Tank swapping for fuel cell heavy-duty trucks: economic feasibility analysis

Hydrogen fuel cell heavy-duty trucks (FCHDTs) offer a critical pathway for decarbonizing transportation, but their widespread adoption is currently hampered by the high cost of hydrogen storage, transportation, and refueling. This study introduces the H2Combo-HDT model to systematically evaluate tank swapping as a cost-effective and operationally efficient alternative business mode to traditional hydrogen refueling methods. Our findings demonstrate that swapping provides immediate economic benefits: in the External Hydrogen Supply (EHS) scenario, tank swapping reduces vehicle energy costs by 6–8% compared to conventional refueling, with the economic advantage expanding significantly as the station utilization rate increases and the hydrogen transportation distance lengthens. Furthermore, combining swapping with On-site Hydrogen Production (OHP) shows strong potential for promoting FCHDTs in long-haul transportation to reduce FCHDT purchase cost. This combined approach is projected to remain competitiveness toward 2040, driven by technological advancements such as lower tank prices and faster refueling rates. This research highlights tank swapping as a crucial strategy for enhancing FCHDT economic viability in key transportation segments. These insights offer valuable guidance for developing sustainable hydrogen supply chain strategies, while recognizing the continued need to address policy and market uncertainties.