Thermodynamic and economic assessment of a liquid nitrogen precooling dual-pressure Claude cycle for hydrogen liquefaction

Hydrogen liquefaction remains one of the most energy-intensive steps in the hydrogen value chain. This study proposes a liquid-nitrogen-precooled dual-pressure Claude cycle and evaluates its performance using a detailed steady-state Aspen HYSYS model incorporating realistic turbomachinery characteristics, distributed ortho–para conversion, and temperature-dependent heat-exchanger constraints. Simulation results show that LN 2 precooling provides approximately 40% of the total refrigeration duty, lowering the specific energy consumption to 11.95 kWh·kg -1 -LH 2 , about 12% lower than that of a single-pressure Claude process. The process achieves 98% para-hydrogen purity, ensuring stable subcooled storage. Regional techno economic assessment indicates production costs of 1.7–1.8 USD per kilogram in China, 2.2 to 2.6 USD per kilogram in the United States, and 3.0 to 3.4 USD per kilogram in the European Union, corresponding to an estimated payback time of approximately 7.5–13 years for a 30 tonne per day plant depending on local energy prices. A 100,000-run Monte Carlo analysis further confirms strong economic robustness, with the vast majority of global market scenarios yielding production costs below the nominal international benchmark of 3.5 USD per kilogram, and more than 99% of realizations maintaining a positive cost advantage when benchmark adjustments for transport- and tax-related factors are applied. These findings demonstrate that combining liquid nitrogen assisted warm end load shifting with dual pressure expansion provides an energy efficient and economically competitive pathway for medium to large scale hydrogen liquefaction.