Hydrogen's competitiveness as a sustainable energy carrier depends greatly on its transportation and storage costs. Liquefying hydrogen for these purposes offers benefits like purity, versatility, and higher density. However, current industrial hydrogen liquefaction processes face efficiency and cost challenges, with a second-law efficiency below 25% and costs between 2.5-3.0 US$/kg_LH2, and they are mainly limited to small-scale. Scaling up liquefaction plants is a potential solution to reduce costs, but existing models often overlook the economic and technical viability of the conceptual plants.

Most reported liquefaction costs rely on "ballpark" estimation, hindering process economic comparisons between various processes. Industry-sponsored studies often use confidential data, limiting accessibility. Thus, this thesis aims to develop a comprehensive framework for modelling large-scale liquefaction processes and assessing their feasibility, focusing on the large-scale high-pressure hydrogen Claude-cycle liquefier concept.

The technical analysis focuses on the preliminary designs of main equipment, such as compressors, turboexpanders, and heat exchangers, ensuring compatibility with existing technology limitations. Aspen Process Economic Analyzer (APEA) is employed to estimate the capital and operating expenditure. At 0.1 €/kWh electricity price, the techno-economic assessment of the 125 tonnes per day (TPD) Claude-cycle concept yields specific liquefaction costs (SLC) of 1.55 €/kg_LH2. Sensitivity analysis shows electricity price has significant influence. Applying the established design approach, incorporating high-speed centrifugal compressors could reduce the SLC by 5.42% and potentially more.

Scaling up to 250 and 500 TPD shows potential SLC reductions of 7.80% and 9.45%, respectively, at electricity price of 0.1 €/kWh. Future projections suggest a potential 12.6% SLC reduction as the Claude-cycle liquefiers matures. In an ideal scenario, with incentives and low-cost renewable electricity, costs could range from 0.87 to 1.09 €/kg_LH2.

Finally, a cost-scaling curve for hydrogen liquefaction plants are estimated based on the cost results from this study. The curve is comparable to existing cost curves reported by industrial and government joint research projects, validating the methodologies developed in this thesis. Moreover, an experience curve is also predicted using cost data from this study and data found in the literature. The curve indicates a 17% price decrease in hydrogen liquefiers with each doubling of global liquefaction capacity.