A national laboratory of the U.S. Department of Energy

Office of Energy Efficiency & Renewable Energy

National Renewable Energy Laboratory 

Innovation for Our Energy Future 

H2A Production Model, 

Version 2 User Guide 

Technical Report 

NREL/TP-560-43983 

September 2008 

D. Steward and T. Ramsden 

National Renewable Energy Laboratory 

J. Zuboy 

Independent Contractor

NREL is operated by Midwest Research Institute ● Battelle Contract No. DE-AC36-99-GO10337 
H2A Production Model, 

Version 2 User Guide 

D. Steward and T. Ramsden 

National Renewable Energy Laboratory 

J. Zuboy 

Independent Contractor

Prepared under Task No. H278.2150 

Technical Report 

NREL/TP-560-43983 

September 2008 

National Renewable Energy Laboratory

1617 Cole Boulevard, Golden, Colorado 80401-3393 

303-275-3000 • www.nrel.gov 

Operated for the U.S. Department of Energy 

Office of Energy Efficiency and Renewable Energy 

by Midwest Research Institute • Battelle 

Contract No. DE-AC36-99-GO10337
NOTICE

This report was prepared as an account of work sponsored by an agency of the United States government. 

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warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or 

usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not 

infringe privately owned rights. Reference herein to any specific commercial product, process, or service by 

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recommendation, or favoring by the United States government or any agency thereof. The views and 

opinions of authors expressed herein do not necessarily state or reflect those of the United States 

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Printed on paper containing at least 50% wastepaper, including 20% postconsumer waste
The H2A Production Model analyzes the technical and economic aspects of central and 

forecourt hydrogen production technologies. Using a standard discounted cash flow rate of 

return methodology, it determines the minimum hydrogen selling price (or levelized cost), 

including a specified after-tax internal rate of return from the production technology. Users 

have the option of accepting default technology input values—such as capital costs, 

operating costs, and capacity factor—from established H2A production technology cases or 

entering custom values. Users can also modify the model's financial inputs. 

This new version of the H2A Production Model features enhanced usability and functionality. 

Input fields are consolidated and simplified. New capabilities include performing sensitivity 

analyses and scaling analyses to various plant sizes. 

The model is actually two models: one Microsoft Excel spreadsheet to analyze central 

hydrogen production technologies and another to analyze forecourt hydrogen production 

technologies. The two models are very similar; the primary difference is that the central 

model performs carbon sequestration calculations, whereas the forecourt model performs 

refueling station compression, storage, and dispensing calculations. The models and detailed 

technology cases can be downloaded from www.hydrogen.energy.gov/h2a_production.html. 

This User Guide helps users already familiar with the basic tenets of H2A hydrogen 

production cost analysis get started using the new version of the model. It introduces the 

basic elements of the model then describes the function and use of each of its worksheets. 

More detailed and explanatory instructional materials are being developed. 

Contents 

Quick Start: Getting Around ..................................................................................1

Quick Start: Performing Simple Production Cost Analyses ...................................3

Tips & Troubleshooting .........................................................................................4

General Tips .................................................................................................... 4

Solutions to Commonly Encountered Problems............................................... 5

Information Worksheets ........................................................................................8

Input_Sheet_Template Worksheet ...................................................................... 10

Project Description ......................................................................................... 10

Table of Contents .......................................................................................... 10

Technical Operating Parameters and Specifications ..................................... 11

Financial Input Values ................................................................................... 11

Energy Feedstocks, Utilities, and Byproducts ................................................ 12

Capital Costs ................................................................................................. 14

Fixed Operating Costs ................................................................................... 15

Variable Operating Costs ............................................................................... 15

Other Materials and Byproducts ............................................................... 16

Other Variable Operating Costs ............................................................... 17

Replacement Costs Worksheet ........................................................................... 18

Capital Costs Worksheet ..................................................................................... 19

Plant Scaling Worksheet ..................................................................................... 20

Carbon Sequestration Worksheet (Central Model Only) ..................................... 23

i
ii

Refueling Station Worksheet (Forecourt Model Only) ......................................... 25

H2A Toolkit ......................................................................................................... 27

Importing Existing H2A Cases ....................................................................... 27

Printing and Exporting Inputs and Results ..................................................... 29

Editing Input Parameters ............................................................................... 29

Delete Feed, Utility, and Byproduct Inputs ............................................... 29

Set up Plant Scaling ................................................................................. 30

Performing Sensitivity Analyses..................................................................... 30

Results Worksheet .............................................................................................. 32

Cash Flow Analysis Worksheet ........................................................................... 35

Tornado Chart Worksheet ................................................................................... 36

Sensitivity_Analysis Worksheet........................................................................... 37

Energy Feed & Utility Prices Worksheet ............................................................. 38

Non-Energy Material Prices Worksheet .............................................................. 40

AEO Data Worksheet .......................................................................................... 41

HyARC Physical Property Data Worksheet ......................................................... 42

References .................................................................................................... 43

Debt Financing Calculations Worksheet ............................................................. 44

Depreciation Worksheet ...................................................................................... 45

Constants and Conversions Worksheet .............................................................. 46

Lists Worksheet................................................................................................... 47

Technical Support ............................................................................................... 48

Appendix 1: Carbon Sequestration Calculations and Sources ............................ 49

References .................................................................................................... 54

Appendix 2: Forecourt Hydrogen Delivery Calculations ...................................... 56

References .................................................................................................... 59

Appendix 3: Default Values and Assumptions .................................................... 60

Appendix 4: Derivations and Definitions .............................................................. 62

Derivation of Forecourt Production Unit Operating Capacity Factor .............. 62

Definitions ...................................................................................................... 62

Index ................................................................................................................... 63
Quick Start: Getting Around 

The spreadsheet is organized into 19 or more worksheets, which have tabs color coded 

according to their function, as shown below. The schematic on the following page shows a 

generalized data flow among the worksheets. 

Overview of H2A Production Model Tabs and Worksheets 

 

Title 

Description Information 

ProcessFlow 

Input_Sheet_Template 

Inputs 

Replacement Costs 

Capital Costs 

Plant Scaling 

Refueling Station [forecourt model only] 

Carbon Sequestration [central model only] 

Results 

Results Cash Flow Analysis 

Tornado Chart 

Sensitivity_Analysis 

Energy Feed & Utility Prices 

Data & Properties Non-Energy Material Prices 

AEO Data 

HyARC Physical Property Data 

Debt Financing Calculations Standard 

Calculations & 

Variables

Depreciation 

Constants and Conversions 

Lists 

TIP 

Most users will 

add/modify cells 

within the input 

worksheets 

(dark green 

tabs) only. 

1
Schematic of Data Flow among H2A Worksheets

2
Quick Start: Performing Simple Production Cost Analyses 

To perform a simple production cost analysis, select the Input_Sheet_Template tab. Accept 

the default (e.g., production technology case) values or enter new values into the orange 

cells. The contents of the blue cells are calculated automatically. Use the drop-down menus 

and buttons to enter information for Energy Feedstocks, Utilities, and Byproducts and Other 

Materials and Byproducts. Once all information is entered, click the Calculate Cost button at 

the top of the worksheet. 

Input_Sheet_Template Worksheet (Inputs) 

Clicking the Calculate Cost button sends you to the Results worksheet, which displays the 

production cost, energy, and emissions results. 

Results Worksheet (Forecourt Model Shown) 

Calculate Cost button

Input cell (orange) 

Calculation cell (blue)

Total hydrogen 

cost

3
Tips & Troubleshooting 

General Tips 

• Before you start modifying the model, save the file under a new name. This will make it 

simple to go back to the unmodified model later if necessary. 

• If the file you are working with accumulates numerous errors, or if you delete information 

that you later find you need, etc., it might be easier to discard the file and start afresh with 

the original version of the model and/or production technology case. If you have not kept 

an original version, download the model again from the H2A Web site: 

www.hydrogen.energy.gov/h2a_production.html. 

• Throughout the model, orange cells are meant to accept static user-input values or userdefined equations, and blue cells are calculated automatically by the model. Use care if 

you overwrite the blue calculation cells with static values or your own equations; once 

overwritten, the original equation information is permanently deleted. Green cells are for 

user-input information and notes. Yellow cells contain H2A information and default values. 

• Do not type values into cells with drop-down menus. Select only from values in the menu. 

• If it is not obvious how to close or move on past a pop-up window, you can close it by 

clicking the in the upper right corner. 

• Mouse over small red triangles for useful notes as shown below. 

• The Input_Sheet_Template worksheet works best (i.e., has the least likelihood of errors) 

when you fill it out as completely as possible, starting with the top and working down. After 

filling out the worksheet completely, click the Calculate Cost button at top to view results. 

• Tabs for the Plant Scaling and Tornado Chart worksheets do not appear until you initiate 

their use. See pages 20 and 36 for details. 

User Guide Symbols

Follow instructions carefully to prevent errors or unwanted results. 

CAUTION

d 

y 

4

rmation. 

Skip this section if you are a novice user or want to perform only simple analyses. 

Advance

users onl

Read for useful info

TIP 
Solutions to Commonly Encountered Problems 

Problem Possible Solution Relevant Worksheets 

1. Clicking the Use Default Values

button unintentionally replaced some of your user-defined values. 

To retain user-defined values while filling in blank cells with default values, click No in the Use Default Valuespop-up window. 

Input_Sheet_Template Carbon Sequestration Refueling Station 

2. After adding energy feedstocks, 

utilities, and byproducts in the Input_Sheet_Templateworksheet, you received an error message and null results when you clicked the Calculate Cost 

button. 

Make sure you use the same price table for each energy feedstock, utility, and byproduct you add. Using different price tables creates an error in the calculations. 

Input_Sheet_Template 

3. After deleting energy feedstocks, 

utilities, and byproducts or other materials and byproducts in the Input_Sheet_Templateworksheet using Microsoft Excel's delete functionality, you received an error message and null results when you clicked the Calculate Cost button. 

Do not use Excel's delete functionality to delete entries under Energy Feedstocks, Utilities, and Byproductsor Other Materials and Byproductswithin the Input_Sheet_Template

worksheet. If you have used Excel's delete functionality in one or both of these sections, discard your current file and start afresh with the original version of the model and/or production technology case. In the future, make sure to use the H2A Model's Deletebutton to delete entries within these sections. 

Input_Sheet_Template 

5
Problem 

4. You did not perform the actions 

described in problems 2 and 3 above, but you still received an error message when you clicked the Calculate Cost button. 

Possible Solution Relevant Worksheets 

Make sure to enter all critical values in the Technical Operating Parameters and Specifications and Financial Input Values sections before completing the rest of the Input_Sheet_Templateworksheet and calculating cost. In particular, make sure values are present for reference year, startup year, and plant capacity. 

Input_Sheet_Template 

5. You used the Delete button to 

delete an entry under Energy Feedstocks, Utilities, and Byproducts or Other Materials and Byproducts, and more entries—or different entries—were deleted than you had intended. 

Be careful to choose the correct item from the Delete drop-down menu within the H2A Toolkit. It deletes all entries of the selected type. 

Input_Sheet_Template H2A Toolkit 

6. You performed a sensitivity 

analysis, and the resulting tornado chart contained bad or nonsensical results. 

Try switching the values you entered for "Value Reducing Hydrogen Price" and "Value Increasing Hydrogen Price" within the Sensitivity Analysis window. It is not always obvious how changing the value of a variable will affect the hydrogen price. 

