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.     

Performance and cost of fuel cells for off-road heavy-duty vehicles

Replacing hydrocarbon-powered off-road vehicles with hydrogen fuel cell-powered off-road vehicles can reduce carbon dioxide and criteria pollutant emissions in the agriculture, construction, and mining industries. Off-road vehicles perform challenging work in harsh environments that complicate deployment of their fuel cell-powered counterparts. Customers and vehicle manufacturers recognize the health and environmental benefits of emissions reductions but are compelled by the total cost of ownership of their vehicles. This study provides a novel technoeconomic comparison of hydrogen fuel cell + battery hybrid powertrains to traditional diesel powertrains for three hallmark off-road vehicles: tractors, wheel loaders, and excavators. Performance metrics include fuel cell engine power, hydrogen consumption rate, hydrogen storage system volume, energy-regenerative drivetrain efficiency, cost of capital, operating and maintenance cost, fuel cost, and fuel storage cost. Results demonstrate that state-of-the-art fuel cell-powered wheel loaders and excavators are currently cost competitive with diesel platforms by total cost of ownership: compact wheel loaders are 19% less expensive, large wheel loaders are equally expensive, mini/compact excavators are 11% more expensive, and standard/full excavators are 9% less expensive. If targeted improvements to cost, performance, and durability of fuel cell stacks and storage systems are achieved, fuel cell systems would be cost competitive for tractors and significantly lower total cost of ownership options for wheel loaders and excavators. This study also elucidates the relationship between performance, cost, and vehicle duty cycle and provides guidance for optimal deployment of fuel cell off-road vehicles.     

Demonstration of a novel assessment methodology for hydrogen infrastructure deployment

To reduce criteria pollutant emissions and greenhouse gases from mobile sources, the use of hydrogen as a transportation fuel is proposed as a new paradigm in combination with fuel cells for vehicle power. The extent to which reductions can and will occur depends on the mix of technologies that constitute the hydrogen supply chain. This paper introduces an analysis and planning methodology for estimating emissions, greenhouse gases, and the energy efficiency of the hydrogen supply chain as a function of the technology mix on a life cycle, well to wheels (WTW) basis. The methodology, referred to as the preferred combination assessment (PCA) model, is demonstrated by assessing an illustrative set of hydrogen infrastructure (generation and distribution) deployment scenarios in California's South Coast Air Basin. Each scenario reflects a select mix of technologies for the years 2015, 2030, and 2060 including (1) the proportion of fossil fuels and renewable energy sources of the hydrogen and (2) the rate of hydrogen fuel cell vehicle adoption. The hydrogen deployment scenarios are compared to the existing paradigm of conventional vehicles and fuels with a goal to reveal and evaluate the efficacy and utility of the PCA methodology. In addition to a demonstration of the methodology, the salient conclusions reached from this first application include the following.

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Emissions of criteria pollutants increase or decrease, depending on the hydrogen deployment scenario, when compared to an evolution of the existing paradigm of conventional vehicles and fuels.     

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.     

Off-grid solar powered charging station for electric and hydrogen vehicles including fuel cell and hydrogen storage

This paper designs an off-grid charging station for electric and hydrogen vehicles. Both the electric and hydrogen vehicles are charged at the same time. They appear as two electrical and hydrogen load demand on the charging station and the charging station is powered by solar panels. The output power of solar system is separated into two parts. On part of solar power is used to supply the electrical load demand (to charge the electric vehicles) and rest runs water electrolyzer and it will be converted to the hydrogen. The hydrogen is stored and it supplies the hydrogen load demand (to charge the hydrogen-burning vehicles). The uncertainty of parameters (solar energy, consumed power by electrical vehicles, and consumed power by hydrogen vehicles) is included and modeled. The fuel cell is added to the charging station to deal with such uncertainty. The fuel cell runs on hydrogen and produces electrical energy to supply electrical loading under uncertainties. The diesel generator is also added to the charging station as a supplementary generation. The problem is modeled as stochastic optimization programming and minimizes the investment and operational costs of solar and diesel systems. The introduced planning finds optimal rated powers of solar system and diesel generator, operation pattern for diesel generator and fuel cell, and the stored hydrogen. The results confirm that the cost of changing station is covered by investment cost of solar system (95%), operational cost of diesel generator (4.5%), and investment cost of diesel generator (0.5%). The fuel cell and diesel generator supply the load demand when the solar energy is zero. About 97% of solar energy will be converted to hydrogen and stored. The optimal operation of diesel generator reduces the cost approximately 15%.     

