Marcin: /* Main Readout */

2026-03-16T01:19:04Z

Main Readout

Marcin: Created page with "= NiFe Factory Material and Plate Model for 20 MWh/year = Assumptions: * Plant output: 20,000 kWh/year * Planning mass intensity: 20 kg/kWh finished wet battery * Total finished battery mass: 400 t/year * 20-foot container payload basis: 28.3 t/container * Plate area model: 40 mg/cm² coated-face loading, 75% utilization, 1.2 V nominal * Resulting areal energy density used for sizing: 104 Wh/m² of coated face {| class="wikitable sortable" ! Material / Metric ! Unit ba..."

2026-03-16T00:49:16Z

Created page with "= NiFe Factory Material and Plate Model for 20 MWh/year = Assumptions: * Plant output: 20,000 kWh/year * Planning mass intensity: 20 kg/kWh finished wet battery * Total finished battery mass: 400 t/year * 20-foot container payload basis: 28.3 t/container * Plate area model: 40 mg/cm² coated-face loading, 75% utilization, 1.2 V nominal * Resulting areal energy density used for sizing: 104 Wh/m² of coated face {| class="wikitable sortable" ! Material / Metric ! Unit ba..."

New page

= NiFe Factory Material and Plate Model for 20 MWh/year =

Assumptions:
* Plant output: 20,000 kWh/year
* Planning mass intensity: 20 kg/kWh finished wet battery
* Total finished battery mass: 400 t/year
* 20-foot container payload basis: 28.3 t/container
* Plate area model: 40 mg/cm² coated-face loading, 75% utilization, 1.2 V nominal
* Resulting areal energy density used for sizing: 104 Wh/m² of coated face

{| class="wikitable sortable"
! Material / Metric
! Unit basis
! Per kWh
! Annual total for 20 MWh
! Commodity cost
! Commodity $/kWh
! Annual commodity cost
! Integrated $/kWh
! Annual integrated cost
! 20 ft containers by weight
|-
| Nickel, contained metal
| kg
| 1.20
| 24.0 t
| $17.34/kg
| $20.81
| $416,160
| $20.81
| $416,160
| 0.85
|-
| Nickel hydroxide equivalent
| kg
| 1.90
| 37.9 t
| derived from nickel content
| n/a
| n/a
| n/a
| n/a
| 1.34
|-
| Iron powder
| kg
| 5.50
| 110.0 t
| $2.00/kg purchased
| $11.00
| $220,000
| $4.40
| $88,000
| 3.89
|-
| Steel mesh / sheet / case internals
| kg
| 6.00
| 120.0 t
| $1.018/kg purchased
| $6.11
| $122,160
| $3.60
| $72,000
| 4.24
|-
| KOH, dry basis
| kg
| 2.00
| 40.0 t
| $0.91/kg
| $1.82
| $36,400
| $1.82
| $36,400
| 1.41
|-
| HDPE / PP case resin
| kg
| 1.00
| 20.0 t
| $0.87/kg
| $0.87
| $17,400
| $0.87
| $17,400
| 0.71
|-
| Copper bus bars / terminals
| kg
| 0.30
| 6.0 t
| $12.758/kg
| $3.83
| $76,548
| $3.83
| $76,548
| 0.21
|-
| Separator + binder + additives
| kg
| 0.80
| 16.0 t
| $3.00/kg assumed
| $2.40
| $48,000
| $2.40
| $48,000
| 0.57
|-
| Deionized water
| kg
| 3.20
| 64.0 t
| $0.001/kg assumed
| $0.00
| $64
| $0.00
| $64
| 2.26
|-
! Total
!
! 20.00 kg
! 400.0 t
!
! $46.84/kWh
! $936,732
! $37.73/kWh
! $754,572
! 14.13
|}

= Electrode Plate Area Model =

The next table is for factory sizing of the electrode fabrication line.
It uses the aggressive planning assumption of 104 Wh/m² of coated face.

{| class="wikitable"
! Plate metric
! Formula basis
! Per kWh
! Annual total for 20 MWh
|-
| Positive coated-face area
| 1000 Wh / 104 Wh/m²
| 9.62 m²
| 192,308 m²
|-
| Negative coated-face area
| matched to positive area
| 9.62 m²
| 192,308 m²
|-
| Total coated-face area, both polarities
| positive + negative
| 19.23 m²
| 384,615 m²
|-
| Positive metal-sheet plate area
| double-coated plates, so coated-face area / 2
| 4.81 m²
| 96,154 m²
|-
| Negative metal-sheet plate area
| double-coated plates, so coated-face area / 2
| 4.81 m²
| 96,154 m²
|-
| Total metal-sheet electrode area
| positive sheet + negative sheet
| 9.62 m²
| 192,308 m²
|}

= Shipping Container Summary =

{| class="wikitable"
! Shipping item
! Annual tonnage
! 20 ft containers at 28.3 t payload
|-
| Finished wet batteries
| 400.0 t
| 14.13
|-
| All nickel input, contained metal basis
| 24.0 t
| 0.85
|-
| Iron powder
| 110.0 t
| 3.89
|-
| Steel
| 120.0 t
| 4.24
|-
| KOH
| 40.0 t
| 1.41
|-
| Everything except water
| 336.0 t
| 11.87
|}

= Main Readout =

* A 20 MWh/year NiFe plant at 20 kg/kWh is about 400 t/year of finished battery output.
* On purchased materials, this planning model lands near $46.84/kWh.
* With aggressive in-house iron and steel integration, the same model lands near $37.73/kWh.
* Finished-battery outbound logistics are about 14 standard 20-foot containers per year by weight.
* The electrode line must process about 384,615 m²/year of coated electrode faces under the plate-loading assumption used here.

Nickel Iron Battery Manufacturing - Revision history

Marcin: /* Main Readout */