H2A Toolkit Tornado Chart Sensitivity Analysis

A

6
7

Problem Possible Solution Relevant Worksheets 

7. You added your own energy 

feedstock, utility, or byproduct using the Energy Feed & Utility Prices worksheet, but your new item did not appear in the Energy Feedstocks, Utilities, and Byproducts section within the Input_Sheet_Templateworksheet. 

First, "refresh" the Energy Feedstocks, Utilities, and Byproducts section by selecting another price table from the drop-down menu then selecting the table in which your new item was added; use the next two drop-down menus to check if your item now appears. If your item still does not appear, go to the HyARC Physical Property Data worksheet, Table A, and make sure the item has values in every required column. 

Input_Sheet_Template Energy Feed & Utility Prices HyARC Physical Property Data

8. You modified the Lists

worksheet, and now the model does not work properly. 

Do not add, delete, or change anything on the Lists worksheet. Modifying the 

lists can disable or introduce major errors into the model. If you have modified the lists, discard your current file and start afresh with the original version of the model and/or production technology case. 

Lists 
Information Worksheets 

Established H2A production technology cases contain information worksheets linked from the 

light-green tabs. These worksheets do not participate in the model's calculations but contain 

valuable information about the project file and the hydrogen production technology being 

modeled. Clicking the Input Sheet button on any of the information worksheets sends you to 

the Input_Sheet_Template worksheet to begin using the model. 

Example Title Worksheet (Central Biomass Gasification) 

Input Sheet

button

Example Description Worksheet (Central Biomass Gasification) 

8
Example ProcessFlow Worksheet (Central Biomass Gasification) 

9
Input_Sheet_Template Worksheet 

The Input_Sheet_Template worksheet is the H2A Model's primary user interface. You use 

this worksheet to input the data the model uses for calculations, perform analyses, and 

access the automated functions of the model through the H2A Toolkit utility. After filling out 

the worksheet, you click the Calculate Cost button to calculate and view results. The 

worksheet is organized into seven main sections plus the Toolkit, which are described below 

(see page 27 for details on the H2A Toolkit). Throughout the worksheet, entries in the Notes

column describe calculations being performed or offer guidance on user inputs. 

Project Description 

The first line of the Input_Sheet_Template worksheet lists the name and date of the H2A file 

you are using. Click the View Description button to view a brief project description and history 

of updates in the Title worksheet (see page 8 for a sample Title worksheet). 

Table of Contents 

At the top of the Table of Contents are five buttons. The Project Info button sends you to the 

Title worksheet. The Key button describes the color coding used in the H2A Model. 

CAUTION 

The Use Default Values button links to a pop-up window, which provides two options for 

automatically using H2A default values. Clicking Yes replaces all Input_Sheet_Template

inputs for which default values exist with the default values. Clicking No enters 

default values only for those inputs that have default values and are blank (see 

illustration on page 11). Be careful when using this button so as not to replace 

values unintentionally. 

The Toolkit button brings up the H2A Toolkit window. Although this button is at the top of the 

worksheet, typically it is not the first thing you need to use—you will use it to perform a variety 

of important functions as described under H2A Toolkit (page 27) and in several other sections 

of this User Guide. 

Use the Calculate Cost button after completing the Input_Sheet_Template worksheet and 

associated worksheets. For illustrations, read through the rest of this section or see Quick 

Start: Performing Simple Production Cost Analyses (page 3). 

Beneath the row of buttons, the Table of Contents links to the major sections of the 

Input_Sheet_Template worksheet, which are described in the subsequent sections of this 

User Guide (the order of sections varies slightly between central and forecourt models). 

These sections include the following: 

• Technical Operating Parameters and Specifications 

• Financial Input Values 

• Energy Feedstocks, Utilities, and Byproducts 

• Capital Cost 

• Fixed Operating Costs 

• Variable Operating Costs - Other Materials and Byproducts 

• Variable Operating Costs - Other Variable Operating Costs.

10
Example of Automatically Entering Default Values in the Input_Sheet_Template Worksheet 

Technical Operating Parameters and Specifications 

Here you define the hydrogen output of your plant. Enter values for capacity factor and plant 

design capacity. The model uses these values to calculate plant output. 

Financial Input Values 

Here you define the financial characteristics of your plant. Several of the fields have an "H2a 

Default" checkbox adjacent to them. Checking this box automatically fills the cell with the H2A 

Model default value for that input. The fields Reference Year, Length of Construction Period, 

Depreciation Schedule Length, and Depreciation Type have drop-down menus containing 

The user has 

entered a nondefault value into 

cell 1 while 

erasing the value 

in cell 2 

1 

Clicking Yes in 

the Use Default 

Values pop-up 

window enters 

default values 

into both cells 

2 

1 

Clicking the Use Default Values button brings up this window 

Clicking No

enters a default 

value into the 

previously blank 

cell (2) while 

retaining the 

user-defined 

value in cell 1 

2 

1

2

11
predefined values. Select a value from the drop-down menu for these fields; values not listed 

in the drop-down menus cannot be entered. The only field calculated by the model is Total 

Tax Rate. 

Energy Feedstocks, Utilities, and Byproducts 

This important section follows the Financial Input Values section in the central model and is 

part of the Variable Operating Costs section (see page 15) in the forecourt model. It allows 

you to define energy feedstock, utility, and byproduct costs and credits—up to four of each 

type. Each element is added by first defining it using the drop-down menus and data entry 

fields, then clicking the Add button. 

CAUTION 

The first drop-down menu selects the price data table that will be used to calculate feedstock, 

energy, and byproduct costs and credits. These U.S. Energy Information Administration (EIA) 

data are drawn from the model's Energy Feed & Utility Prices worksheet (see page 38). 

Select one of the tables from the drop-down menu. The U.S. Department of Energy (DOE) 

has selected the AEO 2005 High A Case as the standard for all H2A production 

technology cases. For more information on the price data, see AEO Data 

Worksheet on page 41. Note, you must use only one price table for each 

analysis, i.e., you must use the same price table for each energy feedstock, 

utility, and byproduct you enter. 

Use the next two drop-down menus to select feedstocks, utility inputs, and byproducts; see 

Energy Feed & Utility Prices Worksheet on page 38 for an easy way to add items that are not 

already in these menus. The lower heating value (LHV) is automatically drawn from the 

HyARC Physical Property Data worksheet, Table A (see page 42). 

Next, accept the shown Price in Startup Year or click the Enter Price button to enter a 

different price. If you accept the Price in Startup Year, the model looks up the price for each 

year of the analysis in the selected price table and inflates that value using the inflation rate 

entered in the Financial Input Values section. If you enter your own price, the model inflates 

that price over the analysis period. For Usage/Production, enter the amount of energy or 

material required to produce a kilogram of hydrogen for sale—or the amount of byproduct 

produced per kilogram of hydrogen produced—in the unit shown (kg, kWh, Nm3, or L). For 

feedstock, you can click the Enter Conversion Efficiency (%) button to enter the feedstock 

conversion efficiency. (Note this is the efficiency of feedstock conversion only; if there are 

other energy inputs, the overall plant energy efficiency will be lower.) Once these fields are 

completed, click the Add button, which records your entry as shown in the screen capture on 

page 13. 

Remember that a feedstock, utility, or byproduct does not become part of the model's 

calculations until you click the Add button and the entry is recorded. Values present in the 

input fields but not recorded in this manner do not participate in the calculations. Established 

H2A production technology cases include recorded feedstock, utility, and byproduct values. 

Some also include unrecorded values in the input fields (for example, see the screen capture 

on page 13). You can disregard these unrecorded values or select new values (then click the 

Add button) if you wish to add your own feedstocks, utilities, or byproducts. 

12
Energy Feedstocks, Utilities, and Byproducts (Input_Sheet_Template Worksheet) 

CAUTION 

To delete entries, click the Delete button, which pulls up the Toolkit menu. Use the drop-down 

menu under Editing to select the type of entry you want to delete. Then click the Delete

button. This deletes all entries of the selected type. For example, if you had selected three 

energy byproducts, choosing Energy Byproduct from the drop-down menu and clicking the 

Delete button will delete all three. 

When deleting entries, it is critical to use the Delete button. Do not delete the 

rows using Excel's delete function. Also, be careful to choose the correct item 

from the Delete drop-down menu within the Toolkit. It can delete not only the 

energy feedstocks, utilities, and byproducts selected in this section, but also the 

other materials and byproducts selected in the Variable Operating Costs section 

(page 15). 

The model uses the selected entries to automatically calculate total energy feedstock and 

utilities costs and byproduct credits in the startup year. These values appear in the three blue 

cells at the bottom of the section but are not used in the cash-flow calculations. You can view 

the yearly values being used in the cash-flow calculations in the lowermost table of the Cash 

Flow Analysis worksheet (see the bottom screen capture in the schematic on page 15). 

If desired, advanced users can change the units applied to each material 

selected in this section. For example, the units for natural gas feedstock 

could be changed from Nm3 to scf. This requires changes be made 

elsewhere in the model. Go to the HyARC Physical Property Data

worksheet, Table A, and change the unit in the column H2A Usage Input 

Unit/ kg H2. In the column H2A LHV (GJ or mmBtu/ H2A usage input unit), 

Advanced 

users only 

Clicking 

Add

button 

records 

your 

selected 

feed 

here 

Add button Delete button 

Input field values do not 

participate in calculations until 

recorded using Add button 

13
enter the numerical value of the LHV corresponding to the new input unit; the LHV must be 

entered as GJ/usage unit for metric values and mmBtu/usage unit for English values. Check 

that the calculated results accord with the new-unit input values. 

Advanced users also can take advantage of a shortcut in this section. If you want 

to perform numerous modeling runs—for example, by modeling the hydrogen 

costs resulting from an array of feedstock, utility, and byproduct input price and 

production/usage values—you can save time by typing values directly into certain 

Excel cells instead of using the model's Add and Delete functions every time. 

Initially, add your chosen feedstocks, utilities, and byproducts using the Add

function. If you want to vary items by typing over values, click the Enter Price

button for those items and enter your own price; this automatically changes the Lookup 

Prices field to "no." After completing the rest of the model's sections and recording the 

resulting hydrogen cost, return to the Energy Feedstocks, Utilities, and Byproducts section. 

For any items with "no" in the Lookup Prices field, you can manually replace the values for 

Usage/Production and Price in Startup Year—simply type over the existing values. Once you 

have finished typing in values, click the Calculate Cost button to see the resulting hydrogen 

cost. 

Advanced 

users only 

Advanced Users Can Manually Enter Certain Feedstock, Utility, and Byproduct Values 

Capital Costs 

Here you define the capital costs of your plant. For quick analyses, enter the total direct 

capital costs in the first input cell. When developing cases or detailed analyses, entering 

detailed capital costs is recommended. Click the first Link to Detail Sheet button, which takes 

you to the Capital Costs worksheet for data entry 

(see page 19). Clicking the second Link to Detail 

Sheet button takes you to the Carbon Sequestration

worksheet (in the central model; see page 23) or the 

Refueling Station worksheet (in the forecourt model; 

see page 25) to calculate detailed capital costs for those functions. Note that some of the 

orange input fields can contain suggested equations. You can overwrite these with your own 

static values or equations. Once all applicable fields are filled with inputs and calculated 

values, the model calculates Total Depreciable Capital Costs, Total Non-Depreciable Capital 

Costs, and Total Capital Costs. 