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.     

A comparative techno-economic and quantitative risk analysis of hydrogen delivery infrastructure options

The comparative techno-economic analysis and quantitative risk analysis (QRA) of the hydrogen delivery infrastructure covering the national hydrogen demands are presented to obtain a comprehensive understanding of the infrastructure of commercial hydrogen delivery. The cost calculation model, which was based on the hydrogen delivery scenario analysis model (HDSAM), was employed to estimate the costs of hydrogen fuel delivery in Seoul, Korea, whose area is small enough to not require intermediate delivery stations. The QRA methodology was modified to be suitable for the comparative analysis of the whole hydrogen infrastructure. The capacities of a hydrogen refueling station and the hydrogen market penetration were employed as the main variables and the two scenarios, viz. the gaseous and liquid hydrogen delivery options, were considered. The analysis results indicate that the delivery system of gaseous hydrogen was superior in terms of cost and that of liquid hydrogen was superior in terms of safety. Both delivery options were affected by the capacity of the station and the market penetration, and the cost and risk drastically changed, especially when the two variables were small. Thus, according to the results, the economic and safety issues of the hydrogen delivery infrastructure are critical to achieving a hydrogen energy society.     

Impact of refueling parameters on storage density of compressed hydrogen storage Tank

Hydrogen fuel cell vehicle (HFCV) is one of the key contributors to sustainable development of the society. For commercial deployment and market acceptability of fuel cell vehicles, efficient storage of hydrogen with an optimum refueling is one of the important challenge. Compressed hydrogen storage in Type IV tanks is a mature and promising technology for on-board application. The fast refueling of the storage tank without overheating and overfilling is an essential requirement defined by SAE J2601. In this regard, station parameters such as hydrogen supply temperature, filling rate and vehicle tank parameters such as filling time strongly influences the storage capacity of the tank, affecting driving range of the fuel cell vehicle. This paper investigates the impact of these parameters on storage density of the tank defined in terms of state of charge. For this, refueling simulation based on SAE J2601 protocol has been performed using computational fluid dynamic approach to investigate the influence of station parameters on storage density of the tank. Further, the root cause analysis was carried out to investigate the contribution of station and vehicle tank parameters for enhancing the storage density of the tank. Finally, the regression model based on these refueling parameters was developed to predict the density attained at different filling conditions. The results confirmed the strong contribution of pressure, filling time, supply temperature and least contribution of temperature, filling rates in enhancing the storage density of the tank. The results can provide new insight into refueling behavior of the Type IV tank for fuel cell vehicle.     

Assessing the operation and different refuelling cost scenarios of a fuel cell electric bicycle under low-pressure hydrogen storage

The transition to low- or zero-emission vehicles in the transportation sector is a challenging task toward meeting the greenhouse gas emission targets set by the majority of countries. One way of achieving this goal is to utilise hydrogen gas via fuel cell electric vehicles. This paper investigates the operation, driving range and refuelling process of a fuel cell electric bicycle. The methodology applied includes an estimation of the bike's range under different routes and riders, the riders' opinions and a financial evaluation of the hydrogen fuel cost compared to other urban vehicle alternatives. The results showed a minimum median range-to-energy consumption ratio of 20.5 km/kWh, while the maximum hydrogen cost was found to reach 0.025 €/km when refuelling the hydrogen bicycle in an autonomous hydrogen station. The outcome of this study indicates that the introduction of light-duty hydrogen vehicles in urban transportation may adequately meet the average daily driving distance of city residents.     

