Comparative analysis of thermodynamic performance and economic viability of compressed and liquid hydrogen refueling stations

Compressed gaseous hydrogen refueling station (CHRS) and liquid hydrogen refueling station (LHRS) represent two principal pathways to enable large-scale hydrogen mobility; yet rigorous comparative evaluations remain scarce. This study systematically assesses thermodynamic and economic characteristics under unified design conditions at capacities of 800, 1,000, and 2000 kg/day. Results show that the LHRS achieves 47 % lower energy than the CHRS (111.6 kW reduction), owing to pump-based pressurization and reduced cooling requirements. Economic analysis indicates pronounced economies of scale; as the capacity increases, the levelized cost of hydrogen (LCOH) decreases by 41.9 % (2.42 USD/kg) for the CHRS and 51.3 % (2.82 USD/kg) for the LHRS. At 2000 kg/day, both systems achieve an LCOH below 2.1 USD/kg. The LCOH comprises hydrogen procurement, capital expenditure, and operating expenditure. The CHRS is more sensitive to electricity price, while the LHRS is affected more by the discount rate. These findings provide insights for rational hydrogen infrastructure planning.