Only enter values 

manually when Lookup 

Prices says "no" 

Values that can be 

entered manually 

Orange cells are overwritten 

automatically when you import a 

new case (pg 27) or use the cell

variable in plant scaling (pg 20). TIP 

14
Schematic of Data Flow to and from Energy Feedstocks, Utilities, and Byproducts Section 

HyARC Physical Property 

Data worksheet 

Energy Feed & Utility 

Prices worksheet 

Inputs

Input_Sheet_Template

worksheet 

Calculations

Cash Flow Analysis 

worksheet

Fixed Operating Costs 

Here you define your plant's fixed operating costs. Once values are entered or calculated for 

each field, the model calculates Total Fixed Operating Costs. In the forecourt model, enter 

information for the staff needed to run the hydrogen production equipment in the first two 

cells and for the filling station staff in the fourth and fifth cells. If you linked to the Refueling 

Station worksheet in the Capital Cost section (see above), the storage and dispensing labor 

costs will be set to zero here. 

Variable Operating Costs 

Here you define process material costs and other variable operating costs and the value of 

non-energy byproducts. In the forecourt model, this section also contains the function for 

15
defining energy feedstocks, utilities, and byproducts; this function is described for both the 

central and forecourt models on page 12. The remaining parts of the Variable Operating 

Costs section are Other Materials and Byproducts and Other 

Variable Operating Costs. To prevent model errors, enter all 

critical values in the Technical Operating Parameters and 

Specifications (page 11) and Financial Input Values (page 11) 

sections before completing these sub-sections. 

Make sure 

values are 

present for 

reference year, 

startup year, & 

plant capacity 

TIP 

Other Materials and Byproducts

This sub-section works in a fashion similar to the Energy Feedstocks, Utilities, and 

Byproducts function described on page 12. It allows you to define up to three non-energy 

input materials and three byproducts. Each element is added by first defining it using the 

drop-down menus and data entry fields, then clicking the Add button. 

This sub-section requires fewer user choices than the Energy Feedstocks, Utilities, and 

Byproducts function. You do not need to select price tables; prices are automatically drawn 

from the lists on the Non-Energy Material Prices worksheet, or you can enter your own price 

by clicking the Enter Price button. 

The Byproduct check box allows you to switch between materials consumed as process 

inputs (which incur costs) and materials produced as byproducts (which produce 

income/credits). When the box is unchecked, the material in the drop-down menu (cooling 

water, demineralized water, etc.) is labeled as a feed or utility, and the number you input is 

usage per kilogram of hydrogen produced for sale. When the box is checked, the material in 

the drop-down menu is labeled as a byproduct, and the number you input is production per 

kilogram of hydrogen. 

You can add materials to the drop-down menu simply by going to the Non-Energy Material 

Prices worksheet and adding information for the new material in the rows underneath the 

existing information. See Non-Energy Material Prices Worksheet on page 40 for an 

illustration. This is also where you can modify the material prices if desired. 

When deleting entries, you must use the Delete button. Do not delete the rows 

using Excel's delete functionality. Also, be careful to choose the correct item 

from the Delete drop-down menu within the H2A Toolkit. It can delete not only 

the other materials and byproducts selected in this sub-section, but also the 

energy feedstocks, utilities, and byproducts selected previously (see page 12). 

CAUTION 

Advanced 

users only 

Advanced users can take advantage of a shortcut in this section by typing values 

directly into certain Excel cells instead of using the model's Add and Delete

functions every time. This is done in a fashion similar to that in the Energy 

Feedstocks, Utilities, and Byproducts section—see page 14 for instructions. 

16
Other Materials and Byproducts (Input_Sheet_Template Worksheet) 

Other Variable Operating Costs

This sub-section defines additional variable operating costs. Fill in the appropriate input 

(orange) cells. The factor you enter in the field Total Unplanned Replacement Capital Cost 

Factor is transferred to the Replacement Costs worksheet (see page 18), which calculates 

replacement costs based on this factor and the value for total depreciable capital costs (see 

Capital Costs, page 14). Clicking the Enter Specific Costs button takes you to the 

Replacement Costs worksheet, where you can specify additional replacement costs. 

For the central model, the field CO2 sequestration O&M costs and credits is filled in 

automatically if you linked to the Carbon Sequestration worksheet in the Capital Costs

section (see page 14). For the forecourt model, the field Refueling Station O&M costs shows 

a value of zero if you linked to the Refueling Station worksheet in the Capital Costs section 

(see page 14). Note, these O&M costs are not actually zero; rather, a separate cash flow 

analysis is performed for the refueling station (compression, storage, and dispensing), and 

the results are presented in a separate column in the Results worksheet. 

Once you have entered all the information you want to enter, scroll to the top of the 

Input_Sheet_Template worksheet and click the Calculate Cost button. This sends you to the 

Results worksheet, which displays results as illustrated under Quick Start: Performing Simple 

Cost Analyses (page 3).

Byproduct check box 

Non-Energy Material 

Prices tab 

17
Replacement Costs Worksheet 

The Replacement Costs worksheet is the source of replacement cost information for the cash 

flow analysis calculations. It accounts for planned and unplanned replacement costs. 

Enter planned replacement costs (in reference year $) for each 

year in the Specified Yearly Replacement Costs column. The 

values in the Unplanned Replacement Costs column are 

calculated automatically in the following way: 

1) The Total Unplanned Replacement Capital Cost Factor you entered in the Other Variable 

Operating Costs sub-section of the Input_Sheet_Template worksheet (see page 17) is 

automatically imported into the Replacement Costs worksheet (in the uppermost blue cell; 

see screen capture below). Clicking the Input Sheet button sends you directly to the relevant 

cost factor cell in the Input_Sheet_Template worksheet. 

2) This cost factor is multiplied times the Total Depreciable Capital Costs value from the 

Input_Sheet_Template worksheet (see page 14); the result is automatically entered for each 

year in the Unplanned Replacement Costs column. 

The inflation-adjusted sum of the specified (i.e., planned) and unplanned replacement costs 

is automatically entered into the Total Yearly Replacement Costs column. When finished, 

click the Input Sheet button to return to the Input_Sheet_Template worksheet. 

Replacement Costs Worksheet (Forecourt Model Shown) 

Unplanned 

replacement cost 

factor (from the 

Input_Sheet_Template

worksheet) 

Planned 

replacement 

costs 

(user input) 

Unplanned 

replacement 

costs 

(calculated) 

Total 

replacement 

costs 

(calculated) 

Enter planned 

replacement 

costs in 

reference year 

dollars—do not 

inflate. 

TIP 

Reference year 

Input Sheet

button

18
Capital Costs Worksheet 

The Capital Costs worksheet accepts inputs for individual capital costs and calculates total 

direct capital cost. This total direct capital cost can then be imported into the Capital Costs

section of the Input_Sheet_Template worksheet (see page 14). For the central model, this is 

the direct capital cost of the production equipment not including carbon sequestration 

equipment (see page 23 for carbon sequestration calculations). For the forecourt model, it is 

the direct capital cost of the production unit plus compression, storage, and dispensing if you 

choose to enter these costs using this worksheet; see page 25 for instructions on calculating 

optimal compression, storage, and dispensing costs using the Refueling Station worksheet. 

Activate the Capital Costs worksheet by clicking the Link to Detail Sheet button next to the 

H2A Total Direct Capital Cost (for the central model) or H2A Production Process Total Direct 

Capital Cost (for the forecourt model) field in the Capital Costs section of the 

Input_Sheet_Template worksheet. Enter the names of capital equipment items in the column 

Major pieces/systems of equipment. Enter uninstalled costs for each item in the column 

Baseline Uninstalled Costs. Under the column Installation Cost Factor, enter values by which 

the uninstalled costs of each item will be multiplied to give installed costs. The model 

automatically calculates total installed direct capital cost in the Baseline Installed Costs

column. When you are finished inputting values, click the Input Sheet button at top to return 

to the Input_Sheet_Template worksheet, where the total capital cost will appear; the screen 

captures below show the linkage. 

Capital Costs Worksheet (Central Model Shown) 

Input Sheet

button

Input_Sheet_Template Worksheet (Central Model Shown) 

Installed Cost from 

Capital Costs worksheet 

links to Total Direct 

Capital Cost in 

Input_Sheet_Template

worksheet 

19
Plant Scaling Worksheet 

The H2A Model is designed to determine the levelized cost of hydrogen from a facility with a 

specific hydrogen production capacity. Similarly, established H2A production technology 

cases model facilities with specific production capacities. The Plant Scaling worksheet makes 

it easy to analyze facilities with different production capacities. Complete the following steps 

in the order shown: 

1) Set Baseline Plant Values (Input_Sheet_Template Worksheet & H2A Toolkit) 

Baseline plant values are imported into the Plant Scaling worksheet from the 

Input_Sheet_Template worksheet, so the first step is to fill out the Input_Sheet_Template

worksheet completely (see page 10). Once you have finished, open the H2A Toolkit (by 

clicking the Toolkit button at the top of the Input_Sheet_Template worksheet) and click the 

Set up Plant Scaling button. Clicking this button exports values from the 

Input_Sheet_Template worksheet into the Plant Scaling worksheet (the Plant Scaling

worksheet tab appears when you click the button), specifically into the first cell (Baseline 

Design Capacity) in the Plant Scaling Factors section and the baseline value cells within the 

Capital Investment and Plant Scaling Method sections. 

2) Establish Scaling Parameters (Plant Scaling Worksheet) 

After you click the Set up Plant Scaling button and answer OK to the query, you are sent to 

the Plant Scaling worksheet, where you establish your scaling parameters. In the Plant 

Scaling Factors section, accept the Default Scaling Factor Exponent or enter a new one. 

Changing the Scaling Factor Exponent changes how the cost of each item of capital 

equipment varies in relation to the Scale Ratio (the ratio of new design capacity to baseline 

design capacity) as follows: 

Scaled Cost = Baseline Cost × Scale RatioScaling Factor Exponent 

For example, a Scaling Factor Exponent of 1.0 means the cost of the equipment increases by 

the same ratio as the increase in plant capacity. Scaling Factor Exponents are typically 1.0 or 

less. If values for individual pieces of equipment are entered in the column Scaling Factor 

Exponent within the Capital Investment section, those values are used in the scaling 

calculations. If a value is not present in this column for a given item, the Default Scaling 

Factor Exponent in the Plant Scaling Factors section is used. 

The Lower Limit for Scaling Capacity and Upper Limit for Scaling Capacity fields define the 

capacity range within which the scaling you are defining is valid. The model will alert you 

when you click the Calculate Cost button (in step 3, see below) if you attempt to scale your 

plant capacity outside the range you specify. 

20
Plant Scaling Worksheet: Plant Scaling Factors and Capital Investment Sections 

Baseline design capacity 

from Input_Sheet_Template

worksheet

Scaling Factor Exponent 

used if values in Capital 

Investment section not 

present 

After you have added Scaling Factor Exponents to the Plant Scaling Factors and Capital 

Investment sections, go down to the next section to define scaling parameters for indirect and 

non-depreciable capital costs and operating costs. The baseline values for these items 

(Engineering & Design, Site Preparation, etc.) were imported from the Input_Sheet_Template

worksheet. Note that, in the forecourt model, the variables used in the Refueling Station

worksheet are scaled within that worksheet and, therefore, do not appear in the Plant Scaling

worksheet. 

