Design and Costs Analysis of Hydrogen Refuelling Stations Based on Different Hydrogen Sources and Plant Configurations

In this study, the authors present a techno-economic assessment of on-site hydrogen refuelling stations (450 kg/day of H-2) based on different hydrogen sources and production technologies. Green ammonia, biogas, and water have been considered as hydrogen sources while cracking, autothermal reforming, and electrolysis have been selected as the hydrogen production technologies. The electric energy requirements of the hydrogen refuelling stations (HRSs) are internally satisfied using the fuel cell technology as power units for ammonia and biogas-based configurations and the PV grid-connected power plant for the water-based one. The hydrogen purification, where necessary, is performed by means of a Palladium-based membrane unit. Finally, the same hydrogen compression, storage, and distribution section are considered for all configurations. The sizing and the energy analysis of the proposed configurations have been carried out by simulation models adequately developed. Moreover, the economic feasibility has been performed by applying the life cycle cost analysis. The ammonia-based configurations are the best solutions in terms of hydrogen production energy efficiency (>71%, LHV) as well as from the economic point of view, showing a levelized cost of hydrogen (LCOH) in the range of 6.28 EUR/kg to 6.89 EUR/kg, a profitability index greater than 3.5, and a Discounted Pay Back Time less than five years.