Generation of high-pressure hydrogen for fuel cell electric vehicles using photovoltaic-powered water electrolysis

Increasing the utilization of electric drive systems including hybrid, battery, and fuel cell electric vehicles (FCEV) will reduce the usage of petroleum and the emission of air pollution by vehicles. The eventual production of electricity and hydrogen in a renewable fashion, such as using solar energy, can achieve the long-term vision of having no tailpipe emissions, as well as eliminating the dependence of the transportation sector on dwindling supplies of petroleum for its energy. Before FCEVs can be introduced in large numbers, a hydrogen-fueling infrastructure is needed. This report describes an early proof-of-concept for a distributed hydrogen fueling option in which renewably generated, high-pressure hydrogen is dispensed at an FCEV owner’s home. In an earlier report we described the design and initial characterization of a solar photovoltaic (PV) powered electrolyzer/storage/dispensing (ESD) system that was a proof-of-concept for a single FCEV home fueling system. In the present report we determined the efficiency and other operational characteristics of that PV-ESD system during testing over a 109-day period at the GM Proving Ground in Milford, MI, at a hydrogen output pressure of approximately 2000 psi (13.8 MPa). The high pressure was achieved without any mechanical compression via electrolysis. Over the study period the photovoltaic solar to electrical efficiency averaged 13.7%, the electrolyzer efficiency averaged 59%, and the system solar to hydrogen efficiency averaged 8.2% based on the hydrogen lower heating value. A well-documented model used to evaluate solar photovoltaic power systems was used to calculate the maximum power point values of the voltage, current, and power of our PV system in order to derive the coupling factor between the PV and ESD systems and to determine its behavior over the range of environmental conditions experienced during the study. The average coupling factor was near unity, indicating that the two systems remained coupled in an optimal fashion. Also, the system operated well over a wide range of meteorological conditions, and in particular it responded quickly to instantaneous changes in the solar irradiance (caused by clouds) with negligible effect on the overall efficiency. During the study up to 0.67 kg of high-pressure hydrogen was generated on a sunny day for fueling FCEV. Future generations of high-pressure electrolyzers, properly combined with solar PV systems, can offer a compact, efficient, and environmentally acceptable system for FCEV home fueling.     

Development of a renewable hydrogen economy: Optimization of existing technologies

There is an increasing need for new and greater sources of energy for future global transportation applications. One recognized possibility for a renewable, clean source of transportation fuels is solar radiation collected and converted into useable forms of electrical and/or chemical (hydrogen) energy. This paper describes methods for utilizing and combining existing technologies into systems that optimize solar energy collection and conversion into useful transportation fuels. Photovoltaic (PV)-electrolysis (solar hydrogen) and PV-battery charging systems described in this paper overcome inefficiencies inherent in past concepts, where DC power from the PV system was first converted to AC current and then used to power electrical devices at the point of generation, or fed back to the grid to reduce electricity costs. These past, non-optimized concepts included efficiency losses in power conversion and unnecessary costs. These drawbacks can be avoided by capitalizing on the unique feature of solar photovoltaic devices that match their maximum power point to the operating point of an electrolyzer or a battery charger without intervening power transformers. This concept is illustrated for two systems designed, built, and tested by General Motors for fueling a fuel cell electric vehicle and charging an automotive propulsion battery. Based on this research, we propose a scenario in which individual home-owners, businesses, or sites at remote locations with no grid electricity, can capture solar energy, store it as hydrogen generated via water electrolysis, or as electrical energy used to charge storage batteries. Such a decentralized energy system provides a home refueling option for drivers who only travel limited distances each day.     

Projecting full build-out environmental impacts and roll-out strategies associated with viable hydrogen fueling infrastructure strategies

A transition from gasoline internal combustion engine vehicles to hydrogen fuel cell electric vehicles (FCEVs) is likely to emerge as a major component of the strategy to meet future greenhouse gas reduction, air quality, fuel independence, and energy security goals. Advanced infrastructure planning can minimize the cost of hydrogen infrastructure while assuring that energy and environment benefits are achieved. This study presents a comprehensive advanced planning methodology for the deployment of hydrogen infrastructure, and applies the methodology to delineate fully built-out infrastructure strategies, assess the associated energy and environment impacts, facilitate the identification of an optimal infrastructure roll-out strategy, and identify the potential for renewable hydrogen feedstocks. The South Coast Air Basin of California, targeted by automobile manufacturers for the first regional commercial deployment of FCEVs, is the focus for the study. The following insights result from the application of the methodology:

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Compared to current gasoline stations, only 11%-14% of the number of hydrogen fueling stations can provide comparable accessibility to drivers in a targeted region.

