Designing of Onsite H2 Generation and Public Refueling Station with microgrid in central Valley, CA

Design of Onsite Green Hydrogen Generation and Public Refueling Hydrogen Station with support of DERs in San Joaquin Valley, California.

The white paper aim of achieving sustainable and environmentally friendly public transportation, this research delves into the challenges and opportunities associated with designing and sizing of on-site hydrogen generation and refueling station for transit agencies in pursuit of electrification goals. Hydrogen fuel cell buses offer a viable solution for transit agencies operating in challenging geographic locations and have longer routes where battery electric buses face many limitations.  

However, designing on-site hydrogen generation infrastructure is a critical consideration that involves accurately determining station sizing and daily hydrogen requirements. This study aims to address these challenges by providing insights into the design and cost considerations of on-site hydrogen generation. The design focuses on where on-site generation becomes an economically viable solution compared to delivery, focusing on integrating distributed energy resources (DER) such as microgrid and energy storage unit. The study encompasses the design and development of on-site hydrogen generation supporting public refueling infrastructure for hydrogen fuel cell buses and other light, medium, and heavy-duty vehicles in San Joaquin Valley, California.

CALSTART conducted a techno-economic feasibility study to evaluate a multi-facing hydrogen refueling station with a daily hydrogen demand of ranging from 900 to 1,500 kg/day, considering transit fleet size, local traffic patterns, and the needs of light and heavy-duty vehicles stations in the Bakersfield area. Based on these demands, CALSTART initiated the design process for a public facing refueling station capable of servicing both vehicle types. This study thoroughly examines the production of green hydrogen via electrolysis and provides insight into how to maximize its benefits and incentives. It also analyzes the costs involved in meeting current and future demand by considering two different utility rate structures to determine the operating costs of the generation and refueling station. Moreover, the study helps in determine the levelized cost of hydrogen (LCOH) with integration of DER to provide resilience and continued operation during any outage event as the ZEVs technologies reliant on grid electricity, as grid power is used directly as fuel to run these buses or to generate the onsite hydrogen. As a result, it is vital that the transit system maintains access to an uninterrupted electricity supply to run these ZEBs. This is especially crucial for transit agencies that face economic risks when reliant on grid electricity, which is increasingly susceptible to outages caused by wildfires.

Based on the findings and results, it is concluded that on-site generation has become more economically viable solution compared to on-site delivery solutions for higher daily dispensing rate. In summary, this study presents a comprehensive approach to sizing hydrogen infrastructure for any public transit agency, considering specific fleet demands.