For each item in the table, choose one of the following scaling methods from the drop-down 

menus in the Select Method column: 

• Use Scale Ratio—uses the scale ratio to scale the item cost in relation to plant capacity 

(i.e., linearly) (Scaled Value = Baseline Value × Scale Ratio) 

• Use Scale Factor—uses the scale factor (the ratio of total scaled installed capital cost to 

total baseline installed capital cost) to scale the item cost in relation to plant capital cost 

(i.e., scale with capital costs) (Scaled Value = Baseline Value × Scale Factor) 

• Use Baseline Value—uses the shown baseline value with no scaling 

• Skip—skips the value, does not change the cell value or equation. 

Once you have selected scaling methods for all items, click the Finish Scaling button. 

Scaling Factor 

Exponents used 

if present 

Limits for 

scaling 

capacity 

21
Plant Scaling Worksheet: Plant Scaling for Indirect & Non-Depreciable Capital and Operating Costs 

Baseline values from 

Input_Sheet_Template

worksheet 

Scaling 

method dropdown menu 

Finish Scaling

button 

3) Set Scaled Plant Capacity (Input_Sheet_Template Worksheet) 

After you click the Finish Scaling button, you are sent back to the Input_Sheet_Template

worksheet. Enter a value for your new plant's design capacity in the Technical Operating 

Parameters and Specifications section (see screen capture below). If this value is larger than 

the baseline design capacity, the scale factor and ratio will be greater than 1.00. If it is 

smaller, the scale factor and ratio will be less than 1.00. Once you have entered this value, 

the cost values in the Input_Sheet_Template and Plant Scaling worksheets are scaled 

automatically according to the parameters you set in the Plant Scaling worksheet (step 2 

above). Click the Calculate Cost button to calculate the new hydrogen cost. 

Input_Sheet_Template Worksheet 

New design capacity

Scale up cost 

calculations by 

increasing this value vs. 

the baseline; scale 

down cost calculations 

by decreasing it 

TIP 

Turning Off Plant Scaling 

To turn off plant scaling, click the Toolkit button at the top of the Input_Sheet_Template

worksheet, and click the Turn Plant Scaling Off button within the H2A Toolkit. Your plant 

characteristics will revert to the previously established baseline values. 

22
Carbon Sequestration Worksheet (Central Model Only) 

This worksheet is the source of values for carbon sequestration capital, operating, and 

electrical costs as well as carbon sequestration efficiency (proportion of carbon emissions 

captured from hydrogen production feedstocks) and energy use. It calculates costs for CO2

compression, transportation to the sequestration site, and injection. Costs for CO2 capture 

are assumed to be included in the production facility's capital and operating costs and are not 

included in this worksheet. Further, the worksheet only covers CO2 emissions from the 

hydrogen production feedstocks, not CO2 emissions from fuels used as utilities (e.g., natural 

gas used in a heater). 

Before completing the Carbon Sequestration worksheet, specify all feedstocks and utilities in 

the Input_Sheet_Template worksheet (see Energy Feedstocks, Utilities, and Byproducts, 

page 12). After you have specified the feedstocks and utilities, activate the Carbon 

Sequestration worksheet by clicking the Link to Detail Sheet button next to the H2A Carbon 

Sequestration Total Direct Capital Cost field in the Capital Costs section of the 

Input_Sheet_Template worksheet (see screen capture below). 

Input_Sheet_Template Worksheet 

Clicking the Link to Detail Sheet button sends you to the Carbon Sequestration worksheet. At 

the top of the worksheet are notes, three self-explanatory buttons (see page 10 for a 

description of the Use Default Values functionality), and links to tables within the worksheet. 

Of the four tables, you will input values only into Carbon Sequestration Input Values; 

complete or accept the default values for the orange-shaded fields. The other tables display 

the calculations and results based on your inputs. When you are finished inputting values, 

click the Input Sheet button at top to return to the Input_Sheet_Template worksheet. 

The cost results (seen in the Summary of Output Values table) are the source of carbon 

sequestration direct capital costs and CO2 sequestration operation and maintenance costs 

Click to activate 

and go to Carbon 

Sequestration

worksheet 

23
and credits within the Input_Sheet_Template worksheet as well as carbon sequestration 

electricity use, which is used in the cash flow analysis—see the schematic below. The 

calculations also feed the carbon sequestration cost, energy use, and emissions results 

within the Results worksheet. 

See Appendix 1 (page 49) for more information about the carbon sequestration inputs, 

outputs, and calculations used in this worksheet plus references for further reading. 

Schematic of Cost Outputs from Carbon Sequestration Worksheet to Other H2A Worksheets 

24
Refueling Station Worksheet (Forecourt Model Only) 

This extensive worksheet calculates the optimal cost for compressing, storing, and 

dispensing hydrogen at a refueling station with a convenience store. Costs are calculated per 

kilogram of hydrogen dispensed. The average capacity can be varied up to 6,000 kg/day. 

Because the capital, fixed, and operating costs vary along with the varying capacity, none of 

the variables included in this worksheet appear in the Plant Scaling worksheet. 

Activate the Refueling Station worksheet by clicking the Link to Detail Sheet button next to 

the H2A Compression, Storage, and Dispensing Total Direct Capital Cost field in the Capital 

Costs section of the Input_Sheet_Template worksheet (see screen capture below). When 

you have linked to the Refueling Station worksheet, the capital and operating costs for the 

model's cash flow analysis are calculated on that worksheet; thus, the corresponding fields 

within the Capital Costs and Other Variable Operating Costs sections of the 

Input_Sheet_Template worksheet show as zero. 

Input_Sheet_Template Worksheet 

Click to activate 

and go to 

Refueling Station

worksheet 

Clicking the Link to Detail Sheet button sends you to the Refueling Station worksheet. At the 

top of the worksheet are notes, three self-explanatory buttons (see page 10 for a description 

of the Use Default Values functionality), and links to tables within the worksheet. The 

following six tables are designed to accept user inputs; complete or accept the default values 

for the orange-shaded fields: 

• Forecourt Specific Economic Assumptions 

• Refueling Station Design Inputs 

• Refueling Station Scenario Inputs 

• CAPITAL INVESTMENT - Equipment Costs 

• Other Compression, Storage, Dispensing Capital Costs 

• Compression, Storage, Dispensing O&M Costs. 

25
The other tables display the calculations and results based on your inputs. When you are 

finished inputting values, click the Input Sheet button at top to return to the 

Input_Sheet_Template worksheet. 

The Refueling Station cost results (displayed in the Calculation Outputs table) are transferred 

to the Results worksheet—see the schematic below. The Refueling Station worksheet also 

provides the values needed to calculate energy use and emissions due to compression, 

storage, and dispensing. 

See Appendix 2 (page 56) for more information about the refueling station inputs, outputs, 

and calculations used in this worksheet plus references for further reading. 

Refueling Station Worksheet 

Results Worksheet 

26
H2A Toolkit 

The H2A Toolkit is not an Excel worksheet—it is a pop-up window accessed by clicking the 

Toolkit button at the top of the Input_Sheet_Template worksheet or by clicking the Delete

buttons within the worksheet. The Toolkit performs a number of functions: 

• Importing existing H2A cases 

• Printing and exporting inputs and results 

• Editing input parameters 

• Setting up plant scaling 

• Performing sensitivity analyses. 

H2A Toolkit 

Importing Existing H2A Cases 

You can use the H2A Toolkit to import technology cases that are stored in 

previous versions of the H2A Model into the new version of the model. In the 

Toolkit, click the Import an Existing H2A Case button. A window will pop up, 

which states, "The values in the current case will be deleted." If you have any CAUTION 

27
information in the current file that you want to save, click Cancel and save your file to a new 

name before proceeding. If your file does not need to be saved, click OK. Another window will 

pop up stating, "Data may exist in the sheet(s) selected for deletion. To permanently delete 

the data, press Delete." Instead of clicking the Delete button, click the Cancel button to 

proceed. 

Click OK on the next pop-up to select a case to import. Use the Browse window that appears 

to locate the technology case you want to import. Select the case and click OK. Values from 

the technology case you selected are automatically imported into the new model. During 

importation, the case you are importing data from will open, and a window will pop up asking 

if you want to save changes to it. Click the No button to close the case. 

The model imports data by searching the technology case for variables present in the 

Import_Variable_List within the Lists worksheet (see page 47 for more information about the 

Lists worksheet). The model does not always find the target variables in this way; once the 

case is imported review the input fields and fill in missing values manually by referring to the 

old version of the technology case. Commonly missed values include Reference Year and 

several of the Indirect Depreciable Capital Costs within the Input_Sheet_Template worksheet 

and Specified Yearly Replacement Costs within the Replacement Costs worksheet. The 

detailed capital cost breakdown (Capital Costs worksheet) and information worksheets are 

not imported. 

You must also manually add information to the Energy Feedstocks, Utilities, and Byproducts

and Other Materials and Byproducts sections within the Input_Sheet_Template worksheet; 

the automatic importation function does not capture this information. The old version of the 

model draws from the same price tables as the new version, so this is a relatively easy 

process. See Energy Feedstocks, Utilities, and Byproducts (page 12) and Other Materials 

and Byproducts (page 16) for instructions on adding information to these sections. 

Input_Sheet_Template Worksheet (Forecourt Model Shown) 

After importing a 

technology case, add 

information to these 

sections manually 

28
Printing and Exporting Inputs and Results 

Clicking the Print Input Report and Print Result Report buttons automatically prints 

information from the Input_Sheet_Template and Results worksheets, respectively. Automatic 

printing does not work with all printers. If it does not work for you, simply go to the worksheet 

you would like to print, click File at the top of your Excel window, and then click Print. 

You can also export the inputs and results from your analysis to an Excel file. Click the Export 

Data button. Click Yes in the pop-up window that asks if you want to save your file. After you 

save the file, it will close automatically. The resulting file contains input and result values in 

an easily importable format, which you can bring into other analysis models. You could also 

use the Importing an Existing Case function (see page 27) to import the values into another 

H2A Production Model file. 

Editing Input Parameters 

Two functions are available within the H2A Toolkit's Editing section: Delete Feed, Utility, and 

Byproduct Inputs and Set up Plant Scaling. 

Delete Feed, Utility, and Byproduct Inputs

This function deletes items that have been added to the Energy Feedstocks, Utilities, and 

Byproducts and Other Materials and Byproducts sections within the Input_Sheet_Template

worksheet (see pages 12 and 16). Use the drop-down menu under Editing to select the type 

of item you want to delete. Then click the Delete button. This deletes all items of the selected 

type. For example, if you had selected three energy byproducts, choosing Energy Byproduct 

from the drop-down menu and clicking the Delete button will delete all three. 

CAUTION 

When deleting items, it is critical to use the Toolkit's Delete button. Do not delete 

the corresponding rows within the Input_Sheet_Template worksheet using 

Excel's delete function. Also, be careful to choose the correct item from the 

Delete drop-down menu. All items of the selected type are deleted within the 

Energy Feedstocks, Utilities, and Byproducts or Other Materials and Byproducts

sections. Choosing “All” at the bottom of the drop-down menu deletes all energy and nonenergy feeds, utilities, and byproducts. 

H2A Toolkit: Delete Feed, Utility, and Byproduct Inputs 

Select the item to 

delete from the 

drop-down menu 

then click the Delete

button

29
Set up Plant Scaling

The H2A Toolkit's Set up Plant Scaling button is part of the process that scales your capital 

and operating costs to smaller or larger plant sizes. Do not click this button except as part of 

the scaling process. See Plant Scaling Worksheet (page 20) for details. 

