Unified Case Study Analysis of Techno-Economic Tools to Study the Viability of Off-Grid Hydrogen Production Plants

The increasing interest in off-grid green hydrogen production has elevated the importance of reliable techno-economic assessment (TEA) tools to support investment and planning decisions. However, limited operational data and inconsistent modeling approaches across existing tools introduce significant uncertainty in cost estimations. This study presents a comprehensive review and comparative analysis of seven TEA tools—ranging from simplified calculators to advanced hourly based simulation platforms—used to estimate the Levelized Cost of Hydrogen (LCOH) in off-grid Hydrogen Production Plants (HPPs). A standardized simulation framework was developed to input consistent technical, economic, and financial parameters across all tools, allowing for a horizontal comparison. Results revealed a substantial spread in LCOH values, from EUR 5.86/kg to EUR 8.71/kg, representing a 49% variation. This discrepancy is attributed to differences in modeling depth, treatment of critical parameters (e.g., electrolyzer efficiency, capacity factor, storage, and inflation), and the tools’ temporal resolution. Tools that included higher input granularity, hourly data, and broader system components tended to produce more conservative (higher) LCOH values, highlighting the cost impact of increased modeling realism. Additionally, the total project cost—more than hydrogen output—was identified as the key driver of LCOH variability across tools. This study provides the first multi-tool horizontal testing protocol, a methodological benchmark for evaluating TEA tools and underscores the need for harmonized input structures and transparent modeling assumptions. These findings support the development of more consistent and reliable economic evaluations for off-grid green hydrogen projects, especially as the sector moves toward commercial scale-up and policy integration.