a hydrogen production and provision. A state of the art hydrogen refuelling station in Hamburg/Germany opened in February 2012 is therefore taken into consideration. Here at least 50% hydrogen from renewable sources of energy is produced on-site by water electrolysis based on surplus electricity from wind (mainly offshore wind parks) and water. The remaining other 50% of hydrogen to be sold by this station mainly to hydrogen-fuelled buses is provided by trucks from a large-scale production plant where hydrogen is produced from methane or glycerol as a by-product of the biodiesel production. These two pathways are compared within the following explanations with hydrogen production from biomass and from coal. The results show that – with the goal of reducing GHG emissions on a life cycle perspective – hydrogen production based on a water electrolysis fed by electricity from the German electricity mix should be avoided. Steam methane reforming is more promising in terms of GHG reduction but it is still based on a finite fossil fuel. For a climatic sound provision of hydrogen as a fuel electricity from renewable sources of energy like wind or biomass should be used.     

Research on sealing performance and self-acting valve reliability in high-pressure oil-free hydrogen compressors for hydrogen refueling stations

Piston ring sealing and valve design play an important role in high-pressure oil-free reciprocating compressors for hydrogen refueling stations. The severe non-uniformity of the pressure distribution was suggested to be the root cause of the premature failure of the sealing rings, and therefore a mathematical model was established to simulate the unsteady flow within the gaps of piston rings, based on which the pressure distribution was obtained and the mechanism of the non-uniform abrasion of the rings was disclosed. The method to equalize the pressure difference through each ring was proposed by re-distributing the cut size of each ring, and it was validated experimentally. Aiming at the problem that the self-acting valves in hydrogen compressors could be easily destroyed by severe impact, this paper investigated the motion and impact of valves theoretically and experimentally, based on which the methodology was explored to design the parameters of valves for hydrogen compressors.     

Energetic evaluation of hydrogen refueling stations with liquid or gaseous stored hydrogen

The future success of fuel cell electric vehicles requires a corresponding infrastructure. In this study, two different refueling station concepts for fuel cell passenger cars with 70 MPa technology were evaluated energetically. In the first option, the input of the refueling station is gaseous hydrogen which is compressed to final pressure, remaining in gaseous state. In the second option, the input is liquid hydrogen which is cryo-compressed directly from the liquid phase to the target pressure. In the first case, the target temperature of −33 °C to −40 °C [1] is achieved by cooling down. In the second option, gaseous deep-cold hydrogen coming from the pump is heated up to target temperature. A dynamic simulation model considering real gas behavior to evaluate both types of fueling stations from an energetic perspective was created. The dynamic model allows the simulation of boil-off losses (liquid stations) and standby energy losses caused by the precooling system (gaseous station) dependent on fueling profiles. The functionality of the model was demonstrated with a sequence of three refueling processes within a short time period (high station utilization). The liquid station consumed 0.37 kWh/kg compared to 2.43 kWh/kg of the gaseous station. Rough estimations indicated that the energy consumption of the entire pathway is higher for liquid hydrogen. The analysis showed the high influence of the high-pressure storage system design on the energy consumption of the station. For future research work the refueling station model can be applied to analyze the energy consumption dependent on factors like utilization, component sizing and ambient temperature.     

Techno-economic modelling and analysis of hydrogen fuelling stations

Climate change is probably the most relevant global challenge. For this reason, governments are promoting energy efficiency programmes, carbon capture technologies, and renewable energies as a way to reduce carbon emissions and mitigate climate change. Hydrogen is a clean alternative to fossil fuels in automotive applications. In this context, the objective of this project is to find the best design of a hydrogen refuelling station in terms of the number of banks and their size, having as a final aim the most cost-efficient design. This study suggests that, from an economic point of view, a state of charge for the vehicle of 100% is not adequate, since it requires very large high-pressure banks at the station, which increases significantly its setup costs. The study finds that high-pressure banks have to be bigger in volume than the low-pressure banks to minimise the total cost of the station, including setup and operational costs along its timespan. Finally, the project shows that the optimal number of banks is 4 or a maximum of 5. As a side conclusion, these results have practical implications for firms, as they might reduce the time spent in the design process of a hydrogen refuelling station.     

Technical potential of on-site wind powered hydrogen producing refuelling stations in the Netherlands

This study assesses the technical potential of wind turbines to be installed next to existing fuelling stations in order to produce hydrogen. Hydrogen will be used for Fuel Cell Vehicle refuelling and feed-in existing local gas grids. The suitable fuelling stations are selected through a GIS assessment applying buffer zones and taking into account risks associated with wind turbine installation next to built-up areas, critical infrastructures and ecological networks. It was found that 4.6% of existing fuelling stations are suitable. Further, a hydrogen production potential assessment was made using weather station datasets, land cover data and was expressed as potential future Fuel Cell Electric Vehicle demand coverage. It was found that for a 30% FCEV drivetrain scenario, these stations can produce 2.3% of this demand. Finally, a case study was made for the proximity of those stations in existing gas distribution grids.     

Optimal sites selection of oil-hydrogen combined stations considering the diversity of hydrogen sources

The popularity of hydrogen refueling stations in China is hindered by unreasonable site selection and high initial costs. Built gas stations with large consumer groups and reasonable locations can be expanded into oil-hydrogen combined stations. which can effectively reduce construction costs and approval complexity, improve hydrogenation infrastructure and reduce hydrogenation costs. Taking Chinese social-economic environment into consideration, this paper created an optimal site selection decision framework for oil-hydrogen combined stations to achieve the goal of reducing construction costs, transportation costs and carbon emissions in the whole process. A two-stage criteria system including veto criteria system and evaluation criteria system was established, and fuzzy analytic hierarchy process (AHP) method and TOmada De decis ão Interativa Multicritério (TODIM) method were utilized to determine the criteria weight and obtain the ranking of alternatives respectively. Finally, a case study was conducted and the most suitable gas station site for the construction of oil-hydrogen combined station was determined. Moreover, the economics of the several hydrogen sources were discussed from the perspective of best site selected, it is concluded that hydrogen from natural gas or coal is still the best hydrogen source for oil-hydrogen combined stations.     

