Optimal Design, Scheduling, and Control of Electrolysis-Based Hydrogen Production Plants

Abstract

Hydrogen has long been utilized as an energy carrier, from its early applications in internal combustion engines, balloons, and airships over 200 years ago to its modern role in oil refining and industrial processes. Amid growing climate change concerns, global demand for low-carbon hydrogen has increased significantly, positioning green hydrogen—produced via water electrolysis powered by renewable or other low-carbon electricity sources—as a key pathway toward energy decarbonization. However, most low-carbon hydrogen technologies remain economically uncompetitive with fossil-fuel-based alternatives. Among commercial electrolysis technologies, alkaline electrolyzers (AE) and proton exchange membrane electrolyzers (PEME) are mature solutions, while solid oxide electrolyzer cells (SOEC) are still under development. PEME technology is particularly promising due to its compact design, high current density, high efficiency, fast dynamic response, and capability to produce ultra-pure hydrogen, but its reliance on noble metals results in high capital costs and elevated levelized cost of hydrogen (LCOH). Therefore, optimal integration and operation of electrolysis hydrogen production plants (EHPPs), particularly PEME-based systems, within power grids is essential to improve economic viability and enhance grid resilience. This dissertation develops a comprehensive modeling and optimization framework for EHPP design, configuration, and operation. Detailed electrochemical models for AE and PEME technologies are formulated and embedded into novel optimization problems that simultaneously determine plant sizing, equipment ratings, internal electrolyzer parameters, configuration options (with or without battery energy storage systems), and hourly operational scheduling. The proposed formulations aim to minimize LCOH while extending PEME safe operating ranges, improving efficiency at partial loading, and enhancing integration with renewable energy sources. Furthermore, a comprehensive framework is developed to optimize EHPP participation in grid ancillary services—including capacity auction markets, operating reserves, and renewable power smoothing—under various electricity pricing schemes, while meeting hydrogen demand across multiple sectors and pressure requirements. Finally, a coordinated dynamic control and scheduling strategy is introduced to optimally regulate PEME cathodic pressure and operating temperature, thereby improving efficiency across all loading conditions and further reducing hydrogen production costs. The proposed methodologies contribute toward economically viable hydrogen production and improved power system flexibility in low-carbon energy systems.