Techno-Economic Optimization of Hydrogen Refueling Stations for a Vehicle Fleet

In collaboration with industry partners, the Fraunhofer Institute for Solar Energy Systems ISE investigated the technically and economically optimal design of hydrogen production plants for supplying mobility applications – ranging from PEM electrolysis to buffer batteries, refueling a fleet of commercial vehicles, and trailer filling – as part of the “H₂FleetOptimization” project. The added value for the industry: well-informed design and investment decisions for a reliable and cost-efficient supply of H₂-vehicle fleets.

Initial Situation

The market ramp-up of hydrogen-powered commercial vehicles places high demands on a demand-responsive hydrogen production, storage, and refueling infrastructure. Particularly in fleet applications within the commercial vehicle sector, a fluctuating electricity supply from renewable energy sources used for hydrogen production often clashes with temporary spikes in hydrogen demand. At the same time, stack degradation, different pressure levels at the dispenser (380/500 bar), and the optimal integration of PV or grid power significantly influence economic viability. We offer comprehensive analyses that map operation, aging, and energy system integration over long periods of time.

Objective

The goal of the project was to develop optimized plant designs for hydrogen production and supply to power a fleet of H₂-powered commercial vehicles. Various scenarios involving PV power and grid electricity were evaluated from a technical and economic perspective. In addition, stationary battery systems for buffering power generation, control strategies, and the aging of PEM stacks over a 15-year period were taken into account to enable reliable conclusions regarding costs, efficiency, and service life.

Approach

The Fraunhofer ISE conducted a model-based analysis and simulation of various hydrogen plant scenarios, including trailer refueling at 380 or 500 bar and the refueling of a municipal commercial vehicle fleet. The study examined different types of buffer batteries and operational concepts in combination with PEM electrolysis. A time-resolved aging simulation modeled stack degradation over a period of 15 years and enabled the evaluation of system lifespan under realistic operating conditions. The integrated techno-economic assessment linked technical performance indicators with cost parameters to derive optimal and long-lasting system configurations.

Results

A wide range of plant scenarios were dynamically simulated, and their respective economic viability was assessed. Based on this, optimal plant designs were identified, taking into account the specific conditions and assumptions.

Specific results cannot be published due to confidentiality.