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To meet reasonable capacity demand for hydrogen fueling, approximately 30% the number of hydrogen stations are required compared to current gasoline stations.

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Replacing gasoline vehicles with hydrogen FCEVs has the potential to (1) reduce the emission of greenhouse gases by more than 80%, reduce energy requirements by 42%, and virtually eliminate petroleum consumption from the passenger vehicle sector, and (2) significantly reduce urban concentrations of ozone and PM2.5.

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Existing sources of biomethane in the California South Coast Air Basin can provide up to 30% of the hydrogen fueling demand for a fully built-out hydrogen FCEV scenario.

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A step-wise transition of judiciously located existing gasoline stations to dispense and accommodate the increasing demand for hydrogen addresses proactively key infrastructure deployment challenges including a viable business model, zoning, permitting, and public acceptance.

     

Technical and economical design of PV system and hydrogen storage including a sodium hypochlorite plant in a small community: Case of study of Paraguay

The increasing use of renewable power sources for distributed generation (DG) has made the application of storage systems a necessity to ensure the continuous supply. This paper analyzes technically and economically an autonomous sodium hypochlorite plant using a renewable energy source and a hydrogen storage system in the Western Region of Paraguay. In this region, there is abundant underground brackish water to produce industrial and energetic hydrogen. In addition, an isolated photovoltaic (PV) system feeds with electricity an electrolyzer, used for sodium hypochlorite production, and the brackish water and freshwater pumping systems. The hydrogen and fuel cell are used as backup system in the operation of the electrolyzer. Preliminary results show that hydrogen stored during the day can increase hypochlorite production by up to 31%. The PV solar system surplus can supply the demand of an off-grid community near the plant. The results show that the plant's return on investment (ROI) is 7 years.     

Flexible sector coupling with hydrogen: A climate-friendly fuel supply for road transport

The substantial expansion of renewable energy sources is creating the foundation to successfully transform the German energy sector (the so-called ‘Energiewende’). A by-product of this development is the corresponding capacity demand for the transportation, distribution and storage of energy. Hydrogen produced by electrolysis offers a promising solution to these challenges, although the willingness to invest in hydrogen technologies requires the identification of competitive and climate-friendly pathways in the long run. Therefore, this paper employs a pathway analysis to investigate the use of renewable hydrogen in the German passenger car transportation sector in terms of varying market penetration scenarios for fuel cell-electric vehicles (FCEVs). The investigation focuses on how an H₂ infrastructure can be designed on a national scale with various supply chain networks to establish robust pathways and important technologies, which has not yet been done. Therefore, the study includes all related aspects, from hydrogen production to fueling stations, for a given FCEV market penetration scenario, as well as the CO₂ reduction potential that can be achieved for the transport sector. A total of four scenarios are considered, estimating an FCEV market share of 1–75% by the year 2050. This corresponds to an annual production of 0.02–2.88 million tons of hydrogen. The findings show that the most cost-efficient H₂ supply (well-to-tank: 6.7–7.5 €/kg_H2) can be achieved in high demand scenarios (FCEV market shares of 30% and 75%) through a combination of cavern storage and pipeline transport. For low-demand scenarios, however, technology pathways involving LH₂ and LOHC truck transport represent the most cost-efficient options (well-to-tank: 8.2–11.4 €/kg_H2).     

