Evaluating national hydrogen refueling infrastructure requirement and economic competitiveness of fuel cell electric long-haul trucks

This study explored the national hydrogen refueling infrastructure requirement along major United States (US) interstate highway corridors to support the deployment of fuel cell electric trucks (FCETs) for the national long-haul trucking fleet. Given the long-haul trucking shipment demand in 2025 projected by the Freight Analysis Framework, locations and capacities of hydrogen stations were identified for inter-zone freight flows, and the total daily refueling demand was estimated for intra-zone flows for each FAF zone. Based on the infrastructure deployment results, we conducted an economic feasibility analysis of FCETs by evaluating the total ownership cost. We found that when the FCET penetration is relatively high (e.g., 10% penetration), FCETs become more competitive in terms of fuel cost and idling cost and could be economic viable if the incremental vehicle cost is reduced to meet the near-term FCET technology cost targets and the liquefaction cost is reduced to an optimal case. We also observed that the station cost depends on regional factors, particularly regional demand, which is used to determine station capacity. Thus, one possible strategy for station roll-out is to have early investment in target regions where station costs are expected to be relatively low such as the Pacific and West South Central regions.