Pathway to sustainability: Hydrogen-powered gensets for electric vehicle charging

The transition from traditional fossil fuel-powered vehicles to electric vehicles (EVs) involves more than just a change in vehicle type; it requires a comprehensive transformation of the transportation infrastructure. When operated with green hydrogen produced through renewables, INNIO Group’s fuel-flexible Jenbacher engines represent a promising solution to the challenge of supporting the entire e-mobility green power infrastructure, even in cities and regions far from the renewable energy plant location.

Hydrogen, Jenbacher, Sustainability

In its 2024 EV report, IEA predicts an installed vehicle charger capacity of more than 4 TW globally by 2035. The EV charging infrastructure faces power capacity challenges in its future evolution. These include the need for high-performance charging stations capable of fast charging, the cost and complexity of network connections, the shifting electricity demand throughout the day and subsequent need for storage, and the desire of developers for quick, economical, and sustainable solutions. A key advantage of hydrogen for the EV charging infrastructure is its benefit as an “energy carrier.” It can be conveniently shipped and used to power gensets in multiple locations, and does not impact the existing grid infrastructure, unlike traditional hardware such as electrical-based battery energy storage solutions (BESS), which need to be located close to the facility.

Pioneering hydrogen technology for the energy transition

As a key enabler and an integral part of the energy transition, INNIO Group has launched its “Ready for H2” portfolio, which includes 100% hydrogen-powered internal combustion engines. Based on decades of experience gained on power generation from high hydrogen content fuels and despite the current limitations in green hydrogen availability, INNIO Group already can showcase several commercial hydrogen projects worldwide, underlining its technological expertise through its Jenbacher solutions. A comprehensive simulation from INNIO Group explores a practical use case scenario and determines load requirements, operational hours, and the extent of EV load satisfaction, and as well the heat demand. Using EV load profiles derived from industry experience and informed assumptions, INNIO Group models EV demand that can be met flexibly based on the EV station’s loads schedule. This simulation determines the amount of electricity the station can provide on an hourly basis and the daily requirement. This strategic approach helps ensure efficient energy management, aligning hydrogen on site supply with energy demand while considering the unique characteristics and requirements of the EV charging infrastructure.

Enhancing efficiency through heat recovery

In addition to managing EV charging loads, the Jenbacher hydrogen genset produces heat as a byproduct. The waste heat, collected from the exhaust gas, jacket water, and lubricant circuits, improves the overall efficiency of the H2-Engine by meeting heating and cooling demands. Heat utilization not only enhances the fuel utilization ratio but also supports more effective EV decarbonization solutions leveraging cogeneration and trigeneration, leading to increased end-user revenue equivalent to a reduction of the levelized cost of electricity at the charging point. For instance, if the EV station is located near a public district heating network, the generated heat can be used to offset the winter load. This capability makes the H2-Engine an even more valuable component of a sustainable and versatile energy infrastructure.

Efficient and sustainable EV charging stations

INNIO Group’s proposed EV charging infrastructure solution is a comprehensive system designed for both efficiency and sustainability. Central to this design is the Jenbacher genset, a robust engine that runs on green hydrogen to provide a reliable source of electricity and heat. Accompanying the genset is a system for hydrogen fueling through a virtual pipeline, which also can mix hydrogen with natural gas (if needed), offering flexibility in fuel use. An absorption chiller harnesses the heat produced by the genset to deliver cooling during warmer months. This increases the overall efficiency and energy utilization of the hydrogen To further increase heat utilization, a heat storage system is integrated to reduce thermal waste. Optionally, a “hydrogen-ready” boiler can be incorporated to meet peak heating demands. The entire system is controlled by the INNIO Group’s Jenbacher Microgrid Controller to achieve consistently high output and overall efficiency. The interconnections to the loads are designed to deliver generated power precisely where it’s needed, completing this well-rounded, sustainable setup for the EV charging station.

Financial viability and decarbonization potential

With INNIO Group’s Jenbacher product capabilities, the evaluation of the costs for implementation of a virtual pipeline and hydrogen supply for a genset powering an EV charging station can be carried out effectively. For a Jenbacher H2-Engine with a nominal electrical power capacity of 1,000 kW, the projected costs of the delivered energy to the EV charging are not significantly far from a commercially viable value that would appeal to the industry and EV users. While these costs are relatively high without a public incentivization scheme (€1/kWh of 100% green electricity at the point of a superfast EV charging), this solution enables a greener e-mobility solution with almost 100% decarbonization.

Want to know more? INNIO Group’s recently published white paper “Hydrogen-powered gensets for electric vehicle charging” provides an in-depth look into the future of EV charging stations and how Jenbacher solutions can play a major role on this pathway to sustainability. Read it here.