Economic perspective of PV electricity in Oman

Solar and wind energies are likely to play an important role in the future energy generation in Oman. This paper utilizes average daily global solar radiation and sunshine duration data of 25 locations in Oman to study the economic prospects of solar energy. The study considers a solar PV power plant of 5-MW at each of the 25 locations. The global solar radiation varies between slightly greater than 4 kWh/m²/day at Sur to about 6 kWh/m²/day at Marmul while the average value in the 25 locations is more than 5 kWh/m²/day. The results show that the renewable energy produced each year from the PV power plant varies between 9000 MWh at Marmul and 6200 MWh at Sur while the mean value is 7700 MWh of all the 25 locations. The capacity factor of PV plant varies between 20% and 14% and the cost of electricity varies between 210 US$/MWh and 304 US$/MWh for the best location to the least attractive location, respectively. The study has also found that the PV energy at the best location is competitive with diesel generation without including the externality costs of diesel. Renewable energy support policies that can be implemented in Oman are also discussed.     

An integrated quantitative-qualitative study to monitor the utilization and assess the perception of hydrogen fueling stations

Zero-emission vehicle (ZEV) adoption is one of the critical solutions to decarbonize the transportation sector. Among the ZEV fleet in the US, battery electric vehicles (BEV) have been leading the market penetration. However, hydrogen fuel cell electric vehicles (FCEV) have also been increasingly adopted in recent years. Although both technologies have challenges with infrastructure, unlike BEVs that have multiple venues for charging (home, work or public), FCEVs rely solely on fueling at public hydrogen stations, and their availability is a significant factor before the vehicle purchase. Therefore, for the success of FCEV adoption, a need to monitor and understand the driver satisfaction of these stations is extremely critical. This research project introduces a quantitative-qualitative approach for continuous monitoring of hydrogen stations based on the station utilization patterns and to assess their preferability based on driver experiences. To illustrate a proof-of-concept, we collected the hourly utilization data of all the hydrogen fueling stations in California for three months. The time-series data was used to develop a capacity-independent term called “Normalized Relative Utilization Index” (NRUI) that encapsulates the utilization pattern of each station to a single metric. We spatially regressed this metric over the number of FCEVs present in the neighborhood to deduce the relationship. We designed a survey to obtain the refueling experiences of FCEV drivers, where about 100 participants responded with their station preferences. Their answers were used to validate the quantitative approach and identify a “Satisfactory Utilization Range” (SUR) of stations which are preferred by most drivers. Though this project illustrates the analysis of data collected over a small period, this approach is easily scalable with new station installations and can be implemented as a continuous monitoring system with real-time station utilization data. We believe this demand-focused approach could complement the existing supply-side monitoring methods on station performance to provide a smoother fueling experience to drivers. We are also releasing the hourly station capacity dataset that was collected as a part of this study to the research community.     

Technico-economic analysis of off grid solar PV/Fuel cell energy system for residential community in desert region

A technico-economic analysis based on integrated modeling, simulation, and optimization approach is used in this study to design an off grid hybrid solar PV/Fuel Cell power system. The main objective is to optimize the design and develop dispatch control strategies of the standalone hybrid renewable power system to meet the desired electric load of a residential community located in a desert region. The effects of temperature and dust accumulation on the solar PV panels on the design and performance of the hybrid power system in a desert region is investigated. The goal of the proposed off-grid hybrid renewable energy system is to increase the penetration of renewable energy in the energy mix, reduce the greenhouse gas emissions from fossil fuel combustion, and lower the cost of energy from the power systems. Simulation, modeling, optimization and dispatch control strategies were used in this study to determine the performance and the cost of the proposed hybrid renewable power system. The simulation results show that the distributed power generation using solar PV and Fuel Cell energy systems integrated with an electrolyzer for hydrogen production and using cycle charging dispatch control strategy (the fuel cell will operate to meet the AC primary load and the surplus of electrical power is used to run the electrolyzer) offers the best performance. The hybrid power system was designed to meet the energy demand of 4500 kWh/day of the residential community (150 houses). The total power production from the distributed hybrid energy system was 52% from the solar PV, and 48% from the fuel cell. From the total electricity generated from the photovoltaic hydrogen fuel cell hybrid system, 80.70% is used to meet all the AC load of the residential community with negligible unmet AC primary load (0.08%), 14.08% is the input DC power for the electrolyzer for hydrogen production, 3.30% are the losses in the DC/AC inverter, and 1.84% is the excess power (dumped energy). The proposed off-grid hybrid renewable power system has 40.2% renewable fraction, is economically viable with a levelized cost of energy of 145 $/MWh and is environmentally friendly (zero carbon dioxide emissions during the electricity generation from the solar PV and Fuel Cell hybrid power system).     

