Techno-Economic and Life Cycle Assessment for a Hydrogen Production System Using Renewable Energy

Abstract

: Distributed hydrogen production has garnered significant attention due to its potential to reduce transportation costs and utilize local renewable energy sources. This study develops a comprehensive life cycle assessment (LCA) and techno-economic analysis framework for distributed hydrogen production based on a 100 MW alkaline water electrolysis system modeled in Aspen Plus. The process simulation provides detailed mass and energy balances to quantify the system’s performance across three key dimensions: environmental, economic, and energy. Environmentally, when powered by photovoltaic electricity, the system achieves a total life cycle carbon footprint of 1.94 kg CO 2 eq/kg H 2 , with approximately 91% of emissions originating from the electrolyzer’s power consumption. Economically, the levelized cost of hydrogen (LCOH) is calculated at 25.403 CNY/kg, placing the system competitively within current green hydrogen estimates, though it remains above traditional fossil-based routes. Energetically, the system exhibits an overall energy efficiency of 56.57% and an exergy efficiency of 55.61%, revealing that system irreversibility (exergy destruction) is predominantly concentrated within the electrolyzer unit. Sensitivity analysis indicates that annual operating hours (capacity factor) and renewable power carbon intensity (electricity prices) are the most critical drivers for economic viability. Therefore, securing low-carbon, low-price renewable electricity and extending operational hours are essential to enhancing the competitiveness of distributed hydrogen production.