In the era of climate change and increasing transportation emissions, hydrogen fuel cell vehicles (HFCVs) emerge as a promising solution to achieve decarbonization. The establishment of a comprehensive hydrogen refueling infrastructure is crucial for their successful implementation. Recent research published in 2025 provides a detailed techno-economic analysis of a hydrogen refueling station (HRS) that utilizes on-site hydrogen production through water electrolysis, along with necessary storage and dispensing systems.
The study focuses on minimizing the total annualized cost (TAC) of the hydrogen system while meeting essential mass and heat flow requirements. It points out that the hydrogen ecosystem can rely solely on electricity to power every process, including the heating of liquid organic hydrogen carriers (LOHC). This presents a significant shift towards electrification in energy solutions.
The researchers examined three distinct scenarios, allowing for an in-depth exploration of how variations among electricity sources, differences in renewable energy pricing, and distinct LOHC integrations can affect performance and costs. Remarkably, the results indicate that a grid-connected hydrogen refueling system leveraging LOHCs offers competitive production costs and a higher capacity factor compared to traditional systems.
The study indicates that N-ethylcarbazole stands out among the LOHCs studied, showcasing an effective balance between efficiency and resilience in variable conditions. As it turns out, utilizing this system in Canberra, Australia, yields hydrogen dispensation costs below A$8 per kilogram, demonstrating significant potential for scalable and cost-effective hydrogen fueling infrastructure.
Passenger vehicles contribute substantially to global carbon emissions; approximately 45.1% of road vehicle emissions stem from them. In 2021, global CO2 emissions from transport surged, elevating concern from climate activists and policymakers alike. Recognizing the need for remediation, many countries have committed to reducing emissions in line with the Paris Agreement, which further enhances the relevance of HFCVs and hydrogen refueling stations.
As of 2023, only 921 hydrogen refueling stations were operational worldwide, of which 724 are located outside of China. This shows a stark need for rapid infrastructure development to facilitate the broader adoption of HFCVs. Hydrogen production costs pose a significant barrier, primarily due to reliance on natural gas. As referenced in the study, nearly 95% of global hydrogen production comes from fossil fuel and centralized facilities, requiring transportation to end-users. This approach generates carbon emissions that undermine the eco-friendliness of hydrogen technologies.
Conversely, the emerging focus on green hydrogen presents a solution to these issues. By utilizing renewable energy sources like solar and wind for electricity, hydrogen can be produced without carbon emissions and be generated near demand centers, thus eliminating transportation needs. The analysis also notes that while renewable resources present benefits, they also introduce challenges related to their intermittent nature. This, in turn, necessitates the incorporation of effective storage solutions to maintain hydrogen supply reliability.
The authors have selected liquid organic hydrogen carriers as a preferred method for hydrogen storage due to their favorable thermodynamic properties. The LOHC process involves a catalytic reaction, wherein hydrogen bonds with a carrier material during hydrogenation and subsequently releases it in the dehydrogenation phase. This approach allows for ambient temperature storage and enhances safety and transport capabilities.
The optimisation model used in the research aimed to minimize the costs associated with HRS development by optimizing the hydrogen supply chain and integrating LOHC technology effectively. The operational analysis showcased that various electricity supply sources contributed different dynamics to the hydrogen production and storage units, and subsequent financial costs. This adaptable model is fundamental for the economic viability and scalability of hydrogen infrastructure.
In practice, the study also highlights the importance of balancing hydrogen supply and demand through effective operational scheduling that considers fluctuating energy prices and demand patterns. According to the findings, under conditions of peak hydrogen demand, the system was capable of producing 39.5 kg per hour at 5:00 p.m., although overnight low-demand hours presented challenges, adhering to a daily total of 500 kg of hydrogen.
The complexity of optimizing HRS through costs and equipment sizing influences the design choices made in the analysis. The economic considerations presented supported the selection of specific LOHC pairs and the application of modelled inputs such as electricity pricing and production forecasting.
The implications of this study suggest that optimal hydrogen refueling stations can play a crucial role in establishing a sustainable hydrogen economy. With appropriate support and infrastructure investment, LOHC technology can lead to enhanced hydrogen storage capabilities, which could foster wider adoption of HFCVs globally.
Such advancements highlight a promising future for renewable energy utilization and hydrogen applications in transportation. To successfully transition from fossil fuels and fully realize a hydrogen economy, continued research into storage technologies, operational strategies, and cost improvements is essential. By solidifying hydrogen production, storage, and distribution frameworks, nations can take meaningful steps toward reducing carbon emissions and furthering their environmental objectives.