Predicting efficiency of solar powered hydrogen generation using photovoltaic-electrolysis devices

Hydrogen fuel for fuel cell vehicles can be produced by using solar electric energy from photovoltaic (PV) modules for the electrolysis of water without emitting carbon dioxide or requiring fossil fuels. In the past, this renewable means of hydrogen production has suffered from low efficiency (2–6%), which increased the area of the PV array required and therefore, the cost of generating hydrogen. A comprehensive mathematical model was developed that can predict the efficiency of a PV-electrolyzer combination based on operating parameters including voltage, current, temperature, and gas output pressure. This model has been used to design optimized PV-electrolyzer systems with maximum solar energy to hydrogen efficiency. In this research, the electrical efficiency of the PV-electrolysis system was increased by matching the maximum power output and voltage of the photovoltaics to the operating voltage of a proton exchange membrane (PEM) electrolyzer, and optimizing the effects of electrolyzer operating current, and temperature. The operating temperature of the PV modules was also an important factor studied in this research to increase efficiency. The optimized PV-electrolysis system increased the hydrogen generation efficiency to 12.4% for a solar powered PV-PEM electrolyzer that could supply enough hydrogen to operate a fuel cell vehicle.     

Stand-alone PEM water electrolysis system for fail safe operation with a renewable energy source

A complete stand-alone electrolyser system has been constructed as a transportable unit for demonstration of a sustainable energy facility based on hydrogen and a renewable energy source. The stand-alone unit is designed to support a polymer electrolyte membrane (PEM) stack operating at up to ∼4 kW input power with a stack efficiency of about 80% based on HHV of hydrogen. It is self-pressurizing and intended for operation initially at a differential pressure of less than 6 bar across the membrane electrode assembly with the hydrogen generation side being at a higher pressure. With a slightly smaller stack, the system has been operated at an off-site facility where it was directly coupled to a 2.4 kW photovoltaic (PV) solar array. Because of its potential use in remote areas, the balance-of-plant operates entirely on 12 V DC power for all monitoring, control and safety requirements. It utilises a separate high-current supply as the main electrolyser input, typically 30–40 V at 100 A from a renewable source such as solar PV or wind. The system has multiple levels of built-in operator and stack safety redundancy. Control and safety systems monitor all flows, levels and temperatures of significance. All fault conditions are failsafe and are duplicated, triggering latching relays which shut the system down. Process indicators monitor several key variables and allow operating limits to be easily adjusted in response to experience of system performance gained in the field.     

Design of a hydrogen community

This paper discusses the conceptual design of a scalable and reproducible hydrogen fueling station at Santa Monica, California. Hydrogen production using renewable energy sources such as biogas, which accounts for 100% of the total production, has been discussed. The fueling station consists of a direct fuel cell (DFC) 300 fuel cell for on-site generation of 136 kg/day of hydrogen and 300 kW of electric power, five hydrogen storage tanks (storage capacity of 198 kg of H₂ at 350 and 700 bar), four compressors which assist in dispensing 400 kg of hydrogen in 14 h, two hydrogen dispensers operating at 350 bar and 700 bar independently and a SAE J2600 compliant hydrogen nozzle. Potential early market customers for hydrogen fuel cells and their daily fuel requirements have been computed. The safety codes, potential failure modes and the methods to mitigate risks have been explained. A well-to-wheel analysis is performed to compare the emissions and the total energy requirements of conventional gasoline and fuel cell vehicles.     

Solar powered residential hydrogen fueling station

This paper presents a conceptual design of a solar powered hydrogen fueling station for a single family home in Wallingford, Connecticut, USA. Sixty high-efficiency monocrystalline silicon photovoltaic (PV) solar panels (Total capacity: 18.9 kW) account for approximately 94.7% of the hydrogen home’s power consumption. The fueling station consists of a 165 bar high pressure electrolyzer for on-site production of 2.24 kg/day of hydrogen, three-bank cascade configuration storage tanks (4.26 kg of H₂ at 350 bar) and a SAE J2600 compliant hydrogen nozzle. The system produces 0.8 kg/day of hydrogen for a fuel cell vehicle with an average commute of 56 km/day (Fuel mileage: 71 km/kg H₂). Safety codes and standards applicable at the facility are described, and a well-to-wheel analysis is performed to contrast the carbon dioxide emissions of conventional gasoline and fuel cell vehicles. The energy efficiency obtained by incorporating a solar-hydrogen system for residential applications is also computed.     