Developing an infrastructure for hydrogen vehicles: a Southern California case study

We have examined the technical feasibility and economics of developing a hydrogen vehicle refueling infrastructure for a specific area where zero emission vehicles are being considered, Southern California. Potential hydrogen demands for zero emission vehicles are estimated. We then assess in detail several near term possibilities for producing and delivering gaseous hydrogen transportation fuel including: (1) hydrogen produced from natural gas in a large, centralized steam reforming plant, and truck delivered as a liquid to refueling stations; (2) hydrogen produced in a large, centralized steam reforming plant, and delivered via small scale hydrogen gas pipeline to refueling stations; (3) by-product hydrogen from chemical industry sources; (4) hydrogen produced at the refueling station via small scale steam reforming of natural gas; and (5) hydrogen produced via small scale electrolysis at the refueling station. The capital cost of infrastructure and the delivered cost of hydrogen are estimated for each hydrogen supply option. Hydrogen is compared to other fuels for fuel cell vehicles (methanol, gasoline) in terms of vehicle cost, infrastructure cost and lifecycle cost of transportation. Finally, we discuss possible scenarios for introducing hydrogen as a fuel for fuel cell vehicles.     

Integration of a light mobility urban scale hydrogen refuelling station for cycling purposes in the transportation market

Road transportation consists of a significant contributor to total greenhouse gas emissions in developed countries. New alternative technologies in transportation such as electric vehicles aim to reduce substantially vehicle emissions, particularly in urban areas. Incentives of using two-wheel electric vehicles such as bicycles in big cities centres are promoted by local governments, and in fact, some countries are already trying to adopt this transition. An interesting case consists of the use of hydrogen fuel cells in such vehicles to increase their driving range under short refuelling times. To this end, this paper investigated the social and financial prospects of hydrogen infrastructure for city-oriented fuel cell electric vehicles such as bicycles. The results of the research indicated that a light mobility urban hydrogen refuelling station able to provide refuelling processes at pressures of 30 bar with a hydrogen fuel cost of 34.7 €/kgH₂ is more favourable compared to larger stations.     

Cost of a potential hydrogen-refueling network for heavy-duty vehicles with long-haul application in Germany 2050

Long-distance road-freight transport emits a large share of Germany's greenhouse gas (GHG) emissions. A potential solution for reducing GHG emissions in this sector is to use green hydrogen in fuel cell electric vehicles (FC-HDV) and establish an accompanying hydrogen refueling station (HRS) network. In this paper, we apply an existing refueling network design model to a HDV-HRS network for Germany until 2050 based on German traffic data for heavy-duty trucks and estimate its costs. Comparing different fuel supply scenarios (pipeline vs. on-site), The on-site scenario results show a network consisting of 137 stations at a cost of 8.38 billion € per year in 2050 (0.40 € per vehicle km), while the centralized scenario with the same amount of stations shows a cheaper cost with 7.25 billion euros per year (0.35 € per vehicle km). The hydrogen cost (LCOH) varies from 5.59 €/kg (pipeline) to 6.47 €/kg (on-site) in 2050.     

Systematic planning to optimize investments in hydrogen infrastructure deployment

