Techno-Economic Optimization of Liquid Hydrogen Refueling Station for Heavy-Duty Transportation

Abstract

The decarbonization of heavy-duty transportation remains a critical challenge in achieving global net-zero targets due to high energy demands and limited zero-emission alternatives. Hydrogen fuel cell vehicles (FCEVs) offer a promising solution, but widespread adoption is constrained by the cost, complexity, and reliability of hydrogen refueling infrastructure. This thesis develops a techno-economic optimization framework for a fully integrated liquid hydrogen refueling station (HRS) that combines grid electricity with on-site renewable hydrogen production via PEM electrolysis liquefaction, cryogenic storage, and 700-bar dispensing. A mixed-integer linear programming (MILP) model is formulated to co-optimize equipment sizing and operational scheduling under realistic constraints, minimizing energy consumption, boil-off losses, and capital expenditure while ensuring reliable hydrogen delivery. The proposed system architecture is evaluated through detailed component modeling and optimization across two configurations: pump plus compressor and pump-only dispensing. Results indicate that a pump-only design achieves comparable throughput with 7.2% lower CAPEX and 3.1% lower energy demand, with modest venting losses. PEM electrolyzer and Liquefaction dominates energy consumption, highlighting the need for efficiency improvements. Economic analysis using discounted cash-flow methods yields a Levelized Cost of Hydrogen (LCOH) of $9.34/kg at 2 metric tons per day, aligning with DOE and NREL projections for near-term heavy-duty hydrogen infrastructure. The optimized design demonstrates high-capacity factors (>97%) and operational resilience under grid outages through strategic buffer storage management. These findings establish a pathway for cost-effective, self-sustaining hydrogen refueling hubs that reduce supply-chain dependence and enable scalable deployment for heavy-duty transportation.