Hydrogen Electrolyzer & Fuel Cell Manufacturing worked example

Catalyst Loading Cost at 99% catalyst utilization in coating: a worked example

Push catalyst utilization in coating up to 99% and the picture changes. This example computes every intermediate figure at that operating point. Use it when a process engineer is comparing catalyst loading recipes (for example 0.4 vs 0.2 mg Pt per cm squared) and needs to see the dollar impact per stack before committing to a coating change.

The inputs for this scenario

  • Catalyst metal per stack: 6 g of PGM (unchanged)
  • Catalyst metal price per gram: 32 $ / g (unchanged)
  • Catalyst utilization in coating: 99 % (raised for this scenario; the documented default is 90)
  • Fixed ink-prep or coater setup cost per stack: 600 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Variable catalyst cost per stack = catalyst metal per stack × metal price per gram × catalyst utilization) to the inputs above produces each figure below.
  • At this operating point the engine returns 790 $ for total catalyst cost per stack, the number this scenario is built around.
  • At this operating point the engine returns 132 $ / piece for catalyst cost per gram of metal.
  • At this operating point the engine returns 190 $ for variable catalyst cost per stack.
  • At this operating point the engine returns 600 $ for fixed ink-prep or coater setup cost.

How this compares with the baseline

  • Against the tool's baseline example, where catalyst utilization in coating sits at 90% and the headline result is 773 $, this scenario comes in 2.24% above the baseline at 790 $.
  • It computes total catalyst cost per stack and cost per gram of metal loaded, combining variable PGM cost with fixed ink-prep and coater setup. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Total catalyst cost per stack: 790 $ (headline result)
  • Catalyst cost per gram of metal: 132 $ / piece
  • Variable catalyst cost per stack: 190 $
  • Fixed ink-prep or coater setup cost: 600 $

Run it with your numbers

  • Every input above is editable in the live Catalyst Loading Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.