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Ammonia cracking to hydrogen: cracker and PSA cost of service

Fired catalytic ammonia cracker with PSA purification, 20 to 3,500 t/d of ammonia: cracking service cost in EUR/kg of hydrogen (ammonia excluded), hydrogen delivered, LHV efficiency, ammonia burned as fuel and CAPEX, on the IEA 2019 and IRENA 2022 reference cases.

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Open Jack

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  • CurrencyEUR 2019
  • Battery limitfully financed
  • 61 documented assumptions
  • Updated27 Oct 2026

Mass and energy balance

What the asset draws and delivers for the case and load you choose.

Reference case

Share of the year at full feed. Default 90 %, the IEA 2019 assumption for reconversion plants. It sets the hydrogen delivered a year and spreads the fixed costs.

Flows

  • In: Liquid ammonia (cracked and burned)—
  • In: Electricity for PSA—

Asset

Ammonia cracker with PSA purification (fired catalytic furnace)

  • Out: Hydrogen (PSA product, 99.97 % or better)—

Annual quantities at the current usage.

Liquid ammonia entering the plant per day, both the share cracked and the share burned in the furnace. This is the capacity the catalogue binds on. Sourced cost coverage: the IEA anchor is 4,110 t/d and Topsoe designs span 100-2,400 t/d per line (IRENA 2022). Below 100 t/d, including the 30 t/d Air Liquide pilot, the CAPEX is an exponent extrapolation, not a sourced value.

Hydrogen output at full feed
— kg/h
Hydrogen capacity (LHV)
— MW
Average electrical load
— MW

CAPEX

Specific cost at this size, what backs it, and how it behaves with scale.

Specific CAPEX at this size

—

Reference size 4,110 t/d

IRENA 2022 Part II, Table 6.1

Model value: the IEA 2019 reference CAPEX at 4,110 t/d scaled with the IRENA 0.65 exponent. Customized: your own quote per t/d of feed, used as is at every size; the value is then no longer sourced.

Specific CAPEX by ammonia feed

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  1. Ex-factory
  2. Installed
  3. Fully financed· this figure
CAPEX at the battery limit—

Included

  • Equipment and installation
  • Indirect and owner's costs
  • Contingency

Not included

  • Nothing

Added at project level

  • Nothing: project mode uses the figure as is

Project figures

Values passed to project mode when this asset is added to a project.

Concept sketch, not to scale · drag to rotate

Liquid ammonia (cracked and burned) in
—
Electricity for PSA in
—
Hydrogen (PSA product, 99.97 % or better) outMain product
—
CAPEX to the battery limit
—
Fixed O&M
—
Variable O&M, excluding feedstocks
0 EUR/year
Asset lifetime
30 years

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Cracking service cost

A standalone indicator for a quick read. Project mode recomputes it for the whole system.

—

  • Service cost: capital—
  • Service cost: fixed O&M—
  • Service cost: PSA electricity—

Linked to the balance above

Share of the year at full feed. Default 90 %, the IEA 2019 assumption for reconversion plants. It sets the hydrogen delivered a year and spreads the fixed costs.

Price of the PSA electricity. Default 75 EUR/MWh: Eurostat nrg_pc_205, EU27 non-household band IF (70-150 GWh/y), excluding VAT and recoverable taxes, 2019-S2, in the same 2019 euros as the CAPEX. The 2025-S2 value of the same series is 121.7 EUR/MWh.

Delivered price of the ammonia, cracked and burned. Leave at 0 to read the cracking service cost alone; enter a price to read the total cost of the imported hydrogen. Not part of the cracking service cost.

Real rate of the capital recovery factor on constant 2019 euro costs. Default 8 %, the IEA 2019 assumption. A zero rate is accepted (CRF = 1/n).

Service and economic life of the plant. Default 30 years, the IEA 2019 system lifetime.

Cracking service cost by utilisation

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Benchmarks

This model's figures against published references and reference cases.

Energy efficiency (LHV), %

86 IRENA 2022 Part II, p. 48

Yield, share of the stoichiometric maximum, %

75 IRENA 2022 Part II, p. 48

CAPEX per kW of hydrogen (USD), USD/kW

310.8 IRENA 2022 Part II, Table 6.3

604.9 IRENA 2022 Part II, Table 6.3

783.4 IRENA 2022 Part II, Table 6.3

1,525 IRENA 2022 Part II, Table 6.3

Reference cases at this size and usage

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All results

Every model output at the current settings, grouped, with the sensitivity charts.

