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Title: Manufacturing competitiveness analysis for hydrogen refueling stations

Abstract

Fuel cell electric vehicles (FCEVs) have now entered the market as zero-emission vehicles. Original equipment manufacturers such as Toyota, Honda, and Hyundai have released commercial cars in parallel with efforts focusing on the development of hydrogen refueling infrastructure to support new FCEV fleets. Persistent challenges for FCEVs include high initial vehicle cost and the availability of hydrogen stations to support FCEV fleets. This study sheds light on the factors that drive manufacturing competitiveness of the principal systems in hydrogen refueling stations, including compressors, storage tanks, precoolers, and dispensers. To explore major cost drivers and investigate possible cost reduction areas, bottom-up manufacturing cost models were developed for these systems. Results from these manufacturing cost models show there is substantial room for cost reductions through economies of scale, as fixed costs can be spread over more units. Results also show that purchasing larger quantities of commodity and purchased parts can drive significant cost reductions. Intuitively, these cost reductions will be reflected in lower hydrogen fuel prices. A simple cost analysis shows there is some room for cost reduction in the manufacturing cost of the hydrogen refueling station systems, which could reach 35% or more when achieving production rates of more than 100more » units per year. In conclusion, we estimated the potential cost reduction in hydrogen compression, storage and dispensing as a result of capital cost reduction to reach 5% or more when hydrogen refueling station systems are produced at scale.« less

Authors:
 [1]; ORCiD logo [1]
  1. National Renewable Energy Lab. (NREL), Golden, CO (United States)
Publication Date:
Research Org.:
National Renewable Energy Lab. (NREL), Golden, CO (United States)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE), Fuel Cell Technologies Office (EE-3F)
OSTI Identifier:
1504217
Alternate Identifier(s):
OSTI ID: 1529167
Report Number(s):
NREL/JA-6A20-67700
Journal ID: ISSN 0360-3199
Grant/Contract Number:  
AC36-08GO28308
Resource Type:
Journal Article: Accepted Manuscript
Journal Name:
International Journal of Hydrogen Energy
Additional Journal Information:
Journal Volume: 44; Journal Issue: 18; Journal ID: ISSN 0360-3199
Publisher:
Elsevier
Country of Publication:
United States
Language:
English
Subject:
08 HYDROGEN; fuel cell electric vehicles; (FCEV); hydrogen; hydrogen station; manufacturing

Citation Formats

Mayyas, Ahmad T., and Mann, Margaret K. Manufacturing competitiveness analysis for hydrogen refueling stations. United States: N. p., 2019. Web. doi:10.1016/j.ijhydene.2019.02.135.
Mayyas, Ahmad T., & Mann, Margaret K. Manufacturing competitiveness analysis for hydrogen refueling stations. United States. doi:10.1016/j.ijhydene.2019.02.135.
Mayyas, Ahmad T., and Mann, Margaret K. Fri . "Manufacturing competitiveness analysis for hydrogen refueling stations". United States. doi:10.1016/j.ijhydene.2019.02.135.
@article{osti_1504217,
title = {Manufacturing competitiveness analysis for hydrogen refueling stations},
author = {Mayyas, Ahmad T. and Mann, Margaret K.},
abstractNote = {Fuel cell electric vehicles (FCEVs) have now entered the market as zero-emission vehicles. Original equipment manufacturers such as Toyota, Honda, and Hyundai have released commercial cars in parallel with efforts focusing on the development of hydrogen refueling infrastructure to support new FCEV fleets. Persistent challenges for FCEVs include high initial vehicle cost and the availability of hydrogen stations to support FCEV fleets. This study sheds light on the factors that drive manufacturing competitiveness of the principal systems in hydrogen refueling stations, including compressors, storage tanks, precoolers, and dispensers. To explore major cost drivers and investigate possible cost reduction areas, bottom-up manufacturing cost models were developed for these systems. Results from these manufacturing cost models show there is substantial room for cost reductions through economies of scale, as fixed costs can be spread over more units. Results also show that purchasing larger quantities of commodity and purchased parts can drive significant cost reductions. Intuitively, these cost reductions will be reflected in lower hydrogen fuel prices. A simple cost analysis shows there is some room for cost reduction in the manufacturing cost of the hydrogen refueling station systems, which could reach 35% or more when achieving production rates of more than 100 units per year. In conclusion, we estimated the potential cost reduction in hydrogen compression, storage and dispensing as a result of capital cost reduction to reach 5% or more when hydrogen refueling station systems are produced at scale.},
doi = {10.1016/j.ijhydene.2019.02.135},
journal = {International Journal of Hydrogen Energy},
issn = {0360-3199},
number = 18,
volume = 44,
place = {United States},
year = {2019},
month = {3}
}

Journal Article:
Free Publicly Available Full Text
This content will become publicly available on March 15, 2020
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