costingenergy_mass_balancehydrogen
Screening levelized cost of dispensing (EUR/kg) at a 350/700 bar hydrogen refuelling station fed with delivered H2.
Dispensed cost (levelized cost of dispensing)
EUR/kg added at the station gate (excludes delivered-H2 commodity)
CAPEX + O&M component of dispensed cost
Fixed-cost contribution per kg (drops as utilisation rises)
Energy component of dispensed cost
Station electricity contribution per kg
Real discount rate used to compute the capital recovery factor (DOE station basis: 8%).
Station analysis period for levelized costing (DOE station basis: 10 years).
Yearly fixed O&M as a fraction of station CAPEX (maintenance, parts, service).
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Design (peak) daily fuelling capacity. Sizes the station equipment (compression, storage, dispensing).
Fraction of nameplate capacity actually dispensed over the year. Early-market HRS run far below nameplate.
Station capacity (nameplate)
Design daily fuelling duty that sizes the equipment
Annual dispensed hydrogen
Actual yearly throughput at the chosen utilisation
Light-duty fills per year
Indicative number of 4 kg light-duty fast-fills served
Equivalent full-capacity days per year
Operating intensity used to annualize throughput
Station electricity to compress H2 to fast-fill pressure (HDSAM ~3.0 kWh/kg to 880 bar; demo sites 1.7-6.4).
Station electricity to pre-cool H2 to -40 C for SAE J2601 T40 fast-fill (HDSAM ~0.2 kWh/kg).
Station specific energy (compression + pre-cooling)
Station own electricity per kg dispensed
Effective specific energy
Station SEC adjusted by a part-load penalty
Part-load penalty factor
Screening adjustment of station energy at low utilisation (neutral by default)
Delivered electricity price to the station (EU non-household H2 2024 ~0.1629 EUR/kWh excl. taxes).
Annual station electricity cost
Compression + pre-cooling electricity over the year
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Installed station equipment cost per unit of daily capacity (DOE capital equipment basis, already installed).
Scaled specific station CAPEX
Installed cost intensity after scale curve and clamps
Equipment purchase cost
Station package cost at the scaled specific CAPEX
Total station CAPEX (all-in)
Installed cost incl. indirect/owner factors (zeroed: DOE basis already installed)
Annualized CAPEX (CRF-based)
Station CAPEX converted to an annual payment equivalent
Annual fixed O&M
Maintenance and service as a fraction of station CAPEX
Total annual station cost
Annualized CAPEX + O&M + electricity
CAPEX breakdown: compression share
Indicative allocation within total station CAPEX
CAPEX breakdown: buffer/cascade storage share
Indicative allocation within total station CAPEX
CAPEX breakdown: pre-cooling & dispensing share
Indicative allocation within total station CAPEX
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Calculator context
Screening levelized cost of DISPENSING at a 350/700 bar hydrogen refuelling station (HRS) that receives H2 already delivered on-site (gaseous tube trailer or liquid tanker). It prices only the station-gate conversion duty — compression, buffer/cascade storage, pre-cooling and dispensing — NOT the delivered-H2 commodity nor production. This is the integrated end-use dispensing asset, distinct from bulk storage, standalone compression and production. The model sizes equipment on the nameplate fuelling duty (kg/day), annualizes station CAPEX with a capital recovery factor, adds fixed O&M and station own-electricity (compression + pre-cooling), and divides by annual dispensed mass to give the EUR/kg added at the nozzle. Cost basis follows the DOE HDSAM / Hydrogen Program cost records (8% discount, 10-year station period); the delivered-H2 purchase price is intentionally excluded and should be added at project level to obtain the full nozzle price. SAE J2601 T40 fast-fill, 4 kg/fill light-duty assumptions underlie the throughput and pre-cooling figures.
18 assumptions used in the calculations
Prevents division-by-zero and NaN propagation in edge cases.
Market range Not applicable (numerical parameter).
Avoids inline literals in DSL expressions per spec.
Market range Exact.
Annualizes daily dispensing throughput.
Market range 365 (non-leap); 366 (leap year).
Lets users explore higher station energy at low utilisation without distorting the grounded nominal case.
Prevents the penalty factor from dropping below 1.
Market range 1 (by definition).
Avoids unrealistically large penalties at low utilisation in a screening model.
Represents the mild economies of scale of modular fuelling stations.
Provides a consistent anchor for scaling specific CAPEX with station size.
The grounded specific CAPEX already includes installation, so no extra installation factor is applied.
Market range 0 here; 0.2-0.5 only if starting from a bare-equipment cost.
Indirect and owner costs are already embedded in the installed DOE figure.
Market range 0 here; 0.1-0.4 only if starting from a narrower cost boundary.
Compression is typically the largest single station cost section.
Buffer and cascade storage is a major station cost section.
Pre-cooling and dispensing equipment make up the remaining station cost.
Converts annual dispensed mass into an indicative number of light-duty fills.
Lower bound of the DOE installed station cost band.
Upper bound of the DOE installed station cost band.
Documents the measured field average behind the compression energy default.
Documents the typical deployed station capacity for context.
Primary reference
DOE Hydrogen Program Records 20007 (Delivery & Dispensing Cost, HDSAM) and 21002 (Fueling Station Cost); cross-checked vs E3S 312/07010 HRS cost model
