Cost Analysis of Heavy-Duty Vehicle Proton Exchange Membrane Fuel Cell Stationary Power Plants

Heavy-duty PEM fuel cells could be a low-cost, low emission alternative to combustion turbines for re-electrifying hydrogen if used as part of a long duration grid energy storage systems. Many studies expect heavy duty PEM fuel cell production costs to reduce as manufacturing volumes ramp up and their expected durability of 25,000-30,000 hours aligns well with a 30-year life for hydrogen seasonal energy storage plants that would likely operate less than 10% of the year. The labor, material, and equipment costs associated with installing PEM fuel cells and their required balance of plant for stationary applications have not been thoroughly explored, however. This study performs a detailed design and cost analysis of a 100 MW stationary PEM fuel cell power plant, capturing costs such as cooling, power electronics, pipes, valves, fittings, cabling, conduit, concrete foundations, buildings, and land. It employs methods consistent with NLR's solar PV benchmarking cost analysis and annual technology baseline to derive the total installed costs of stationary PEM fuel cell plants that utilize heavy duty PEM fuel cells. The anticipated total cost of building a stationary PEM fuel cell plant with today's technology is $954/kW. This cost could reduce to $567/kW - $754/kW by 2050, depending on potential cost reductions in fuel cells, inverters, and transformers. Both the estimated current cost and potential future costs are on the lower end if not less than estimated costs associated with natural gas combustion turbines, which range from $900/kW to $1,500/kW according to the EIA. Because PEM fuel cells do not produce pollutants such as NOx and SOx and can have much higher efficiencies than combustion turbines while still maintaining adequate start-up times and dynamic capabilities, this suggests that stationary PEM fuel cells could outperform combustion turbines for hydrogen long duration grid storage applications on the grounds of capital cost, operating costs, and emissions.