State-of-the-art of commercial electrolyzers and on-site hydrogen generation for logistic vehicles in South Carolina

The majority of the world's hydrogen production is produced in large central Steam Methane Reforming (SMR) plants. In decentralized applications with smaller hydrogen demands such as fuel cell powered logistic vehicles (FCLVs), large electrolyzers can be a cost-competitive alternative to the H₂ delivery from central SMR plants. In this study, the state-of-the-art of commercial electrolyzers has been analyzed based on 16 quotes for commercial systems with electric power inputs between 0.35 and 3.35 MW. Alkaline and PEM electrolyzers were examined regarding economies of scale, H₂ cost structure and capacity utilization based on a 15-year investment in the United States. All overhead costs were taken into account to ensure the transferability to future projects. Since there is little research on the on-site hydrogen generation for FCLVs, this topic was investigated at the example of the BMW Manufacturing Co. plant in South Carolina where 350 FCLVs are in use. The results reveal that alkaline electrolyzers with capacities above 25 kg/h are particularly cost-efficient and produce H₂ at 4.96-5.78 $/kg. It was also found that the capacity utilization plays only a subordinate role for large electrolyzers since three-quarter of the H₂ generation costs are electricity costs and hence variable costs. Conclusively the results show, that the FCLV fleet in South Carolina could be supplied at 5.1-7.5 $/kg-H₂ by electrolysis compared to 5-8 $/kg-H₂ for liquid hydrogen delivered from a central SMR plant.