Performing Sensitivity Analyses 

To perform a sensitivity analysis—which helps you understand how sensitive the cost of 

hydrogen is to changes in key input variables—click the Sensitivity Analysis button in the H2A 

Toolkit. In the Sensitivity Analysis window, use the first drop-down menu to select a variable 

you will use for the analysis (only variables that have a value in the base case will appear in 

the drop-down menu). Highlighting the variable selects it and adds it to the second drop-down 

menu. With your variable now shown in the first line of the second drop-down menu, its value 

from the current case is displayed in the Value from Base 

Case field. Enter a value for Value Reducing Hydrogen 

Price and a value for Value Increasing Hydrogen Price. 

For example, for After-tax Real IRR with a base case 

value of 0.1, you might enter 0.08 for the Value Reducing 

Hydrogen Price and 0.12 for the Value Increasing 

Hydrogen Price (see screen capture below). Repeat this 

process for up to 50 variables. 

H2A Toolkit: Sensitivity Analysis Window 

To delete a variable from the analysis, select the variable in the second drop-down menu and 

click the Delete button. Click Yes in the pop-up window that asks if you want to delete the 

variable. Remember, variables are added simply by highlighting them in the first drop-down 

Select variables using first 

drop-down menu

Second drop-down menu 

displays selected variables 

It's not always obvious 

what will reduce vs. 

increase hydrogen price; 

if you get bad results 

(e.g., a blank tornado 

chart), switch your 

"Reducing" & "Increasing" 

values and try again. 

TIP 

Enter "Reducing" 

and "Increasing" 

values here 

30
menu, so check the second drop-down menu and delete unwanted variables before running 

your analysis. Also, make sure that three values are entered for each variable you do want to 

analyze. 

Once you are satisfied with the variables you have selected and the "Reducing" and 

"Increasing" values you have entered, click the Calculate Prices button. A pop-up window will 

state, "Data may exist in the sheet(s) selected for deletion. To permanently delete the data, 

press Delete." Click the Delete button. Next, close the Sensitivity Analysis window and H2A 

Toolkit. You are now in the Sensitivity Analysis worksheet (see page 37), where you see how 

much the minimum hydrogen selling price varies when your "Reducing" and "Increasing" 

values are entered into the model while holding all other variables constant at their base 

values. To the left of the Sensitivity Analysis tab is the Tornado Chart tab. The Tornado Chart

worksheet shows the results of the sensitivity analysis graphically (see page 36). 

If there were values in the Sensitivity Analysis and Tornado Chart worksheets before you 

performed your sensitivity analysis, they will be overwritten with your new results. Each time 

you perform a sensitivity analysis, the values in these worksheets are overwritten with the 

new values, so you can only have one set of values and one valid tornado chart at a time. If 

you want to create multiple sensitivity analyses/tornado charts, perform your first analysis 

then save your Excel file under a new name, perform your second analysis then save this file 

under a different name, and so forth. 

31
Results Worksheet 

The Results worksheet tabulates the results of your H2A Model analysis. No user input is 

required within this worksheet. You are sent here after you click the Calculate Cost button in 

the Input_Sheet_Template worksheet. The hydrogen cost results are in the Specific Item 

Cost Calculation table at the top (see screen captures below). Note that, in the central model, 

the costs shown in the Approximate Carbon Sequestration Costs table are included in the 

total cost shown in the Specific Item Cost Calculation table. 

Central Model Cost Results Including (Top) and not Including (Bottom) Carbon Sequestration 

Hydrogen cost (production + 

carbon sequestration) 

Hydrogen cost 

(production only)

Costs attributed to 

carbon sequestration 

Box grayed out indicating 

carbon sequestration not 

included 

32
Forecourt Model Cost Results 

Hydrogen cost 

(production + 

compression, 

storage, and 

dispensing) 

The remaining tables show energy and emissions results. The Energy Data table 

summarizes the energy inputs in the form of feedstocks, utilities, carbon sequestration (for 

the central model), and compression, storage, and dispensing (for the forecourt model). It 

also summarizes the energy outputs in the form of hydrogen and byproducts. The Production 

Process Energy Efficiency (for the central model) and Facility Energy Efficiency (for the 

forecourt model) tables show a percentage efficiency calculated by dividing energy outputs 

by energy inputs. Unless otherwise specified, efficiencies are reported on an LHV basis. 

The Upstream Energy Usage table shows total, fossil fuel, and petroleum energy consumed 

by energy inputs during their upstream processing (e.g., natural gas extraction, ethanol 

production, or coal-fired electricity generation). These estimates of upstream energy use are 

calculated based on the GREET (Greenhouse gases, Regulated Emissions, and Energy use 

in Transportation) Model, version 1.86. The GREET Model is continually being updated. For 

the most accurate upstream energy results, download and use the most recent GREET 

version at www.transportation.anl.gov/modeling_simulation/GREET. 

The Emissions Summary table summarizes upstream and process greenhouse gas 

emissions. The next two tables—Production Process GHG Emissions Summary and 

Production Process GHG Emissions—detail the process greenhouse gas emissions. Note 

that the default is to have all process emissions counted as CO2, as defined in the HyARC 

Physical Property Data worksheet, Table A. If you want to add information about CH4 and 

N2O emissions to the energy feeds, enter values in the last two columns of Table A (see 

screen capture below). 

33
HyARC Physical Property Data Worksheet, Table A: Entering CH4 and N2O Values 

Enter CH4 and 

N2O values in 

these columns 

Note: some table columns have been hidden for illustrative purposes. 

The Upstream GHG Emissions table shows greenhouse gas emissions (CO2, CH4, N2O, and 

total) produced by energy inputs during their upstream processing. These estimates of 

upstream emissions are calculated based on the GREET Model, version 1.7. The GREET 

Model is continually being updated. For the most accurate upstream emissions results, 

download and use the most recent GREET version at 

www.transportation.anl.gov/modeling_simulation/GREET. 

Results Worksheet, Upstream GHG Emissions Table 

34
Cash Flow Analysis Worksheet 

The Cash Flow Analysis worksheet shows the inputs, outputs, and calculations of the 

discounted cash flow analysis used to generate the hydrogen cost results (see page 32). No 

user input is required within this worksheet. 

The worksheet contains the following information, which is linked from a table of contents at 

the top: 

• Discounted Cash Flow (DCF) Calculations 

• Yearly Cash Flow Calculations 

• Specific Item Cost Calculation 

• Feedstock, Utility, and Byproduct Cost Information. 

Cash Flow Analysis Worksheet 

35
Tornado Chart Worksheet 

The Tornado Chart worksheet shows sensitivity analysis results graphically; see page 30 for 

information about performing sensitivity analyses and page 37 for the Sensitivity_Analysis

worksheet, which shows the results numerically. The bars within the tornado chart show the 

range of minimum hydrogen selling price values obtained 

by entering—for each specified variable—a base value, a 

"reducing" value (i.e., a value that reduces the hydrogen 

price), and an "increasing" value (i.e., a value that 

increases the hydrogen price) while holding all other 

variables constant at their base values. No user input is 

required within this worksheet. 

Unless you are using an 

H2A technology case 

that has a default 

tornado chart, the 

Tornado Chart tab will 

not appear until you 

perform your first 

sensitivity analysis. 

TIP 

For established H2A production technology cases, a default sensitivity analysis/tornado chart 

is included. The input value ranges used in these analyses are based on feedback from 

analysts consulted as part of the H2A development process and on ongoing DOE research 

into the uncertainties inherent to the various hydrogen production variables. 

Tornado Chart Worksheet 

Base hydrogen price (all 

variables at their base values)

Price when using 

Value Reducing 

Hydrogen Price

Price when using 

Value Increasing 

Hydrogen Price

36
Sensitivity_Analysis Worksheet 

The Sensitivity_Analysis worksheet shows sensitivity analysis results numerically; see page 

30 for information about performing sensitivity analyses and page 36 for the Tornado Chart

worksheet, which shows the results graphically. 

The worksheet's columns show the range of minimum hydrogen selling price values obtained 

by entering—for each specified variable—a nominal (i.e., base) value, a lower value (i.e., a 

value that reduces the hydrogen price), and an upper value (i.e., a value that increases the 

hydrogen price) while holding all other variables constant at their base values. The columns 

at the far right show the difference in price between the lower-value and upper-value 

hydrogen prices and the nominal-value price. 

It is best not to modify anything directly within this worksheet. Use the H2A Toolkit's

sensitivity analysis function (page 30) to make changes. 

Sensitivity_Analysis Worksheet 

37
Energy Feed & Utility Prices Worksheet 

The Energy Feed & Utility Prices worksheet is the source of price information for the Energy 

Feedstocks, Utilities, and Byproducts calculations within the Input_Sheet_Template

worksheet (see page 12). It contains three pairs of tables, which list projected prices in $2005 

for 11 energy inputs/byproducts through the year 2070: 

• AEO 2007 Energy Prices & AEO 2007 Energy Prices Common Units 

• AEO Reference Case 2005 & AEO Reference Case 2005 Common Units 

• AEO 2005 High A Case & AEO 2005 High A Case Common Units 

The AEO 2005 High A Case is the default for all established H2A production technology 

cases. 

The raw prices used to make these tables, through the year 2025 (for AEO Reference Case 

2005 and AEO 2005 High A Case) and 2030 (for AEO 2007 Energy Prices), were drawn from 

the EIA’s Annual Energy Outlook (AEO). The year 2026/2031–2070 prices were projected 

using Pacific Northwest National Laboratory's (PNNL's) Mini-CAM model. See AEO Data 

Worksheet (page 41) for more information. 

You can add your own energy feedstocks, utilities, byproducts, and prices to the tables in the 

Energy Feed & Utility Prices worksheet. Complete the following steps (illustrated in the 

screen captures below): 

1) In the table of your choice (i.e., any table but a "common units" table), scroll down to the 

orange-shaded rows labeled User Defined Feed 1, User Defined Feed 2, etc. in the 

Feedstock Type column. Overwrite one of these User Defined Feed labels with a name 

for your first item (feedstock, utility, or byproduct). Do not use special characters (such as 

parentheses) in the name. Fill in price values for each year in the reference year $/unit 

shown; you can change the unit, but it must be either $/GJ LHV or $/mmBtu LHV. Repeat 

the process for up to five more items (two user-defined feeds in each table). 

2) Go to the HyARC Physical Property Data worksheet, Table A. Your new item's name and 

units will appear automatically near the bottom of the table. Complete all orange-shaded 

cells for your new item. In the List column, select from the drop-down menu. 

3) Optional step: If you want to add upstream energy and emissions values for your item, 

enter them next to the item's name near the bottom of Table C1 (for startup years 2005–

2019) and C2 (for startup years 2020 and beyond). 

4) Within the Input_Sheet_Template worksheet, "refresh" the Energy Feedstocks, Utilities, 

and Byproducts section by selecting another price table from the first drop-down menu 

then selecting the table in which your new item was 

added. Your new item will now appear as part of t

table; find it using the two drop-down menus unde

the heading Select the Feed. 

hat 

r 

If your item does not 

appear, go back to the 

HyARC Physical 

Property Data 

worksheet, Table A, and 

make sure the item has 

values in every required 

column. 

TIP 

38
Energy Feed & Utility Prices Worksheet 

HyARC Physical Property Data Worksheet, Table A 

HyARC Physical Property Data Worksheet, Table C1 & C2 (Optional) 

Input_Sheet_Template Worksheet 

1 

2 

4 

3

39
Non-Energy Material Prices Worksheet 

The Non-Energy Material Prices worksheet is the source of price information for the Other 

Materials and Byproducts calculations within the Input_Sheet_Template worksheet (see page 

16). Add new materials simply by adding information in the rows underneath the existing 

information. You can also modify the prices of materials here if desired. 

