Prototype Development and Experimental Validation of a Modular Rooftop Solar-Driven PV–PEM Green Hydrogen System as a Natural Gas Alternative for Decarbonizing Textile Manufacturing

As the global energy transition accelerates toward low-emission and sustainable industrial energy systems, green hydrogen produced from renewable sources has emerged as a promising alternative to natural gas in energy-intensive sectors. This study presents the design, implementation, and experimental validation of a rooftop photovoltaic–proton exchange membrane (PV–PEM) hydrogen energy system developed as a proof-of-concept for textile industry applications. The proposed system integrates monocrystalline photovoltaic panels with east–west solar tracking, a 4 kW inverter, and a PEM electrolyzer with a hydrogen production capacity of 3.6 L/h, enabling on-site solar-to-hydrogen conversion. Produced hydrogen is stored in a high-pressure metal tank and utilized for downstream energy applications, demonstrating a complete renewable energy pathway. System performance is monitored in real time and evaluated using an experimental methodology supported by GUM-based and Monte Carlo uncertainty analysis. A carbon reduction assessment is conducted under representative industrial operating scenarios, including uncertainty quantification. The results indicate that the prototype system achieves an energy output corresponding to an average monthly emission reduction of approximately 222 kg CO2e. The modular and scalable architecture allows flexible expansion to support gradual natural gas substitution in textile processes such as drying, heating, and steam generation. Overall, the study demonstrates the technical feasibility and environmental potential of integrating rooftop PV–PEM hydrogen systems into textile manufacturing, providing a transferable framework for industrial decarbonization.