49 outputs · 7 groups · 16 also shown above, dimmed

Cracking service cost

5
Cracking service cost
ComputingEUR/kg
Service cost: capital
ComputingEUR/kg
Service cost: fixed O&M
ComputingEUR/kg
Service cost: PSA electricity
ComputingEUR/kg
Capital share of the service cost
Computing%

Imported hydrogen cost

3
Ammonia cost per kg of hydrogen
ComputingEUR/kg
Of which ammonia burned as fuel
ComputingEUR/kg
Cost of hydrogen at the cracker outlet
ComputingEUR/kg

Size and CAPEX

7
Total CAPEX
ComputingEUR
Specific CAPEX
ComputingEUR/(t/d)
Scaling exponent applied
Computingratio
Total CAPEX, exponent 0.67
ComputingEUR
Total CAPEX, exponent 0.745
ComputingEUR
CAPEX per kW of hydrogen (USD)
ComputingUSD/kW
Below sourced size range
Computingbool

Production

7
Hydrogen delivered
Computingt/year
Hydrogen delivered, daily average
Computingt/d
Hydrogen delivered (kg)
Computingkg/year
Hydrogen output at full feed
Computingkg/h
Hydrogen capacity (LHV)
ComputingMW
Full-feed hours
Computingh/year
Hydrogen not produced below full utilisation
Computingt/year

Mass balance

9
Hydrogen yield per tonne of ammonia
Computingt/t
Yield, share of the stoichiometric maximum
Computing%
Ammonia consumed per kg of hydrogen
Computingkg/kg
Ammonia burned as fuel, share of feed
Computing%
Ammonia fed
Computingt/year
Ammonia sent to the cracker
Computingt/year
Ammonia burned as fuel
Computingt/year
Nitrogen released by cracking
Computingt/year
Unconverted ammonia
Computingt/year

Energy balance

13
Energy efficiency (LHV)
Computing%
Energy efficiency including electricity
Computing%
Furnace heat demand
ComputingkWh/kg
Heat from the PSA off-gas
ComputingkWh/kg
Heat from burned ammonia
ComputingkWh/kg
Off-gas share of the heat demand
Computing%
Reaction heat per kg delivered
ComputingkWh/kg
Reaction heat per mole of ammonia
ComputingkJ/mol
Reaction share of the heat demand
Computing%
Energy losses
ComputingMWh/year
PSA electricity per kg
ComputingkWh/kg
Electricity consumed
ComputingMWh/year
Average electrical load
ComputingMW

Yearly costs

5
Capital recovery factor
Computing1/year
Annualised CAPEX
ComputingEUR/year
Fixed O&M
ComputingEUR/year
Electricity cost
ComputingEUR/year
Yearly cost of service
ComputingEUR/year

Sensitivities

4 charts
Cracking service cost components vs utilisation

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Specific CAPEX and service cost vs ammonia feed

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Furnace heat sources by reference case

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Cost of hydrogen at the cracker outlet vs ammonia price

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Sources

61 documented assumptions · 5 sources

About

Calculator context

Reconversion plant at an ammonia import terminal. Liquid ammonia is vaporised and cracked over a catalyst in a fired tubular furnace (2 NH3 -> N2 + 3 H2, endothermic); a PSA purifies the hydrogen and its off-gas is burned in the furnace, with extra ammonia burned to close the heat demand. The calculator gives the cracking service cost in EUR per kg of hydrogen delivered, excluding the ammonia, split into capital, fixed O&M and PSA electricity; the hydrogen delivered a year; the hydrogen yield per tonne of ammonia against the 0.1776 t/t stoichiometric maximum; the LHV energy efficiency; the share of ammonia burned; and the CAPEX. At the defaults (1,000 t/d, IEA 2019 case, 90 % utilisation, 75 EUR/MWh) the service cost is 0.59 EUR/kg, the yield 0.1346 t/t (75.8 % of stoichiometric), the efficiency 86.7 % LHV and 10.0 % of the ammonia is burned. Mass balance and costs come from the IEA 2019 Future of Hydrogen assumptions annex (PSA recovery 85 %, conversion 99 %, heat 9.7 kWh/kg, PSA 1.5 kWh/kg, 460 MUSD at 1,500 kt/y, O&M 4 %, 8 %, 30 years); the IRENA 2022 hydrogen carriers review gives the 0.65 scaling exponent and the 2030 heat cases (11.2 and 16.8 kWh/kg). Enter an ammonia price to read the total cost of imported hydrogen. Below 100 t/d the CAPEX is an extrapolation, and IRENA's reconversion CAPEX differs from the IEA anchor: both gaps are shown. Chains downstream of the Haber-Bosch ammonia synthesis calculator as the return leg of an ammonia import chain.