The introduction of hydrogen infrastructure and fuel cell vehicles (FCVs) to gradually replace gasoline internal combustion engine vehicles can provide environment and energy security benefits. The deployment of hydrogen fueling infrastructure to support the demonstration and commercialization of FCVs remains a critical barrier to transitioning to hydrogen as a transportation fuel. This study utilizes an engineering methodology referred to as the Spatially and Temporally Resolved Energy and Environment Tool (STREET) to demonstrate how systematic planning can optimize early investments in hydrogen infrastructure in a way that supports and encourages growth in the deployment of FCVs while ensuring that the associated environment and energy security benefits are fully realized. Specifically, a case study is performed for the City of Irvine, California – a target area for FCV deployment – to determine the optimized number and location of hydrogen fueling stations required to provide a bridge to FCV commercialization, the preferred rollout strategy for those stations, and the environmental impact associated with three near-term scenarios for hydrogen production and distribution associated with local and regional sources of hydrogen available to the City. Furthermore, because the State of California has adopted legislation imposing environmental standards for hydrogen production, results of the environmental impact assessment for hydrogen production and distribution scenarios are measured against the California standards. The results show that significantly fewer hydrogen fueling stations are required to provide comparable service to the existing gasoline infrastructure, and that key community statistics are needed to inform the preferred rollout strategy for the stations. Well-to-wheel (WTW) greenhouse gas (GHG) emissions, urban criteria pollutants, energy use, and water use associated with hydrogen and FCVs can be significantly reduced in comparison to the average parc of gasoline vehicles regardless of whether hydrogen is produced and distributed with an emphasis on conventional resources (e.g., natural gas), or on local, renewable resources. An emphasis on local renewable resources to produce hydrogen further reduces emissions, energy use, and water use associated with hydrogen and FCVs compared to an emphasis on conventional resources. All three hydrogen production and distribution scenarios considered in the study meet California's standards for well-to-wheel GHG emissions, and well-to-tank emissions of urban ROG and NO_X. Two of the three scenarios also meet California's standard that 33% of hydrogen must be produced from renewable feedstocks. Overall, systematic planning optimizes both the economic and environmental impact associated with the deployment of hydrogen infrastructure and FCVs.     

Hydrogen quality for fuel cell vehicles – A modeling study of the sensitivity of impurity content in hydrogen to the process variables in the SMR–PSA pathway

As fuel cell vehicles approach wide-scale deployment, the issue of the quality of hydrogen dispensed to the vehicles has become increasingly important. The various factors that must be considered include the effects of different contaminants on fuel cell performance and durability, the production and purification of hydrogen to meet fuel quality guidelines, and the associated costs of providing hydrogen of that quality to the fuel cell vehicles. In this paper, we describe the development of a model to track the formation and removal of several contaminants over the various steps of hydrogen production by steam-methane reforming (SMR) of natural gas, followed by purification by pressure-swing adsorption (PSA). We have used the model to evaluate the effects of setting varying levels of these contaminants in the product hydrogen on the production/purification efficiency, hydrogen recovery, and the cost of the hydrogen. The model can be used to track contaminants such as CO₂, CO, N₂, CH₄, and H₂S in the process. The results indicate that a suggested specification of 0.2 ppm CO would limit the maximum hydrogen recovery from the PSA under typical design and operating conditions. The steam-to-carbon ratio and the process pressure are found to have a significant impact on the process efficiency. Varying the CO specification from 0.1 to 1 ppm is not expected to affect the cost of hydrogen significantly, although the cost of gas analysis to comply with such stringent requirements may add 2–10 cents/kg to the cost of hydrogen.     

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.     

H2 refueling assessment of composite storage tank for fuel cell vehicle

Hydrogen as compressed gas is a promising option for zero-emission fuel cell vehicle. The fast and efficient refueling of high pressure hydrogen can provide a convenient platform for fuel cell vehicles to compete with conventional gasoline vehicles. This paper reports the finding of adiabatic simulation of the refueling process for Type IV tank at nominal working pressure of 70 MPa with considering the station refueling conditions. The overall heat transfer involved in refueling process was investigated by heat capacity model based on MC method defined by SAE J2601. The simulation results are validated against experimental data of European Commission's Gas Tank Testing Facility at Joint Research Centre (GasTef JRC), Netherlands. The results confirmed that end temperature and state of charge significantly depends on refueling parameters mainly supply hydrogen temperature and filling rate.     

Dynamic competition between plug-in hybrid and hydrogen fuel cell vehicles for personal transportation

This article addresses the issue of the diffusion of hydrogen cars in the market, particularly the competition with electric cars for the replacement of conventional vehicles. Using the multi-technological competition model developed by Le Bas and Baron-Sylvester’s (Diffusion technologique non binaire et schéma épidémiologique. Une reconsidération. Economie Appliquée 1995; tome XLVIII(3):71–101), it is shown that the early deployment of plug-in hybrid vehicles—the only electric technology which can compete with fuel cell cars in the multipurpose vehicle field—risks closing the market for hydrogen in the future. Moreover, the advent of the hydrogen vehicle depends on the rapid advancements in fuel cell technologies, as well as on the existence of an infrastructure with a sufficient coverage.     