Solar and wind energy in Poland as power sources for electrolysis process - A review of studies and experimental methodology

The production of hydrogen is still a major challenge, due to the high costs and often also environmental burdens it generates. It is possible to produce hydrogen in emission-free way: e.g. using a process of electrolysis powered by renewable energy. The paper presents the concept of a research, experimental stand for the storage of renewable energy in the form of hydrogen chemical energy with the measurement methodology. The research involves the use of proton exchange membrane electrolysis technology, which is characterized by high efficiency and flexibility of energy extraction for the process of electrolysis from renewable sources. The system consist of PV panel, PEM electrolyzer, battery, programmable logic controller system and optional a wind turbine. Preliminary experimental tests results have shown that the electrolyzer can produce in average 158.1 cc/min of hydrogen with the average efficiency 69.87%.     

Successful pathway for locally driven fuel cell electric vehicle adoption: Early evidence from South Korea

South Korea is an outstanding pioneer of fuel cell electric vehicle (FCEV) technology, an industry that is fundamental to the hydrogen ecosystem. This study aims to explore possible pathways for the successful adoption of FCEV in the local region. By using the fuzzy-set quality comparative analysis (fs/QCA) method, we identify three auspicious pathways based on the 16 regional cases in Korea. We find that, first, a large number of hydrogen (H₂) stations will lead to successful FCEV adoption (H₂ STATION→FCEV). Second, the combination of high levels of greenhouse gases(GHGs) and the local government-driven future construction plans of H₂ stations can also be a remarkable pathway (GHGs1 PLAN→FCEV). Lastly, a combination of high levels of GHGs and subsidies can be another compelling pathway (GHGs1 SUBSIDIES→FCEV). This study provides early evidence of FCEVs adoption and can be of use to latecomer countries to the hydrogen economy.     

Tube-trailer consolidation strategy for reducing hydrogen refueling station costs

The rollout of hydrogen fuel cell electric vehicles (FCEVs) requires the initial deployment of an adequate network of hydrogen refueling stations (HRSs). Such deployment has proven to be challenging because of the high initial capital investment, the risk associated with such an investment, and the underutilization of HRSs in early FCEV markets. Because the compression system at an HRS represents about half of the station's initial capital cost, novel concepts that would reduce the cost of compression are needed. Argonne National Laboratory with support from the U.S. Department of Energy's (DOE) Fuel Cell Technologies Office (FCTO) has evaluated the potential for delivering hydrogen in high-pressure tube-trailers as a way of reducing HRS compression and capital costs. This paper describes a consolidation strategy for a high-pressure (250-bar) tube-trailer capable of reducing the compression cost at an HRS by about 60% and the station's initial capital investment by about 40%. The consolidation of tube-trailers at pressures higher than 250 bar (e.g., 500 bar) can offer even greater HRS cost-reduction benefits. For a typical hourly fueling-demand profile and for a given compression capacity, consolidating hydrogen within the pressure vessels of a tube-trailer can triple the station's capacity for fueling FCEVs. The high-pressure tube-trailer consolidation concept could play a major role in enabling the early, widespread deployment of HRSs because it lowers the required HRS capital investment and distributes the investment risk among the market segments of hydrogen production, delivery, and refueling.     