Other Materials and Byproducts (Input_Sheet_Template Worksheet) 

Non-Energy Material Prices Worksheet 

Items entered into the Non-Energy Material 

Prices worksheet are added automatically to 

the Other Materials and Byproducts dropdown menu in the Input_Sheet_Template

worksheet 

40
AEO Data Worksheet 

The data in the AEO Data worksheet are the source of the energy price tables in the Energy 

Feed & Utility Prices worksheet (page 38). For typical users, no actions are required or 

recommended within this worksheet. The worksheet contains four tables: 

• AEO 2007 Energy Prices 

o Based on report no. DOE/EIA-0383(2007), Table 3, Energy Prices by Sector 

and Source, release date full report February 2007 

o Prices given in $(2005)/mmBTU 

• AEO Reference Case 2005 

o Based on report no. DOE/EIA-0383(2005), Table 3, Energy Prices by Sector 

and Source, release date full report January 2005 

o Prices given in $(2003)/mmBTU 

• AEO 2005 High A Case 

o AEO 2005 Reference Case modified for high projected oil prices 

o Details in Market Drivers, www.eia.doe.gov/oiaf/archive/aeo05/index.html

o Prices given in $(2003)/mmBTU 

o Default case for all H2A production technology cases 

• Price Ratios from PNNL Mini Climate Assessment Model (Mini-CAM) 

o Details at www.pnl.gov/gtsp/research/minicam.stm

The first three tables contain EIA AEO data and projections through year 2030 and 

projections for years 2031–2070 extrapolated using the AEO projections and Mini-CAM 

Model results. 

AEO Data Worksheet 

41
HyARC Physical Property Data Worksheet 

The HyARC Physical Property Data worksheet contains constants and conversions used in 

energy feedstock, utility, and greenhouse gas emissions calculations. Most users will not 

need to add or change information in this worksheet; however, Tables A, C1, and C2 contain 

fields designed to accept user input. 

CAUTION 

Advanced users might have occasion to change information in Table A, the 

Energy Feedstock and Utility Properties table. For an example, see the 

"Advanced user" segment under Energy Feedstocks, Utilities, and Byproducts

(page 13). You can also add new energy feedstocks, utilities, and byproducts 

to Table A using the User Defined Feeds within the Energy Feed 

& Utility Prices worksheet. See page 38 to learn how. Although you can add and 

modify items within Table A, do not delete any fields from the table completely; 

this could create serious errors. 

Advanced 

users only 

Table C1 contains upstream energy and greenhouse gas emissions values for hydrogen 

feedstocks for hydrogen production facilities starting operations in years 2005–2019. Table 

C2 contains the same information for plants starting operations in years 2020 and beyond. 

These tables are used to calculate the upstream energy use and greenhouse gas emissions 

shown on the Results worksheet (see page 32). See page 38 to learn how to enter values for 

user-defined energy feedstocks and utilities. Unless otherwise noted, all values in these 

tables are given as LHV. 

HyARC Physical Property Data Worksheet 

Click Notes for 

information about AEO 

price data 

conversions—click View 

HyARC Physical 

Property Data to close 

the Notes window 

 

42
References 

U.S. Department of Energy Hydrogen Program. Hydrogen Analysis Resource Center—

Hydrogen Properties. Web Site, accessed 11/9/07. Washington, DC: U.S. Department of 

Energy. http://hydrogen.pnl.gov/cocoon/morf/hydrogen/article/401. 

The values for the HyARC Energy Constants and Assumptions table were downloaded 

from this Web site. 

U.S. Department of Energy Hydrogen Program. Hydrogen Delivery Component Model 

version 2.0. Washington, DC: U.S. Department of Energy. 

The upstream energy and greenhouse gas emissions information in Tables C1 and C2

came from the Hydrogen Delivery Component Model, Table 4a. The ultimate source of the 

information is the GREET Model, version 1.8b. 

43
Debt Financing Calculations Worksheet 

If debt financing is selected on the Input_Sheet_Template worksheet, the Debt Financing 

Calculations worksheet amortizes the loan. The results are used in the H2A Model's cash 

flow analysis (see page 35). No user input is required within this worksheet. 

Input_Sheet_Template Worksheet 

Any value < 100% in 

the % Equity 

Financing cell 

activates the Debt 

Financing 

Calculations

worksheet 

Debt 

financing 

inputs 

Debt Financing Calculations Worksheet Showing Amortization 

44
Depreciation Worksheet 

This worksheet calculates depreciation for use in the H2A Model's cash flow analysis (see 

page 35). No user input is required within this worksheet. 

Input_Sheet_Template Worksheet 

Depreciation 

inputs 

Depreciation Worksheet 

Values imported from 

Input_Sheet_Template

worksheet

45
Constants and Conversions Worksheet 

The constants and conversion factors listed on this worksheet are used in H2A calculations 

and included for users’ reference. No user input is required within this worksheet. 

Constants and Conversions Worksheet 

46
Lists Worksheet 

The Lists worksheet contains lists of variable labels that the H2A Production 

Model uses to perform all its calculations. Do not add, delete, or change 

anything on this worksheet. Modifying the lists could disable or introduce major 

CAUTION errors into the model. 

Lists Worksheet

47
Technical Support 

Information related to the new H2A Production Model will be posted on the H2A Web site as 

it becomes publicly available: www.hydrogen.energy.gov/h2a_production.html. Visit the Web 

site to download copies of the model and technology cases. 

For technical questions not answered by this guide or the Web site, contact: 

Darlene Steward 

National Renewable Energy Laboratory 

303-275-3837 

darlene_steward@nrel.gov

48
Appendix 1: Carbon Sequestration Calculations and Sources 

This appendix briefly describes the inputs and calculations used within the Carbon 

Sequestration worksheet (which is used for the H2A central model only, see page 23). See 

the sources listed in References at the end of this appendix for detailed descriptions and 

derivations of the calculations. Note that McCollum and Ogden (2006) include CO2 pumps in 

their carbon sequestration calculations as well as compressors. Because super-critical CO2

exhibits liquid-like density at the pressures and temperatures of carbon sequestration, pumps 

or compressors can be used in this application. The choice of using pumps, compressors, or 

both depends on the scale of the carbon sequestration process. At the high production 

capacities of most H2A central model cases, the higher efficiency of compressors offsets 

their higher initial capital cost; industry feedback supports this contention. Therefore, the H2A 

central model includes only CO2 compressors, rather than pumps, in its carbon sequestration 

calculations. 

The Carbon Sequestration worksheet is divided into four tables: 

Table Purpose User Input Required

Carbon Sequestration Information Source of values for carbon 

sequestration calculations 

No 

Carbon Sequestration Input Values Source of values for carbon 

sequestration calculations 

Yes 

Carbon Sequestration Calculations Calculate carbon 

sequestration results 

No 

Summary of Output Values Display carbon 

sequestration results 

No 

See the screen captures of the tables below. The numbers on the left of each table 

correspond with the numbered descriptions of each field. 

Carbon Sequestration Information 

1 

2 

3 

4 

5 

1, 2. CO2 Produced from Feedstock—CO2 emissions produced from the feedstock are 

calculated based on the properties of the feedstock and the amount of feedstock used in 

hydrogen production. The feedstock type and use information comes from the 

Input_Sheet_Template worksheet. The properties come from the HyARC Physical Property 

Data worksheet. 

49
3. CO2 Mass Flowrate—The CO2 mass flow rate (the mass of CO2 transported to the 

injection site each day) is calculated using the value for CO2 produced from feedstock (1) and 

the carbon capture efficiency (6). 

4. Electricity Cost—The industrial electricity cost is drawn from the Energy Feed & Utility 

Prices worksheet for each year of the calculations. The startup year cost is shown here. 

5. Carbon Sequestration Electricity Usage—This value is calculated using the power 

requirement (21) from the Carbon Sequestration Calculations table (in the Carbon 

Sequestration worksheet) and the capacity factor and plant output from the 

Input_Sheet_Template worksheet. 

Carbon Sequestration Input Values

6 

7 

8 

9 

10 

11 

12 

13 

14 

15 

16 

17 

18 

19 

20 

6. Carbon Capture Efficiency—Input the percentage of CO2 emissions captured here (note: 

only CO2 emissions from feedstock processing can be captured). This value is used in the 

calculation of CO2 mass flow rate (3). The default value is 80%. 

7. CO2 Capture Process Outlet Pressure—Input the value for the pressure of CO2 exiting the 

capture phase and entering the compression phase here. This value becomes Pinitial in the 

CO2 compression calculations (23). The default value is 14.7 psia (atmospheric pressure). 

8. CO2 Capture Credit—Input the value for CO2 capture credits here. If a value is entered, 

the credits offset operation and maintenance costs (29). The default value is zero. 

9. Operation and Maintenance Factor for Compressors—Input the compressor operation and 

maintenance factor here. The model multiplies this value times the compressor capital cost to 

determine annual compressor operation and maintenance cost (24). The default value is 

0.04. 

10. Operation and Maintenance Factor for CO2 Pipeline—Input the pipeline operation and 

maintenance factor here. The model multiplies this value times the pipeline capital cost to 

determine annual pipeline operation and maintenance cost (28). The default value is 0.025. 

50
11. Capital Cost for Site Screening and Evaluation (per well)—Input the per-well capital cost 

for site screening and evaluation here. This value is multiplied times the number of wells to 

become Csite in the CO2 compression calculations (25). The default value is $1,857,773. 

12. Number of Injection Wells—Input the number of injection wells here. This value is used in 

the calculations for drilling and injection equipment capital costs as well as injection operation 

and maintenance costs (25, 26). The default value is 1 well, which is the typical number 

needed for injecting 10,000 metric tons/day or less using a 0.15-m-diameter injection pipe. 

For an iterative process for calculating number of wells needed, see McCollum and Ogden 

(2006), page 15. 

13. Well Depth—Input well depth here. This value is used in the calculations for drilling 

capital cost as well as injection operation and maintenance costs (25, 26). The default value 

is 1,524 m, which is the base case for gas reservoirs in McCollum and Ogden (2006), page 

15 (Table 3). Benson (2000) describes California oil and gas reservoirs as no deeper than 

1,500 m. 

14. Location Factor—Select a location factor from the drop-down menu. A location factor of 1 

corresponds to location in the United States, Canada, Europe, Japan, or Australia. A location 

factor of 1.2 corresponds to location in the United Kingdom. This value is used in the 

calculation for pipeline capital cost; a higher location factor increases the cost (27). The 

default value is 1. 

15, 16. Terrain Type/Terrain Factor—Select a terrain type from the drop-down menu. Each 

terrain type corresponds to a specific terrain factor, which is automatically entered into the 

Terrain Factor field as follows: 

• cultivated land = 1.1 

• grassland = 1 

• wooded = 1.05 

• jungle = 1.1 

• stony desert = 1.1 

• <20% mountainous = 1.3 

• >50% mountainous = 1.5 

This value is used in the calculation for pipeline capital cost; a higher terrain factor increases 

the cost (27). The default value is 1.3 (<20% mountainous). 

17. Total CO2 Pipeline Length—Input total pipeline length here. This value is used in the 

calculation for pipeline capital cost (27). The default value is 100 miles. Required CO2

transportation distances (i.e., required pipeline lengths) vary by location. 

