MW‐Scale Hydrogen Electrolysis Plant Design and Optimization Tool Considering Economic and Safety Criteria: Case Study of an Industrial Heating Furnace

ABSTRACT Low‐temperature water electrolysis technologies exhibit a significant potential not only to replace grey hydrogen use in existing chemical industries but also to decarbonize hard‐to‐abate sectors. The main objective of this work is to assess the techno‐economic viability of using an MW‐scale electrolysis‐based green hydrogen plant as a supplier for an industrial heating furnace. HYTECSIM simulation tool is employed to physically model alternative plant configurations and to estimate both onsite footprint and economic metrics, including the levelized cost of hydrogen (LCOH). Consumption measurements from an internal zone of an ingot heating rotary furnace are used as demand profiles in the simulations. Under these premises, three plant configurations are sized and simulated in order to quantify the capital expenditures (CAPEX), footprint, electrolyzer performance, and operational expenditures (OPEX) and to evaluate their combined impact on the LCOH. Results reveal that extending the electrolyzer's stack lifespan by optimizing its operation has great potential to achieve competitive LCOH values.