Model

104 variables — inputs, calculations and outputs, with their dependencies.

104 variables shown of 104
VariableValueUnitDepends on
1000t/d—
90%—
1——
0——
100000EUR/(t/d)—
75EUR/MWh—
0EUR/t—
8%—
30years—
VariableFormulaUnitDepends on
if((<=)+(<=)+(>)+(<)+(>)+(<)+(>)+(<=)+(<)+(<)+(<)+(>)+(<)>,,)bool
*ratio
*ratio
*kWh/kg
/(*)kg/kg
/(**)kg/kg
/kg/kg
*//EUR/(t/d)
VariableFormulaUnitDepends on
*h/year
if(==,,if(==,,))kWh/kg
if(==,,)kWh/kg
(-)*kWh/kg
max(-,)kWh/kg
+kg/kg
/t/t
/*%
/(*)*%
/(*+)*%
/*%
min(,)/*%
*(-/)kWh/kg
(*-)**kJ/mol
/*%
*//kg/h
**MW
**t/year
/t/year
/t/d
*/-t/year
*t/year
*t/year
***(-)t/year
*(-*)t/year
***MWh/year
/MW
**(*+-)*MWh/year
if(<,/,(*(+)^)/max((+)^-,))1/year
if(>=,,)ratio
if(>=,,clamp(*(/)^(-),,))EUR/(t/d)
*EUR
if(>=,,clamp(*(/)^(-),,)*)EUR
if(>=,,clamp(*(/)^(-),,)*)EUR
*/max(*,)USD/kW
*EUR/year
**EUR/year
*EUR/year
++EUR/year
*kg/year
/max(,)EUR/kg
/max(,)EUR/kg
/max(,)EUR/kg
++EUR/kg
/max(,)*%
*/EUR/kg
*/EUR/kg
+EUR/kg
if(<,,)bool

Assumptions

61 assumptions used in the calculations

  • Lower limit in the input guards and the floor of the burned-ammonia balance.

    Market range Exact by definition.

    0
    Numerical constant

  • Unit multiplier in the CRF, the guards, the reference-case switch and the Customized switch.

    Market range Exact by definition.

    1
    Numerical constant

  • Protects divisions by a quantity that is positive inside the valid domain.

    Market range Exact by definition.

    0
    Numerical constant

  • Converts a percent into a fraction.

    Market range Exact by definition.

    0.01
    Numerical constant

  • Converts a fraction into a percent.

    Market range Exact by definition.

    100
    Numerical constant

  • Hours in a year (365 days).

    Market range Exact by definition.

    8760h/year
    Numerical constant

  • Days in a year; also turns the IEA 1,500 kt/y reference into t/d.

    Market range Exact by definition.

    365d/year
    Numerical constant

  • Turns a daily ammonia feed into an hourly hydrogen output.

    Market range Exact by definition.

    24h/d
    Numerical constant

  • Kilograms per tonne.

    Market range Exact by definition.

    1000kg/t
    Numerical constant

  • MWh per kWh.

    Market range Exact by definition.

    0.001MWh/kWh
    Numerical constant

  • kW per MW.

    Market range Exact by definition.

    1000kW/MW
    Numerical constant

  • USD per million USD.

    Market range Exact by definition.

    1000000USD/MUSD
    Numerical constant

  • 1 GJ/t = 1 MJ/kg = 0.2777778 kWh/kg; converts the ammonia LHV.

    Market range Exact by definition.

    0.277778kWh/kg per GJ/t
    Numerical constant

  • kJ per kWh; expresses the reaction heat per mole.

    Market range Exact by definition.