Queuing-based approach for optimal dispenser allocation to hydrogen refueling stations

Dispenser allocation to hydrogen refueling stations aims at minimizing the number of dispensers while ensuring satisfactory performance of vehicle queues during the peak hour of a peak day. A queuing model is developed in this study to evaluate the queuing performance at such stations by incorporating the statistical and thermodynamic characteristics of refueling. An optimization framework is proposed to determine the minimal number of dispensers required to meet the upper limits imposed on two important performance measures: mean waiting time and mean queue length. Reasonable upper limits are provided for 70 MPa stations according to the effects of dispenser allocation and station capacity on queuing performance. Server (dispenser nozzle) utilization under the optimal dispenser allocation generally increases with an increase in station size and tends to exceed 50% for large stations. The proposed approach can offer significant performance improvements for small stations and considerable savings in the number of dispensers for large ones.     

Economic analysis of near-term California hydrogen infrastructure

A detailed economics model of hydrogen infrastructure in California has been developed and applied to assess several potential fuel cell vehicle deployment rate and hydrogen station technology scenarios. The model accounts for all of the costs in the hydrogen supply chain and specifically examines a network of 68 planned and existing hydrogen stations in terms of economic viability and dispensed hydrogen cost. Results show that (1) current high-pressure gaseous delivery and liquid delivery station technologies can eventually be profitable with relatively low vehicle deployment rates, and (2) the cost per mile for operating fuel cell vehicles can be lower than equivalent gasoline vehicles in both the near and long term.     

Development of a cross-contamination-free hydrogen sampling methodology and analysis of contaminants for hydrogen refueling stations

Hydrogen used in proton exchange membrane-based fuel cell applications is subject to very high quality requirements. While the influences of contaminations in hydrogen on long-term stability have been intensively studied, the purity of hydrogen for mobile applications provided at hydrogen refueling stations (HRS) is rarely analyzed. Hence, in this study, we present sampling of hydrogen at HRS with a specially designed mobile tank for up to 70 MPa. These samples are precisely analyzed with a sophisticated ion molecule reaction mass spectrometer (IMR-MS), able to determine concentrations of contaminants down to the ppb-level. Sampling and analysis of hydrogen at an HRS supplied by electrolysis revealed a high purity, but likewise considerable contaminations above the threshold of the international standard ISO 14687:2019. In this study, a state-of-the-art analysis coupled with a developed methodology for fuel cell electric vehicle-independent sampling of hydrogen with a mobile tank system is demonstrated and applied for comprehensive studies of hydrogen purity.     

Public acceptance for the implementation of hydrogen self-refueling stations

The utilization of hydrogen energy is important for achieving a low-carbon society. Japan has set ambitious goals for hydrogen stations and fuel cell vehicles, focusing on the introduction and dissemination of self-refueling systems. This paper evaluates public trust in the fuel, equipment, and self-handling technology related to self-refueling hydrogen stations and compares it with that for widespread gasoline stations. To this end, the results of an online survey of 300 people with Japanese driver licenses are reported and analyzed. The results show that trust in the equipment and self-handling is more important for the user than trust in the fuel. In addition, to introduce and disseminate new technology such as hydrogen stations, users must be made aware of the risk of using the technology until it becomes as familiar as existing gasoline station technology.     

Performance of a hydrogen refueling station in the early years of commercial fuel cell vehicle deployment

Since 2003, the National Fuel Cell Research Center at the University of California, Irvine (UCI) has operated the first U.S. publicly accessible hydrogen refueling station (HRS). During this period, the UCI HRS supported all manufacturers in the early, pre-commercialization years of the fuel cell electric vehicle (FCEV). This paper describes and analyzes the performance of the UCI HRS during the first five years of FCEV commercialization, over which time the station has dispensed the most hydrogen daily in the California network. The station performance is compared to aggregate data published by NREL for all U.S. HRSs. Using the Hydrogen Delivery Scenario Analysis Model, typical daily refueling profiles are analyzed to determine the effect on HRS design. The results show different daily refueling profiles could substantially affect HRS design and ultimately the cost of hydrogen. While technical issues have been reduced, the compressor, dispenser, and fueling rate are areas for improvement.     

Assessment of hydrogen quality dispensed for hydrogen refuelling stations in Europe

The fuel quality of hydrogen dispensed from 10 refuelling stations in Europe was assessed. Representative sampling was conducted from the nozzle by use of a sampling adapter allowing to bleed sample gas in parallel while refuelling an FCEV. Samples were split off and distributed to four laboratories for analysis in accordance with ISO 14687 and SAE J2719. The results indicated some inconsistencies between the laboratories but were still conclusive. The fuel quality was generally good. Elevated nitrogen concentrations were detected in two samples but not in violation with the new 300 μmol/mol tolerance limit. Four samples showed water concentrations higher than the 5 μmol/mol tolerance limit estimated by at least one laboratory. The results were ambiguous: none of the four samples showed all laboratories in agreement with the violation. One laboratory reported an elevated oxygen concentration that was not corroborated by the other two laboratories and thus considered an outlier.