Techno-economic and environmental analysis of Cu–Cl cycle for hydrogen production in hybrid refuelling stations: A case study of Highway 401, Canada

The significant environmental impact of carbon dioxide emissions in the energy sector, especially from transportation, calls for exploring alternative energy carriers to reduce these emissions. Promoting hydrogen as an eco-friendly energy vector can significantly lower greenhouse gas emissions from heavy-duty vehicles. Assessing hydrogen production infrastructure is therefore critical. This research evaluates a network of pilot refuelling stations for heavy-duty applications along Highway 401, a key trade route in Canada. A feasibility analysis combines thermodynamic assessment and cost estimation of the 4-step Cu–Cl cycle, addressing a key gap in its techno-economic study. The integrated energy system proposed utilizes solar panels, the grid, wind turbines, and industrial waste heat to produce hydrogen via the Cu–Cl cycle. The findings reveal the substantial impact of location on the optimal solution configuration, emphasizing the importance of considering local weather data. Employing an optimization algorithm, the best hybrid energy system is composed of 1891 kW PV arrays, 3822 kW WTs, 13.22 kgH 2 /hour, a 220 kg H 2 tank, and 1064 kW CNV with a renewable fraction of 98% in Windsor, Ontario. The levelized cost of hydrogen for Windsor, Toronto, Kingston, and Cornwall are $2.78/kgH 2 , $2.79/kgH 2 , $3.25/kgH 2, and $3.22/kgH 2 , respectively. Additionally, a comprehensive sensitivity analysis explores the effects of energy market fluctuations, fleet size variations, and greenhouse gas emissions on key economic and environmental parameters. The levelized cost of hydrogen decreases significantly from $12.48 for a 10-truck fleet size to $1.56 for a 100-truck fleet size. This research contributes to fostering synergies between the transportation sector and electricity networks, advancing the transition towards a net-zero energy future. • A techno-economic feasibility study on a network of pilot H 2 refuelling infrastructure to serve heavy-duty transportation across Highway 401. • The optimal energy solution is influenced by climate conditions. • 1891 kW PV, 3822 kW WT, 13.22 kgH 2 /hour Cu–Cl unit, and 1064 kW CNV as the optimal system. • The lowest NPC and pertaining LCOH are $7.3 M $2.78/kg for Windsor, Ontario. • The optimal solution emits only about 100 tonnes of CO 2 over the project lifespan.