    3600kJ/kWh
    Numerical constant

  • Identifier of the IEA 2019 reference case in the selector.

    Market range Exact by definition.

    1
    Numerical constant

  • Identifier of the IRENA 2030 optimistic reference case in the selector.

    Market range Exact by definition.

    2
    Numerical constant

  • Identifier of the IRENA 2030 pessimistic reference case in the selector.

    Market range Exact by definition.

    3
    Numerical constant

  • Expresses the reaction heat implied by the two LHVs per mole of ammonia.

    Market range Exact to the third decimal.

    0.017031kg/mol
    IUPAC atomic weights

  • Maximum hydrogen a tonne of ammonia can give if all of it is cracked and none is burned; upper limit of the specific yield.

    Market range Exact (stoichiometry).

    0.1776t/t
    Computed from molar masses

  • Lower heating value of ammonia; values the burned ammonia and the energy efficiency.

    Market range 18.6 GJ/t (IRENA); no other value used.

    18.6GJ/t
    IRENA 2022 Part II, p. 33

  • Lower heating value of hydrogen; values the PSA off-gas and the hydrogen delivered.

    Market range 33.3 kWh/kg LHV.

    33.3kWh/kg
    NAP 2004, appendix

  • Share of the cracked hydrogen that leaves the PSA as product; the other 15 % goes to the furnace in the off-gas.

    Market range 85 % in the IEA table; IRENA 2022 does not give a separate figure.

    85%
    IEA 2019 annex, p. 8

  • Fraction of the ammonia sent to the catalyst that is cracked. The 1 % left is assumed removed from the off-gas (scrubbed), so its heat is not credited to the furnace.

    Market range 99 % in the IEA table; the IEA label is ambiguous between conversion and recovery, hence medium evidence.

    99%
    IEA 2019 annex, p. 8

  • Furnace heat per kg of hydrogen delivered in the IEA 2019 reference case: vaporisation, preheat and the endothermic reaction.

    Market range IEA 9.7; IRENA 2022 Table 6.3 gives 11.2 (optimistic) to 16.8 (pessimistic) for 2030. The two sources disagree; both are exposed as reference cases.

    9.7kWh/kg
    IEA 2019 annex, p. 8

  • Furnace heat of the IRENA 2030 optimistic case.

    11.2kWh/kg
    IRENA 2022 Part II, Table 6.3

  • Furnace heat of the IRENA 2030 pessimistic case.

    16.8kWh/kg
    IRENA 2022 Part II, Table 6.3

  • PSA electricity per kg of hydrogen delivered, used in the IEA 2019 and IRENA 2030 optimistic cases.

    1.5kWh/kg
    IEA 2019 annex, p. 8

  • Upper end of the IRENA range, used in the IRENA 2030 pessimistic case. IRENA does not tie this value to its pessimistic scenario: the pairing is this calculator's choice.

    2kWh/kg
    IRENA 2022 Part II, p. 46

  • Size of the only cost anchor; the scale law is pinned at this feed.

    Market range Single anchor. Below about 100 t/d (smallest Topsoe design cited by IRENA) no source covers the cost.

    4110t/d
    IEA 2019 annex, p. 7, divided by 365

  • Plant investment of the reference cracker, taken as the all-in figure the IEA uses directly in its levelised cost (no OSBL or indirect uplift added in the source). IEA does not detail the scope, hence medium evidence.

    Market range At the reference this is about 600 USD/kW H2 (LHV). IRENA 2022 Table 6.3 gives 783-1,525 USD/kW H2 for 2030 (10 kt/y, first of a kind) and 311-605 for 2040 (100 kt/y): the two sources disagree and the gap is exposed as benchmarks.

    460MUSD
    IEA 2019 annex, p. 8

  • Converts the 2019 USD CAPEX into 2019 euros, and the model CAPEX back into USD for the IRENA benchmark.

    Market range 1.1195 (ECB, annual average 2019).

    1.1195USD/EUR
    ECB 2019 average

  • Economy of scale of the cracker CAPEX with the ammonia feed, applied from the 4,110 t/d IEA anchor across the slider.

    Market range 0.65 (IRENA table); the studies IRENA reviews use 0.67-0.745 (Cesaro 2021, Ishimoto 2020, ISPT 2017), shown as a CAPEX sensitivity.

