Multi-Criteria Optimization and Control of Solar-to-Hydrogen Conversion Using Silicon Heterojunction PV and PEM Electrolyzer Coupling

• Analytical modeling of SHJ, PEM cells, interleaved DC/DC converters, and batteries • SHJ PV systems boost solar-to-hydrogen efficiency by ∼3% vs. monocrystalline PV • Multi-objective optimization balances hydrogen yield, losses, and system efficiency • Reconfigurable direct coupling offers robust, low-cost solutions • Battery integration in reconfigurable direct coupling achieves efficiency above 23.4% The optimization of coupling between photovoltaic (PV) systems and proton exchange membrane (PEM) electrolyzers is crucial for achieving efficient and scalable hydrogen production. Advances in both technology and software can enhance this integration. While static sizing and electrical coupling methods support location-specific design, they struggle to accommodate the dynamic nature of solar irradiance. This study addresses the challenge of solar variability by developing an adaptive reconfiguration and multi-criteria optimization algorithm to control the electrical coupling of silicon heterojunction (SHJ) PV cells with PEM electrochemical cells. Through multi-objective optimization, the algorithm enhances optimal performance by dynamically adjusting the electrical connection between the SHJ PV and PEM stack hourly. This approach replicates maximum power point tracking (MPPT) and power management cabinet functions without requiring additional power converters. The algorithm’s performance is benchmarked against single-objective reconfiguration algorithms and indirect control strategies with advanced power electronics and MPPT. Integrating a battery further enhances the potential of the direct reconfiguration strategy, allowing it to outperform indirect coupling methods with storage. Optimized sizing enables both direct and indirect coupling strategies to achieve solar-to-hydrogen (StH) efficiencies above 14.01 %, capitalizing on the superior performance of SHJ technology. By integrating battery storage, the proposed adaptive direct reconfiguration strategy can achieve total efficiencies of up to 28.6% in high-irradiance locations. This approach not only simplifies system architecture but also delivers robust, cost-effective solar hydrogen production, lowering the levelized cost of hydrogen by 0.25 € – 0.94 € per kilogram in battery-integrated systems comparison.