Willingness to pay for hydrogen fuel cell electric vehicles in China: A choice experiment analysis

The hydrogen energy is considered to be main power source of transport sector in the future, and a huge amount of funds have been invested into developing hydrogen fuel cell electric vehicles (FCEVs). Since FCEVs are in initial development stage and there're few FCEVs on the road, before their expansion this paper intends to conduct an economic analysis for FCEVs by using the choice experiment method. In the choice experiment, 1072 participants were required to select among two FCEVs and one conventional fuel vehicle. Logit models were estimated and then the results were used to calculate the willingness to pay for FCEVs. Results showed that purchase price, driving range, refueling time, fuel cost, emissions reduction, refueling accessibility are significant influences, and the marginal values for every 200 km improvement in driving range, 5 min reduction in refueling time, RMB 0.5/kilometer reduction in fuel cost, 20% reduction in emissions, and 20% improvement of refueling accessibility were estimated to be RMB 49,091, 12,727, 3818, 47,818, and 12,909, respectively. A range of FCEV configurations were calculated, and compared to a gasoline-powered counterpart the extra value that customers were likely to pay for a FCEV ranged from RMB 20,810 to 95,310. These results have significant implications for promoting FCEVs and contribute to better sustainability in transport sector.     

Techno-economical evaluation of a hydrogen refuelling station powered by Wind-PV hybrid power system: A case study for İzmir-Çeşme

Hydrogen fuelling station is an infrastructure for the commercialisation of hydrogen energy utilising fuel cells, particularly, in the automotive sector. Hydrogen fuel produced by renewable sources such as the solar and wind energy can be an alternative fuel to depress the use of fuels based on fossil sources in the transport sector for sustainable clean energy strategy in future. By replacing the primary fuel with hydrogen fuel produced using renewable sources in road transport sector, environmental benefits can be achieved. In the present study, techno-economic analysis of hydrogen refuelling station powered by wind-photovoltaics (PV) hybrid power system to be installed in ?zmir-Çe?me, Turkey is performed. This analysis is carried out to a design of hydrogen refuelling station which is refuelling 25 fuel cell electric vehicles on a daily basis using hybrid optimisation model for electric renewable (HOMER) software. In this study, National Aeronautics and Space Administration (NASA) surface meteorology and solar energy database were used. Therefore, the average wind speed during the year was assessed to be 5.72 m/s and the annual average solar irradiation was used to be 5.08 kW h/m²/day for the considered site. According to optimisation results obtained for the proposed configuration, the levelised cost of hydrogen production was found to be US $7.526–7.866/kg in different system configurations. These results show that hydrogen refuelling station powered by renewable energy is economically appropriate for the considered site. It is expected that this study is the pre-feasibility study and obtained results encougare the hydrogen refuelling station to be established in Turkey by inventors or public institutions.     

The dynamic modeling and the exergy assessment of hydrogen synthesize and storage system with the power-to-gas concept for various locations

In this article, the solar hydrogen storage is modeled and hourly investigated with TRNSYS software. The Photovoltaic (PV) panel is employed for green power generation that is consumed in the electrolyzer subsystem and produced hydrogen. Additionally, the required electricity at the lack of enough solar irradiation is supplied from the grid. The performance of the system is comparatively analyzed for three main cities. Results show that the maximum power generation by PV panel is about 1670 kW in June which approximately is the same for two cities. The energy and Faraday efficiency of electrolyzer changes between 0.85-0.89 and 0.89–0.92 respectively. The amount of hydrogen production reaches 1235 m³/h for one of them in May. The total amount of hydrogen production is 13,181 m³/year in Yazd, 13,143 m³/year in hot city, and 13,141 m³/year in most populated city.     

Performance investigation of hydrogen production from a hybrid wind-PV system

In this study, a hybrid system consisted of 10 kW wind and 1 kWp PV array is built to meet the load demand of a raise chucker partridge raising facility by renewable energy sources. The facility has an average energy consumption of about 20.33 kWh/day, with a peak demand of 2.4 kW. The solar radiation data and wind data of the region are analyzed for sizing of the renewable energy system. The performance of each alternative system is examined in terms of energy efficiency, and H₂ production capacity of the hybrid system from due to excessive electrical energy is studied. A Matlab-Simulink Software is used for analyzing the system performance. The average range of state of charge varies between 56.6% and 88.3% monthly from April to July. The amount of hydrogen production by excess electricity is 14.4 kg in the month of July, due to the high wind speed and solar radiation. Energy efficiency of the electrolyser is found to be varying between 64% and 70% percent. Energy efficiency of each hybrid system is calculated. The overall energy efficiency of wind-electrolyser system varies between 5% and 14% while the energy efficiency of PV-electrolyser system changes within a narrower range, as between 7.9% to and 8.5%, respectively.     

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.