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Fuel cell vehicles using green hydrogen as fuel can contribute to the mitigation of climate change. The increasing utilization of those vehicles creates the need for cost efficient hydrogen refueling stations. This study investigates how to build the most cost efficient refueling stations to fuel small fleet sizes of 2, 4, 8, 16 and 32 fuel cell busses. A detailed physical model of a hydrogen refueling station was built to determine the necessary hydrogen storage size as well as energy demand for compression and precooling of hydrogen. These results are used to determine the refueling costs for different station configurations that vary the number of storage banks, their volume and compressor capacity. It was found that increasing the number of storage banks will decrease the necessary total station storage volume as well as energy demand for compression and precooling. However, the benefit of adding storage banks decreases with each additional bank. Hence the cost for piping and instrumentation to add banks starts to outweigh the benefits when too many banks are used. Investigating the influence of the compressor mass flow found that when fueling fleets of 2 or 4 busses the lowest cost can be reached by using a compressor with the minimal mass flow necessary to refill all storage banks within 24 h. For fleets of 8, 16 and 32 busses, using the compressor with the maximum investigated mass flow of 54 kg/h leads to the lowest costs. • Designing the most cost efficient refueling stations to fuel small bus fleets. • New approach to minimize hydrogen fueling costs using a thermodynamic refueling model. • It is cost efficient to use a minimum of 4 cascade storage banks when fueling busses. • A high mass flow compressor is cost efficient for fleet sizes above 4 busses. • Energy demand for compression makes up a significant share of refueling costs. [ABSTRACT FROM AUTHOR]

Abstract: The aim of this study is to examine how the options for producing electricity, fuels, and heat in a carbon-constrained world affect the cost-effectiveness of a range of fuels and propulsion technologies in the transportation sector. GET 7.0, a global energy system model with five end-use sectors, is used for the analysis. We find that an energy system dominated either by solar or by nuclear tends to make biofuels in plug-in hybrids cost-effective. If coal with carbon capture and storage (CCS) dominates the energy system, hydrogen cars, rather than plug-in hybrids tend to become cost-effective. Performing a Monte Carlo simulation, we then show that the general features of our results hold for a wide range of assumptions for the costs of vehicle propulsion technologies (e.g., batteries and fuel cells). However, sufficiently large changes in say the battery costs may overturn the impact of changes in the energy supply system, so that plug-in hybrid vehicles become cost-effective even if coal with CCS dominate the energy supply. We conclude that analyses of future energy carriers and propulsion technologies need to consider developments in the energy supply system. [Copyright &y& Elsevier]