18–20. These factors (after tax real capital recovery factor, real present value of depreciation, 

and approximate capital charge rate) are automatically calculated using values from the 

Input_Sheet_Template worksheet and financial calculations. They are used in the carbon 

sequestration calculations for capital, electrical, and O&M cost per metric ton of CO2

sequestered. The capital and operating costs for carbon sequestration are also included in 

the model’s discounted cash flow calculations—see the Cash Flow Analysis (page 35) and 

Results (page 32) sections. The results shown on the Results worksheet are for the entire 

plant. 

51
21–28. The Carbon Sequestration Calculations table shows calculations based on the input 

and calculation tables described above as well as default values and constants. The upper 

half of the table (21–24) calculates compressor costs, including a power requirement 

calculation for multi-stage compression (21). The lower half of the table (25–28) calculates 

injection and pipeline costs. See McCollum and Ogden (2006) for details about the 

calculations. Do not change any of the cells in this table directly. 

29. The Summary of Outputs table summarizes the major results of the carbon sequestration 

calculations. The costs are for CO2 compression, transportation to the sequestration site, and 

injection. Costs for CO2 capture are assumed to be included in the production facility's capital 

and operating costs and are not included here. Costs are shown in reference year dollars. Do 

not change any of the cells in this table directly. 

The calculations for the cost of sequestration per metric ton of CO2 are based on the capital 

recovery factor (CRF) method rather than a rigorous discounted cash flow method, which is 

used for the H2A Model's hydrogen production calculations. Although the CRF method is not 

quite as rigorous, the results are comparable when the same economic parameters are used. 

30. The approximate indirect capital costs due to carbon sequestration are calculated by 

multiplying total indirect capital costs by the ratio of carbon sequestration direct capital costs 

to total direct capital costs. This approximation is for information only; it does not participate 

in the model's calculations. 

52
Carbon Sequestration Calculations

21 

22 

23 

24 

25 

26 

27 

28 

53
Summary of Output Values 

29 

30 

References 

The calculations used in the Carbon Sequestration worksheet were developed by Directed 

Technologies, Inc. and the National Renewable Energy Laboratory based on information from 

compressor/turbine manufacturer MAN Turbo and the following publications: 

Benson, S.M. (2000). Comparison of Three Options for Geologic Sequestration of CO2—A 

Case Study for California. LBNL-46365. Berkeley, CA: Lawrence Berkeley National 

Laboratory. http://repositories.cdlib.org/lbnl/LBNL-46365. 

This study examines the distribution of carbon emissions from fossil fuel power plants in 

California and their proximity to active or depleted oil and gas fields and brine formations—

reservoirs that might be suitable for carbon sequestration. It also assesses the feasibility of 

sequestering CO2 from California fossil fuel plants in these reservoirs. 

54
Chen, S.G.; Lu, Y.; Rostam-Abadi, M.; Nyman, D.J.; Dracos, J.S.; Varagani, Rajani. (2004). 

Carbon Dioxide Capture and Transportation Options in the Illinois Basin. Champaign, IL: 

Illinois State Geological Survey. http://sequestration.org/publish/MGSC_year1report.pdf. 

This report describes CO2 capture options from large stationary emission sources in the 

Illinois Basin, focusing on coal-fired power plants. It includes information on pipeline costs. 

McCollum, D.L.; Ogden, J.M. (2006). Techno-Economic Models for Carbon Dioxide 

Compression, Transport, and Storage & Correlations for Estimating Carbon Dioxide Density 

and Viscosity. UCD—ITS—RR—06-14. Davis, CA: Institute of Transportation Studies, 

University of California, Davis. 

http://hydrogen.its.ucdavis.edu/publications/2006pubs/resolveuid/7c6a2993156155db8d3209

af679b4cdb. 

This report is divided into three sections: 

• Techno-Economic Models for Carbon Dioxide Compression, Transport, and Storage

contains models for estimating the engineering requirements and costs of carbon capture 

and storage (CCS) infrastructure. 

• Simple Correlations for Estimating Carbon Dioxide Density and Viscosity as a Function of 

Temperature and Pressure describes simple correlations—which are functions of only 

temperature and pressure—for estimating the density and viscosity of CO2 within the 

range of operating temperatures and pressures that might be encountered in CCS 

applications. 

• Comparing Techno-Economic Models for Pipeline Transport of Carbon Dioxide illustrates 

an approach used to compare several recent techno-economic models for estimating 

CO2 pipeline sizes and costs, resulting in a new CO2 pipeline capital cost model that is a 

function only of flow rate and pipeline length. 

55
Appendix 2: Forecourt Hydrogen Delivery Calculations 

This appendix briefly describes the inputs and calculations used within the Refueling Station

worksheet (which is used for the H2A forecourt model only, see page 25). The Refueling 

Station worksheet is itself a relatively complex model (see schematic below); it is based on 

refueling station modeling from the H2A Delivery Components Model and the Hydrogen 

Delivery Scenario Analysis Model (HDSAM). It calculates optimal hydrogen compression, 

storage, and dispensing costs for a station with a capacity of up to 6,000 kg of hydrogen per 

day and a convenience store. 

In contrast to the H2A Delivery Components Model, which assumes hydrogen is delivered via 

pipeline, the Refueling Station worksheet assumes hydrogen is produced onsite. Because 

hydrogen supply is more likely to be disrupted by planned and unplanned outages of the 

onsite production unit, additional storage is required; a user-input field (in the Refueling 

Station Scenario Inputs table) accounts for the additional low-pressure storage requirement. 

The default value is slightly more than one half (58.3%) of the plant's daily production 

capacity. 

The table descriptions below give an overview of the worksheet's functions and some default 

values. See the sources listed in References at the end of this appendix for detailed 

information. 

Schematic of Complex Data Flow within Refueling Station Worksheet

Note: The Input_Sheet_Template worksheet also provides inputs to the Refueling Station worksheet. 

Calculation Outputs (Results) 

The three Calculation Outputs tables summarize the major results of the Refueling Station

calculations: 

56
• Results - Cost Breakdown per kg H2 

• Results - Capital and Operating Costs 

• Results - Other CSD Parameters.

The Calculation Outputs tables receive input from the Refueling Station Design Inputs; 

Compression, Storage, Dispensing O&M Costs; Cost Calculations, Refueling Station 

Calculations; and Capital Investment—Equipment Costs tables. No user input is required. 

The Cost Breakdown per kg H2 results are output to the main H2A Results worksheet; see 

the schematic on page 26. 

Forecourt Specific Economic Assumptions 

Input or accept the default values for depreciation and component lifetime values here. The 

values are output to the Cost Calculations and Replacement Capital Calculation tables. 

Refueling Station Design Inputs 

Input refueling station design characteristics here. The default values assume a hydrogen 

pressure of 300 psi exiting the production process. The hydrogen is compressed to 2,500 psi 

for storage; this relatively low-pressure storage was found to be economical. 

Using the default values, vehicles fueling at the station take a fill pressure of 5,000 psi after 

equilibration to standard temperature; thus, the default maximum cascade charging system 

pressure is 6,250 psi, which allows the vehicle to refuel within 3 minutes and allows for 

overpressure to compensate for temperature increases during refueling. The cascade 

charging system has three pressure vessels, each with a 21.3-kg capacity and a maximum 

pressure of 6,250 psi. There can be more than one bank of three cascade charging vessels 

depending on the size of the refueling station. To satisfy vehicle filling dynamics, each vessel 

operates under a different minimum pressure: 6,000, 4,350, and 2,000 psi. The default 

compressor values are described in Nexant et al. (2008). 

The Refueling Station Design Inputs table receives input from the Refueling Station Scenario 

Inputs table. Its values are output to the Refueling Station Optimization Calculations, Cost 

Calculations, Refueling Station Calculations, and Calculation Outputs tables as well as the 

Hydrogen Demand Profile. 

Refueling Station Scenario Inputs 

Input details about the refueling station's design and operation here. About half the fields in 

the Value column contain notes that describe the meaning of the values; read them by 

selecting each field. 

The default values are based on a station with six dispensers operating 18 hours per day 

(6:00 AM to 12:00 AM). The 58.3% low-pressure storage vessel excess capacity provides 

about a half day of backup storage for use during unplanned shutdowns. 

The land area a hydrogen refueling station requires is determined by daily average fuel 

demand, setback distances (as determined by the National Fire Protection Association for 

safety purposes), and delivery method. For the purposes of characterizing the default 

station's area and storage vessel dimensions, the assumptions for a station with pipeline 

hydrogen delivery given in Nexant et al. (2008) were used. 

57
The Refueling Station Scenario Inputs values output to the Refueling Station Design Inputs, 

Refueling Station Calculations, and Refueling Station Optimization Calculations tables. 

Capital Investment—Equipment Costs 

The top part of this table gives you the option of accepting H2A-defined compressor, 

dispenser, storage, and electrical costs or entering your own values. Select "yes" in the dropdown menu to accept the H2A costs as described in the Notes fields. If you select "yes" for all 

of the pieces of equipment, you do not need to provide further input to this table. If you select 

"no" for one or more pieces of equipment, you must input values in the bottom part of the 

table as described in the Notes fields. 

The bottom part of the table calculates the installed cost of each piece of equipment and 

calculates total initial capital investment. Equipment characteristics in the Value column come 

from the Refueling Station Scenario Inputs, Refueling Station Design Inputs, and Refueling 

Station Calculations tables. The Capital Investment—Equipment Costs values output to the 

Refueling Station Calculations; Refueling Station Optimization Calculations; Replacement 

Capital Calculation; Other Compression, Storage, Dispensing Capital Costs; and Calculation 

Outputs tables. 

Other Compression, Storage, Dispensing Capital Costs 

Input or accept the default values for indirect compression, storage, and dispensing capital 

costs—as a percentage of the direct capital costs—in the orange cells. The blue cells 

automatically multiply the percentages by the total direct capital cost from the Capital 

Investment—Equipment Costs table. The Total Capital Investment value sums the direct and 

indirect capital costs. The Total Land/Other Capital Costs value (which sums the indirect 

costs) outputs to the Cost Calculations table. 

Compression, Storage, Dispensing O&M Costs 

Input labor and other operating and maintenance costs here. The default labor costs are 

based on a refueling station open 365 days per year, dispensing an average of 1,050 kg of 

hydrogen per day. The convenience store at such a station employs 1.5 people; 33% of the 

labor is associated with fuel dispensing. For stations with capacities other than 1,050 kg/day, 

labor hours scale linearly as a function of station size, i.e., labor hours per year = store hours 

per day × 365 × 0.33 × 1.5 × (station capacity/1,050). The labor rate is $10/hr plus 20% for 

overhead and G&A. 

The Compression, Storage, Dispensing O&M Costs table receives input from the Refueling 

Station Scenario Inputs; Capital Investment—Equipment Costs; Other Compression, Storage, 

Dispensing Capital Costs; and Refueling Station Calculations tables as well as the 

Input_Sheet_Template worksheet. Its values are output to the Cost Calculations and 

Calculation Outputs tables. 

Calculation Tables: Optimizing Refueling Station Design and Cost 

The five tables following the Compression, Storage, Dispensing O&M Costs table work 

together to calculate optimal refueling station design, operation, and cost: 

• Refueling Station Calculations 

58
• Refueling Station Optimization Calculations 

• Cost Calculations 

• Replacement Capital Calculation

• Hydrogen Demand Profile (untitled table at bottom of worksheet). 

