Hydrogen Electrolyzer & Fuel Cell Manufacturing worked example

Cooling Loop Capacity at 99% chiller and di loop uptime: a worked example

This scenario runs the cooling loop capacity calculation on the strong side: 99% chiller and di loop uptime, with every other input held at its documented default. Use it when a facilities or process engineer is sizing a balance-of-plant cooling loop for stack conditioning and EOL test, and needs to know whether the chiller plus DI tank can support the next build rate.

The inputs for this scenario

  • Cooling slots per loop cycle: 4 slots / cycle (unchanged)
  • Planned cooling-loop cycles in the period: 60 cycles (unchanged)
  • Chiller and DI loop uptime: 99 % (raised for this scenario; the documented default is 92)
  • Thermal headroom share (stacks held without trip): 85 % (unchanged)

Working through the calculation

  • Applying the documented formula (Gross cooling-loop capacity = cooling slots per cycle × planned cycles) to the inputs above produces each figure below.
  • At this operating point the engine returns 202 stacks for good cooling-loop stacks per period, the number this scenario is built around.
  • At this operating point the engine returns 240 stacks for gross cooling-loop stacks per period.
  • At this operating point the engine returns 2.4 stacks for chiller and di loop downtime loss.
  • At this operating point the engine returns 35.64 stacks for thermal headroom loss.

How this compares with the baseline

  • Against the tool's baseline example, where chiller and di loop uptime sits at 92% and the headline result is 188 stacks, this scenario comes in 7.61% above the baseline at 202 stacks.
  • Use it when planning period throughput, sizing chiller and DI capacity, or quantifying the throughput cost of cooling-loop downtime. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Good cooling-loop stacks per period: 202 stacks (headline result)
  • Gross cooling-loop stacks per period: 240 stacks
  • Chiller and DI loop downtime loss: 2.4 stacks
  • Thermal headroom loss: 35.64 stacks

Run it with your numbers

  • Every input above is editable in the live Cooling Loop Capacity calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.