The impact of fuel cell vehicle deployment on road transport greenhouse gas emissions: The China case

Considerable attention has been paid to energy security and climate problems caused by road vehicle fleets. Fuel cell vehicles provide a new solution for reducing energy consumption and greenhouse gas emissions, especially those from heavy-duty trucks. Although cost may become the key issue in fuel cell vehicle development, with technological improvements and cleaner pathways for hydrogen production, fuel cell vehicles will exhibit great potential of cost reduction. In accordance with the industrial plan in China, this study introduces five scenarios to evaluate the impact of fuel cell vehicles on the road vehicle fleet greenhouse gas emissions in China. Under the most optimistic scenario, greenhouse gas emissions generated by the whole fleet will decrease by 13.9% compared with the emissions in a scenario with no fuel cell vehicles, and heavy-duty truck greenhouse gas emissions will decrease by nearly one-fifth. Greenhouse gas emissions intensity of hydrogen production will play an essential role when fuel cell vehicles' fuel cycle greenhouse gas emissions are calculated; therefore, hydrogen production pathways will be critical in the future.     

Understanding the design and economics of distributed tri-generation systems for home and neighborhood refueling—Part I: Single family residence case studies

The potential benefits of hydrogen as a transportation fuel will not be achieved until hydrogen vehicles capture a substantial market share. However, although hydrogen fuel cell vehicle (FCV) technology has been making rapid progress, the lack of a hydrogen infrastructure remains a major barrier for FCV adoption and commercialization. The high cost of building an extensive hydrogen station network and the foreseeable low utilization in the near term discourages private investment. Based on the past experience of fuel infrastructure development for motor vehicles, innovative, distributed, small-volume hydrogen refueling methods may be required to refuel FCVs in the near term. Among small-volume refueling methods, home and neighborhood tri-generation systems (systems that produce electricity and heat for buildings, as well as hydrogen for vehicles) stand out because the technology is available and has potential to alleviate consumer's fuel availability concerns. In addition, it has features attractive to consumers such as convenience and security to refuel at home or in their neighborhood.The objective of this paper is to provide analytical tools for various stakeholders such as policy makers, manufacturers and consumers, to evaluate the design and the technical, economic, and environmental performances of tri-generation systems for home and neighborhood refueling. An interdisciplinary framework and an engineering/economic model is developed and applied to assess home tri-generation systems for single family residences (case studies on neighborhood systems will be provided in a later paper). Major tasks include modeling yearly system operation, exploring the optimal size of a system, estimating the cost of electricity, heat and hydrogen, and system CO₂ emissions, and comparing the results to alternatives. Sensitivity analysis is conducted, and the potential impacts of uncertainties in energy prices, capital cost reduction (or increase), government incentives and environmental cost are evaluated. Policy implications of the modeling results are also explored.     

Reliability evaluation and analysis for NEV charging station considering the impact of charging experience

Battery electric vehicles (BEVs) and hydrogen fuel cell vehicles (HFCVs) will predominate in near future, and the new energy vehicle (NEV) charging station which provides charging services for aforementioned NEVs could grow rapidly. The reliability of the NEV charging station would be the primary concern for early construction and NEV users. This study investigates the reliability evaluation of NEV charging station considering the impact of charging experience and analyzes the influence of various factors by comparing the evaluation results. The explicit modelling of the station considering power generation system, coupling devices and hydrogen storage is presented and an optimal revenue model is established to coordinate the operation of the station. A reliability index system is established to evaluate the charging reliability of the NEV charging station and reflect the charging experience. In addition, an amount model estimating the number of vehicles accessed in the coming days is proposed to address the impact of driver charging experience on the reliability evaluation. The results show that it is necessary to consider the charging experience in reliability evaluation. The comparison and analysis of reliability evaluation results reveal that the charging reliability and profit of the charging station are influenced by the initial hydrogen in tank, the price of hydrogen/electricity and the sizes of electrolyzer, hydrogen tank and fuel cell. The reliability evaluation provides guidance for determining the parameters of these factors.