Capacity Optimization of Renewable-Based Hydrogen Production–Refueling Station for Fuel Cell Electric Vehicles: A Real-Project-Based Case Study

Yongzhe Zhang, Wenjie Zhang, Yingdong He (), Hanwen Zhang, Wenjian Chen, Chengzhi Yang and Hao Dong
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Yongzhe Zhang: School of Energy and Power Engineering, Nanjing University of Science and Technology, Nanjing 210094, China
Wenjie Zhang: School of Energy and Power Engineering, Nanjing University of Science and Technology, Nanjing 210094, China
Yingdong He: College of Civil Engineering, Hunan University, Changsha 410082, China
Hanwen Zhang: College of Civil Engineering, Hunan University, Changsha 410082, China
Wenjian Chen: College of Civil Engineering, Hunan University, Changsha 410082, China
Chengzhi Yang: College of Civil Engineering, Hunan University, Changsha 410082, China
Hao Dong: College of Civil Engineering, Hunan University, Changsha 410082, China

Sustainability, 2025, vol. 17, issue 16, 1-29

Abstract: With the deepening electrification of transportation, hydrogen fuel cell electric vehicles (FCEVs) are emerging as a vital component of clean and electrified transportation systems. Nonetheless, renewable-based hydrogen production–refueling stations (HPRSs) for FCEVs still need solid models for accurate simulations and a practical capacity optimization method for cost reduction. To address this gap, this study leverages real operation data from China’s largest HPRS to establish and validate a comprehensive model integrating hydrogen production, storage, renewables, FCEVs, and the power grid. Building on this validated model, a novel capacity optimization framework is proposed, incorporating an improved Jellyfish Search Algorithm (JSA) to minimize the initial investment cost, operating cost, and levelized cost of hydrogen (LCOH). The results demonstrate the framework’s significant innovations and effectiveness: It achieves the maximum reductions of 29.31% in the initial investment, 100% in the annual operational cost, and 44.19% in LCOH while meeting FCEV demand. Simultaneously, it reduces peak grid load by up to 43.80% and enables renewable energy to cover up to 89.30% of transportation hydrogen demand. This study contributes to enhancing economic performance and optimizing the design and planning of HPRS for FCEVs, as well as promoting sustainable transportation electrification.

Keywords: transportation electrification; fuel cells; electric vehicles; hydrogen production–refueling station; renewable hydrogen production; capacity optimization; jellyfish search algorithm; levelized cost of hydrogen; power grid (search for similar items in EconPapers)
JEL-codes: O13 Q Q0 Q2 Q3 Q5 Q56 (search for similar items in EconPapers)
Date: 2025
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