Modelling, design and techno-economic comparison of electrolyzer technologies for photovoltaic-wind grid-tied hydrogen refueling infrastructure

This study presents a comprehensive techno-economic assessment of four electrolyzer (EL) technologies, Proton Exchange Membrane (PEM), Alkaline (ALK), Anion Exchange Membrane (AEM) and Solid Oxide Electrolyzer Cells (SOEC) integrated with photovoltaic and wind turbine systems for green hydrogen (H₂) production in H₂ refueling station applications. The study aims to address a critical gap in the literature concerning the limited comparative understanding of different EL technologies specifically for H₂ refueling infrastructures. To accurately capture the operational dynamics of each EL type, efficiency and performance models were derived from first-principle single-cell electrochemical models and applied for detailed techno-economic analysis. The evaluation considers capital investment, installation costs, operational expenditures, and component replacement over a 25-year investment horizon. Results indicate that the levelized cost of H₂ (LCOH) ranges from $7.2–16.8/kg, contingent on EL technology and refueling capacity. Scaling up H₂ dispensing capacity significantly reduces production costs; at a 500 kg/day refueling capacity, the LCOH was $7.2/kg, $7.6/kg, $8.7/kg, and $7.9/kg for ALK, AEM, PEM, and SOEC systems, respectively. The ALK-based system exhibited the best economic performance, achieving the lowest LCOH, shortest payback period (8.4 years), and highest return on investment (16.7 %). Additionally, a long-term sensitivity analysis was performed to assess the effect of uncertainties in EL capital cost and grid pricing, and the modeled EL performance was validated against market data to ensure accuracy and real-world viability. The findings demonstrate the economic feasibility of PV-wind hybrid-powered H₂ refueling stations and provide a practical framework for technology selection while advancing understanding of EL integration in green H₂ infrastructure.