Hydrogen Electrolyzer & Fuel Cell Manufacturing worked example

Cooling Loop Capacity at 66% chiller and di loop uptime: a worked example

This worked example runs the cooling loop capacity numbers for a tougher week than the baseline: 66% chiller and di loop uptime instead of the typical 92%. Estimate how many stacks the deionized water cooling loop can hold under load from cooling slots per loop cycle, planned cycles in the period, chiller and DI loop uptime, and the share of stacks the loop can support without thermal trip.

The inputs for this scenario

  • Cooling slots per loop cycle: 4 slots / cycle (held at the documented default)
  • Planned cooling-loop cycles in the period: 60 cycles (held at the documented default)
  • Chiller and DI loop uptime: 66 % (the input this scenario stresses; the baseline uses 92)
  • Thermal headroom share (stacks held without trip): 85 % (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross cooling-loop capacity = cooling slots per cycle × planned cycles.
  • Good cooling-loop stacks per period works out to 135 stacks at these inputs, and this is the headline figure for the scenario.
  • Gross cooling-loop stacks per period works out to 240 stacks at these inputs.
  • Chiller and DI loop downtime loss works out to 81.6 stacks at these inputs.
  • Thermal headroom loss works out to 23.76 stacks at these inputs.

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 28.26% below the baseline at 135 stacks.
  • Use it when planning period throughput, sizing chiller and DI capacity, or quantifying the throughput cost of cooling-loop downtime. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Good cooling-loop stacks per period: 135 stacks (headline result)
  • Gross cooling-loop stacks per period: 240 stacks
  • Chiller and DI loop downtime loss: 81.6 stacks
  • Thermal headroom loss: 23.76 stacks

Run it with your numbers

  • To rerun this with your own numbers, open the live Cooling Loop Capacity calculator, set chiller and di loop uptime to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.