    0.65
    IRENA 2022 Part II, Table 6.1

  • Low end of the literature exponent range, used for the CAPEX sensitivity output.

    0.67
    IRENA 2022 Part II, p. 47

  • High end of the literature exponent range, used for the CAPEX sensitivity output.

    0.745
    IRENA 2022 Part II, p. 47

  • Fixed operation and maintenance a year as a share of CAPEX. It includes catalyst replacement, which no source in this calculator costs separately.

    Market range 4 % (IEA); no independent range cited.

    4%
    IEA 2019 annex, p. 8

  • Clamp floor of the scale law. It bites only above about 128,000 t/d, far outside the slider; it never changes a value inside the declared domain.

    Market range Not a market value.

    30000EUR/(t/d)
    Numerical guard

  • Clamp ceiling of the scale law. It bites only below about 0.8 t/d, far outside the slider; it never changes a value inside the declared domain.

    Market range Not a market value.

    2000000EUR/(t/d)
    Numerical guard

  • Smallest design size a source cites. Below it the CAPEX is an exponent extrapolation from the 4,110 t/d anchor and the calculator raises a flag.

    100t/d
    IRENA 2022 Part II, p. 47

  • Default of the utilisation slider.

    Market range 90 % (IEA); no independent range cited.

    90%
    IEA 2019 annex, p. 8

  • Default of the discount rate slider, read as a real rate on constant 2019 euros.

    Market range 8 % (IEA); no independent range cited.

    8%
    IEA 2019 annex, p. 8

  • Default economic lifetime and the service life exported to project mode.

    Market range 30 years (IEA).

    30years
    IEA 2019 annex, p. 8

  • Capacity of the IEA cost anchor; 1,500 / 365 = 4,110 t/d.

    Market range Single anchor.

    1500kt/year
    IEA 2019 annex, p. 7

  • Reference CAPEX in 2019 euros; the model computes it from the two cited figures.

    Market range Converted value, so medium evidence.

    410.9MEUR
    IEA 2019 annex + ECB

  • Default electricity price, in the same 2019 euros as the CAPEX. The PSA of a 1,000 t/d plant draws about 66 GWh a year, inside band IF.

    Market range 2019-S1 77.9 EUR/MWh; 2025-S2 121.7 EUR/MWh (same series, current euros).

    75EUR/MWh
    Eurostat nrg_pc_205, 2019-S2

  • Recent price of the same series, for users who want current prices. Entering it mixes 2025 electricity with 2019 CAPEX euros; the calculator does not index the CAPEX.

    Market range See the 2019 value.

    121.7EUR/MWh
    Eurostat nrg_pc_205, 2025-S2

  • Benchmark for the yield as a share of the stoichiometric maximum. Industry estimate reported second-hand, not a measured plant.

    Market range 75 % (Topsoe via IRENA).

    75%
    IRENA 2022 Part II, p. 48

  • Benchmark for the LHV energy efficiency. Independent of the IEA figures the model uses, so a real cross-check.

    Market range 86 % (Topsoe via IRENA); IRENA notes energy losses of 15 % minimum and up to 30 % of the hydrogen energy.

    86%
    IRENA 2022 Part II, p. 48

  • Largest single-line design cited. The IEA anchor (4,110 t/d) is above it, so plants of that size are read as more than one line.

    2400t/d
    IRENA 2022 Part II, p. 47

  • Benchmark for the CAPEX per kW of hydrogen. IRENA 2030 optimistic case, plant scale about 10 kt H2/y. The IRENA cost year is not restated in the table cited; the model value is in 2019 dollars, so the comparison is an order-of-magnitude check, not a position.

    Market range 2030: 783-1,525 USD/kW (first of a kind, 10 kt/y); 2040: 311-605 USD/kW (100 kt/y).

    783.4USD/kW
    IRENA 2022 Part II, Table 6.3

  • Benchmark for the CAPEX per kW of hydrogen. IRENA 2030 pessimistic case, plant scale about 10 kt H2/y. The IRENA cost year is not restated in the table cited; the model value is in 2019 dollars, so the comparison is an order-of-magnitude check, not a position.

    Market range 2030: 783-1,525 USD/kW (first of a kind, 10 kt/y); 2040: 311-605 USD/kW (100 kt/y).

