Strategic optimization of large-scale solar PV parks with PEM Electrolyzer-based hydrogen production, storage, and transportation to minimize hydrogen delivery costs to cities

This research presents a single-line optimization framework for large-scale, site-to-consumption green hydrogen production, integrating solar photovoltaic parks with proton exchange membrane (PEM) electrolyzers, storage, and transportation systems to minimize hydrogen delivery costs to urban cities. The proposed solar-to-green hydrogen system features photovoltaic (PV) panels generating electricity for the PEM electrolyzer and flat plate collectors (FPC) providing preheated water to the PEM. Storage options include a compressor with a storage tank, and delivery is facilitated by trucks transporting hydrogen to end-users. By analyzing power consumption for hydrogen production and compression to meet a daily target of 1000 kg, this research identifies optimal locations and areas for solar PV and FPC installations in India, considering infrastructural, solar availability, and energy demand parameters. A comprehensive parametric study investigates annual variations in power consumption, hydrogen generation, and system efficiency, alongside a detailed evaluation of the total energy flow within the hydrogen production facility. Additionally, an optimization study minimizes transportation costs by assessing hydrogen demand in selected metropolitan areas, determining locations with the lowest levelized cost of hydrogen (LCOH), and analyzing cost-sharing components. Key findings include the identification of optimal design variables for the PEM system, such as higher operating temperatures, reduced membrane thickness, and minimized cell area, leading to enhanced performance metrics. The study reveals that a PEM electrolyzer requires 6.5 MW of electrical energy for hydrogen production and an additional 0.25 MW for compression at 350 bar. The proposed 4.8 MW PEM capacity system requirements include 0.08 km2 of PV area, 250 m2 of FPC area, 4456 arrays, and 11 PEM cells. Efficiency ranges for solar-to-power and solar-to‑hydrogen generation are identified as 13.3–14.8 % and 6.8–9.5 %, respectively, with LCOH for production and transportation varying between €17.48/kg and €24.33/kg, heavily influenced by storage tank costs.