Potential integration scenarios of low carbon intensity hydrogen in the corn ethanol biofuel value chain in the United States

This paper examines the environmental and logistical implications of incorporating low-carbon intensity hydrogen (LCIH) into the U.S. ethanol production and transportation value chain. We used geospatial analysis, Life Cycle Assessment with GREET 2023, financial analysis with H2A-Lite, and the Heavy-Duty Refueling Station Analysis Model to quantify integration trade-offs. Our findings indicate that the total refueling cost of Hydrogen fuel cell heavy-duty trucks ranges from $ 5.78 – $ 12.00 per kg of hydrogen, translating to $ 1.04 – $ 1.61 per mile distance traveled, compared to $ 0.63 for diesel trucks. emissions per mile can be reduced to 0.14 – 0.40 kg, down from 1.36 kg with diesel trucks. To facilitate early adoption, we identified 70 refueling station locations in the Midwest, prioritizing proximity to ethanol plants, bulk terminals, and highway intersections, with capital investments varying from $ 46 – $ 81 million. Stable demand for hydrogen within the ethanol value chain can drive economies of scale and advance infrastructure development. • Limited demand for hydrogen necessitates integrating it into existing value chains. • LCIH can help decarbonize the corn ethanol biofuel transportation value chain. • The total estimated hydrogen demand per refueling station ranges from 6,000–12,000 kg/day. • Hydrogen supply availability is identified for each potential station.