    1,524.7USD/kW
    IRENA 2022 Part II, Table 6.3

  • Benchmark for the CAPEX per kW of hydrogen. IRENA 2040 optimistic case, plant scale about 100 kt H2/y. The IRENA cost year is not restated in the table cited; the model value is in 2019 dollars, so the comparison is an order-of-magnitude check, not a position.

    Market range 2030: 783-1,525 USD/kW (first of a kind, 10 kt/y); 2040: 311-605 USD/kW (100 kt/y).

    310.8USD/kW
    IRENA 2022 Part II, Table 6.3

  • Benchmark for the CAPEX per kW of hydrogen. IRENA 2040 pessimistic case, plant scale about 100 kt H2/y. The IRENA cost year is not restated in the table cited; the model value is in 2019 dollars, so the comparison is an order-of-magnitude check, not a position.

    Market range 2030: 783-1,525 USD/kW (first of a kind, 10 kt/y); 2040: 311-605 USD/kW (100 kt/y).

    604.9USD/kW
    IRENA 2022 Part II, Table 6.3

  • Method: liquid ammonia is vaporised and cracked in a fired catalytic tubular furnace (2 NH3 -> N2 + 3 H2). Per kg of hydrogen delivered, the PSA recovers 85 % of the cracked hydrogen; the cracker converts 99 % of its feed. The PSA off-gas (15 % of the hydrogen) is burned in the furnace and extra ammonia closes the heat demand of the reference case. Hydrogen a year = ammonia feed x 365 x utilisation / ammonia consumed per kg. CAPEX = IEA anchor scaled with the IRENA exponent; service cost = (CAPEX x CRF + 4 % O&M) / kg + PSA electricity.

    Market range Not applicable.

    —
    Model scope

  • The only cost anchor is 4,110 t/d. Between 100 and 3,500 t/d the CAPEX is the anchor scaled with a published exponent. Below 100 t/d, including the 30 t/d Air Liquide pilot in the catalogue, no source covers the cost: the value is an exponent extrapolation over a factor of up to about 200 and the calculator raises a flag. It is not high evidence.

    Market range Not applicable.

    —
    Model scope

  • Two sources disagree on CAPEX. The IEA anchor gives about 600 USD/kW of hydrogen at 4,110 t/d. IRENA gives 783-1,525 USD/kW for 2030 (10 kt H2/y, first of a kind) and 311-605 for 2040 (100 kt H2/y). At the sizes IRENA quotes, this model sits above both IRENA ranges (about 1,700 USD/kW near 200 t/d and 770 USD/kW near 2,000 t/d). The gap is shown as benchmarks on the CAPEX per kW output, not reconciled.

    Market range Not applicable.

    —
    Model scope

  • Heat demand differs between the sources: IEA 9.7 against IRENA 11.2-16.8 kWh/kg for 2030. The three reference cases span that range. The IRENA 2050 optimistic 5.0 kWh/kg would give an efficiency above 96 % and is outside the defended range, so it is not offered.

    Market range Not applicable.

    —
    Model scope

  • Vendor claims of a hydrogen yield above 78 % without external fuel and 96 % recovery were not found in a primary document and are not used. The only Topsoe figures used are those IRENA reports (75 % weight basis, 86 % energy basis), as benchmarks.

    Market range Not applicable.

    —
    Model scope

  • Electric heating of the cracker is out of scope: all three cases are fired furnaces burning the off-gas and ammonia.

    Market range Not applicable.

    —
    Model scope

  • battery_limit = fully_financed: the IEA uses the CAPEX as the whole investment, with no OSBL or indirect uplift, so project mode adds none. IEA does not detail what the figure covers, hence medium evidence. Ammonia storage and the import terminal are separate items in both IEA and IRENA and are excluded here.

    Market range Not applicable.

    —
    Model scope

  • The 1 % of ammonia left uncracked is assumed removed from the off-gas before the furnace, so its heat is not credited. Crediting it would raise the efficiency by about 0.8 point; leaving it out is the conservative reading.

    Market range Not applicable.

    —
    Model scope

  • All costs are in constant 2019 euros with no escalation, and the discount rate is read as a real rate. Market prices entered by the user should be in 2019 euros to stay consistent; the calculator does not index them.

    Market range Not applicable.

    —
    Model scope