Hydrogen Electrolyzer & Fuel Cell Manufacturing worked example

Humidification Load with humidifier connected load of 3 kW: a worked example

This worked example runs the humidification load numbers for a tougher week than the baseline: humidifier connected load of 3 kW instead of the typical 6 kW. Estimate the electric energy used by the test cell humidifier, plus the cost per stack, from humidifier connected load (heater plus pump), runtime per recipe, the energy rate, and the stacks processed in the period.

The inputs for this scenario

  • Humidifier connected load: 3 kW (the input this scenario stresses; the baseline uses 6)
  • Humidifier runtime per stack: 3 hr (held at the documented default)
  • Electric energy rate: 0.13 $ / kWh (held at the documented default)
  • Stacks processed in the period: 40 stacks (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Humidifier energy used per stack = humidifier load × humidifier runtime per stack.
  • Humidifier kWh per stack works out to 9 kWh at these inputs, and this is the headline figure for the scenario.
  • Humidifier energy cost per stack works out to 1.17 $ at these inputs.
  • Humidifier cost per stack processed works out to 0.03 $ / piece at these inputs.
  • Hourly cost works out to 0.39 $ / hr at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where humidifier connected load sits at 6 kW and the headline result is 18 kWh, this scenario comes in 50% below the baseline at 9 kWh.
  • Use it when costing the humidification step, comparing humidifier sizing options, or building an energy budget for a stack line. 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

  • Humidifier kWh per stack: 9 kWh (headline result)
  • Humidifier energy cost per stack: 1.17 $
  • Humidifier cost per stack processed: 0.03 $ / piece
  • Hourly cost: 0.39 $ / hr

Run it with your numbers

  • To rerun this with your own numbers, open the live Humidification Load calculator, set humidifier connected load to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.