No user input is required for these tables. The schematic on page 56 shows the data flow 

among the various calculation and input tables (the Input_Sheet_Template worksheet also 

provides data to the calculation tables). 

The refueling station optimization calculations are based on the following inputs and 

assumptions: 

• Chevron daily and hourly hydrogen demand profiles 

• Assumed spike in demand at the beginning of each hour 

• Cost of the compressor, cascade, and electrical upgrades 

• Minimum and maximum pressures in each of the cascade vessels 

• Vehicle filling dynamics (tank capacity, fill time, linger time, etc.) 

• Number of compressors in operation and in standby modes 

• Number of dispensers and the average hose occupied fraction during peak hour. 

The optimization methodology—from the H2A Delivery Models—is based on a simple logic. 

The amount of hydrogen and the pressures in each of the cascade vessels are tracked at the 

critical points of the demand profile, and a decision is made regarding the size of the 

compressor and cascade system to satisfy the demand with minimum cost. The selected 

design parameters are those that satisfy the demand profile at all of its critical points. See 

Nexant et al. (2008) for optimization methodology details. 

References 

Nexant et al. (scheduled publication 2008). H2A Hydrogen Delivery Infrastructure Analysis 

Models and Conventional Pathway Options Analysis Results. DE-FG36-05GO15032. 

Washington, DC: U.S. Department of Energy. 

www.hydrogen.energy.gov/systems_analysis.html. 

This report contains results of an analysis of infrastructure options for hydrogen delivery 

and distribution to refueling stations from central, semi-central, and distributed production 

facilities. The H2A Production Model's Refueling Station worksheet is based on the 

refueling station characteristics and calculations described in this report. 

U.S. Department of Energy Hydrogen Program. DOE H2A Delivery Analysis. Web Site. 

Washington, DC: U.S. Department of Energy. www.hydrogen.energy.gov/h2a_delivery.html. 

This Web site includes descriptions of the H2A Delivery Components Model and HDSAM 

as well as user's guides for both models. 

59
Appendix 3: Default Values and Assumptions 

The following default values and assumptions apply to the H2A central and forecourt models, 

unless a specific technology case specifies otherwise: 

Analysis Methodology Discounted cash flow (DCF) model that calculates a 

levelized hydrogen cost yielding a prescribed IRR 

Analysis Period 40 years for central model; 20 years for forecourt 

model 

Average Burdened Labor Rate for 

Staff 

$50/hour for central model; $15/hour for forecourt 

model 

Capacity Factor 90% for central model with case exceptions; 85.2% for 

forecourt model 

Central Storage Optional buffer only as required for efficient operations

CO2 Capture Credit Not included in base cases (default value = 0) 

CO2 Production Taxes Not included in base cases (default value = 0) 

Construction Period and Cash Flow Varies per case for central model; 1 year for forecourt 

model 

Co-produced and Cogenerated 

Electricity Price 

$30/MWh 

Decommissioning 10% of initial capital for central model, with case 

exceptions; 0% for forecourt model 

Depreciation Type and Schedule for 

Initial Depreciable Capital Cost 

MACRS: 20 years for central model with case 

exceptions; 5 years for compressors, 7 years for 

remainder of plant for forecourt model 

Facility Life 40 years for central model with case exceptions; 20 

years for forecourt model with case exceptions 

Forecourt Compressed Hydrogen 

Storage 

117% of maximum daily production 

G&A Rate 20% of the staff labor costs above 

Hydrogen Pressure at Central Gate 300 psig; if higher pressure is inherent to the process, 

apply pumping power credit for pressure > 300 psig 

Hydrogen Purity 98% minimum; CO < 10 ppm, sulfur < 10 ppm 

Hydrogen Storage Pressure at 

Forecourt 

6,250 psig 

Income Taxes 35% federal; 6% state; 38.9% effective 

60
Inflation Rate 1.9%, but with resultant price of hydrogen in reference 

year constant dollars 

Land Cost $5,000/acre purchased for central model; 

$0.5/sqft/month for long-term lease for forecourt 

model 

O2 Credit Not included in base cases 

Process Contingency % adjustment to the total initial capital cost such that 

the result incorporates the mean or expected overall 

performance 

Project Contingency % adjustment to the total initial capital cost such that 

the result represents the mean or expected cost 

value; periodic replacement capital includes project 

contingency 

Property Taxes and Business 

Insurance 

2%/year of the total initial capital cost 

Reference Financial Structure 100% equity with 10% IRR; includes levelized 

hydrogen price plot for 0%–25% IRR; model allows 

debt financing 

Reference Year Dollars 2005, to be adjusted at half-decade increments (e.g., 

2005, 2010) 

Sales Tax Not included on basis that facilities and related 

purchases are wholesale and through a general 

contractor entity 

Salvage Value 10% of initial capital for central model, with case 

exceptions; 0% for forecourt model 

Sensitivity Variables and Ranges Based on applying best judgment of 10% and 90% 

confidence limit extremes to the most significant 

baseline cost and performance parameters 

Technology Development Stage All central and forecourt model cost estimates are 

based on mature, commercial facilities 

Working Capital Rate 15% of the annual change in total operating costs 

61
Appendix 4: Derivations and Definitions 

Derivation of Forecourt Production Unit Operating Capacity Factor 

The following calculations show how 85.2% was chosen as the standard operating capacity 

factor for forecourt production systems. (Source: Directed Technologies, Inc.) 

CF = 100% – Rseason – Rplanned – Runplanned – Rextra

Where: 

CF = Operating capacity factor

Rseason = CF reduction for seasonal loads (winter to summer)

Assumption = 10%

Rplanned = CF reduction for planned shutdown

7 days per year for planned system shutdown (annual maintenance, etc.) 

Rplanned = 7 day/year ÷ 365 day/year = 1.92%

Runplanned = CF reduction for unplanned shutdowns

6 "expected" unplanned system shutdowns per year (equipment failure, power outage, etc.) 

14 hr system down for each unplanned shutdown (average): 

2 hr to react to shutdown (also allows unit to cool) 

6 hr to get repair personnel to site 

4 hr to effect repairs (assumes replacement parts are in hand) 

2 hr to bring unit back to full power and monitor for proper performance 

Runplanned = 6 shutdowns/year × (14 hr/shutdown ÷ 8,760 hr/year) = 0.96%

Rextra = CF reduction for needing extra production capacity to refill storage tanks after unplanned shutdowns

H2 storage for hourly/daily demand fluctuations determined by the Chevron supplied hourly 

demand load calculations in the HDSAM/H2A model 

Chevron demand based on highest daily demand of highest weekly demand (Friday in summer) 

1,500 kg/day maximum rating of forecourt production system 

14 hr system down for each unplanned shutdown (average) 

30 days of design time between unplanned shutdowns 

Rextra = 14 hr/shutdown ÷ (30 days × 24 hr/day) = 1.94%

H2 storage for unplanned shutdowns = 14 hr/shutdown ÷ 24 hr/day × 1,500 kg/day = 875 kg 

CF = 100% – 10% – 1.92% – 0.96% – 1.94% = 85.2%

Definitions 

Working capital A measure of a business' daily operating liquidity, calculated by 

subtracting current liabilities from current assets. Working capital is 

considered a part of operating capital, along with fixed assets such as 

facilities and equipment. Also known as net working capital. 

62
63

Index 

AEO data, 38, 41

Assumptions, 60

Byproducts

check box, 16

defining, 12–14, 38

deleting entries, 13

Calculate Cost button, 10

error message, 6

Capital costs, 14–15, 19

Capital equipment, 19

Carbon sequestration, 23–24, 49–55

calculations, 53

information, 49

input values, 50

O&M costs, 17

output values, 54

worksheet, 14

Cash flow analysis, 35

Cells, color coding, 4

Central hydrogen production, i

CH4 emissions, 33

CO2, 23

Color coding, 10

Convenience store refueling station, 25

Conversion factors, 46

Cost analysis, 3

Debt financing, 44

Default values, 60

Definitions, 62

Delete entry, 6, 13, 16, 29

Depreciation, 45

Efficiency, 33

Emissions summary, 33

Energy Data table, 33

Energy Feed & Utility Prices worksheet, 38

errors, 7

Energy inputs, 33

Errors, 4

Exporting, 29

Feedstocks

conversion efficiency, 12

defining, 12–14, 38

deleting entries, 13

Financial characteristics, 11

Fixed operating costs, 15

Forecourt hydrogen delivery, 56–60

Forecourt hydrogen production, i

Greenhouse gases, 34

GREET model, 33, 34

HyARC physical property data, 38, 42

Importing existing cases, 27

Information worksheets, 8

Input_Sheet_Template worksheet, 10–17

error message, 5

Installed costs, 19

LHV. See Lower heating value

Lists worksheet, 47

errors, 7

Lower heating value, 12

N2O emissions, 33

Non‐Energy Material Prices worksheet, 40

Other materials and byproducts, defining, 16

Plant output, calculating, 11

Plant scaling, 4, 20–22

baseline values, 20

capacity range, 20

factor exponent, 20

methods, 21

worksheet, 20

Price

data table, selecting, 12

defining, 38

in startup year, 12

Printing, 29

Process material costs. See Variable operating costs

Production analysis. See  Cost analysis

Project Info button, 10

Refueling station

calculations, 56

costs, 58

design, 57

O&M costs, 17

worksheet, 14

Refueling Station worksheet, 25–26

Replacement costs, 17, 18

Results, 32–35

Sensitivity analysis, 30–31

Sensitivity Analysis

worksheet, 37

Support, 48

Symbols used, 4

Toolkit, 27

Toolkit button, 10

Toolkit window, 10

Tornado chart, 4, 31

errors, 6

worksheet, 36

Units, changing, 13

Use Default Values button, 10

example, 11

problems, 5

Utilities

defining, 12–14, 38

deleting entries, 13

Variable operating costs, 15

Worksheet

data flow, 1, 2

organization, 1
F1147-E(09/2007) 

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4. TITLE AND SUBTITLE

H2A Production Model, Version 2 User Guide 

5a. CONTRACT NUMBER

DE-AC36-99-GO10337 

5b. GRANT NUMBER

5c. PROGRAM ELEMENT NUMBER

6. AUTHOR(S)

D. Steward, T. Ramsden, and J. Zuboy 

5d. PROJECT NUMBER

NREL/TP-560-43983 

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H2782150 

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National Renewable Energy Laboratory 

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14. ABSTRACT (Maximum 200 Words)

The H2A Production Model analyzes the technical and economic aspects of central and forecourt hydrogen 

production technologies. Using a standard discounted cash flow rate of return methodology, it determines the 

minimum hydrogen selling price, including a specified after-tax internal rate of return from the production technology. 

Users have the option of accepting default technology input values—such as capital costs, operating costs, and 

capacity factor—from established H2A production technology cases or entering custom values. Users can also 

modify the model's financial inputs. This new version of the H2A Production Model features enhanced usability and 

functionality. Input fields are consolidated and simplified. New capabilities include performing sensitivity analyses and 

scaling analyses to various plant sizes. This User Guide helps users already familiar with the basic tenets of H2A 

hydrogen production cost analysis get started using the new version of the model. It introduces the basic elements of 

the model then describes the function and use of each of its worksheets. 

15. SUBJECT TERMS

H2A; hydrogen model; hydrogen cost; user guide; H2A documentation; hydrogen production; Darlene Steward; Todd 

Ramsden; Jarett Zuboy 

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