Open Source Electrolyzer - Revision history

Marcin: /* Combined System View */

2026-03-17T05:29:24Z

Combined System View

@@ Line 344: / Line 344: @@
 ! ~$61,650 – $123,100
 |}
 = Interpretation =

Marcin: /* Balance of System */

2026-03-17T05:25:49Z

Balance of System

← Older revision		Revision as of 05:25, 17 March 2026
Line 224:		Line 224:
	=Balance of System=		=Balance of System=
	(includes PV)		(includes PV)

			= 100 kW Open Source Alkaline Electrolyzer Balance-of-System Budget =

			{\| class="wikitable"
			\|+ Balance-of-System Cost Breakdown (Prototype-Realistic, 100 kW)
			! Category
			! Description
			! Estimated Cost Range
			! Notes
			\|-
			\| Power electronics / DC current control
			\| Rectifier or DC/DC current controller, bus protection, contactors
			\| $6,000–$15,000
			\| Largest BoS bucket; aligns with IRENA showing power supply as the dominant BoP element
			\|-
			\| Water treatment + make-up water
			\| Pre-filtration, deionized water handling, make-up tank
			\| $500–$2,000
			\| Needed to maintain electrolyte quality and reduce contamination
			\|-
			\| Electrolyte circulation loop
			\| Electrolyte reservoir, alkali-compatible pumps, recirculation piping
			\| $2,000–$6,000
			\| Corresponds to the circulation/process side of alkaline BoP
			\|-
			\| Cooling system
			\| Heat exchanger, auxiliary pump, radiator or water cooling loop
			\| $1,500–$5,000
			\| Removes waste heat from stack/electrolyte loop
			\|-
			\| Gas-liquid separators
			\| Hydrogen-side and oxygen-side knockout / separator vessels
			\| $1,500–$4,000
			\| First cleanup stage after stack
			\|-
			\| Demister + coalescing filters
			\| Mist eliminators and particulate protection
			\| $500–$2,000
			\| Minimal gas cleanup for non-fuel-cell use
			\|-
			\| Gas drying
			\| Desiccant dryer or twin-tower dryer
			\| $2,000–$6,000
			\| Required for robust storage and downstream engine use
			\|-
			\| Optional deoxo unit
			\| Oxygen removal reactor for cleaner hydrogen
			\| $0–$6,000
			\| Optional for ICE use; more important for higher-purity gas service
			\|-
			\| Compression and storage
			\| Cylinder manifold, regulators, 30 cylinders at ~1 kg each
			\| ~$10,000
			\| Based on current project assumption
			\|-
			\| Piping, valves, fittings
			\| Stainless / nickel-compatible plumbing, isolation valves, check valves
			\| $2,000–$6,000
			\| Usually underestimated in first-pass budgets
			\|-
			\| Sensors + safety hardware
			\| Pressure, temperature, flow, level, H2 detection, relief valves, vents
			\| $2,000–$6,000
			\| Essential for safe operation
			\|-
			\| Controls + wiring
			\| PLC / controller, relays, HMI, low-voltage wiring, interlocks
			\| $2,000–$8,000
			\| Includes startup/shutdown logic and safeties
			\|-
			\| Structural integration
			\| Skid, mounting frame, panel enclosure, equipment supports
			\| $2,000–$8,000
			\| The main “system integration” bucket
			\|-
			\| Assembly, commissioning, and contingency
			\| Final integration overhead, rework, consumables, prototype inefficiency
			\| $3,000–$10,000
			\| Captures first-build friction realistically
			\|-
			! Total BoS excluding renewable power source
			! All non-stack systems around the electrolyzer
			! $35,000–$84,000
			! Typical practical target: about $45,000–$65,000
			\|}

			= Optional External Energy Supply Hardware =

			{\| class="wikitable"
			\|+ Renewable Power Source (Outside Electrolyzer BoS Proper)
			! Category
			! Description
			! Estimated Cost
			! Notes
			\|-
			\| Solar or wind supply hardware
			\| Example user assumption for 100 kW renewable input hardware
			\| ~$20,000
			\| This is usually treated as external generation plant, not electrolyzer BoS
			\|}

			= Combined System View =

			{\| class="wikitable"
			\|+ 100 kW System-Level Capital Picture
			! Major Block
			! Estimated Cost Range
			\|-
			\| Electrolyzer stack
			\| $6,650–$19,100
			\|-
			\| Balance of system (excluding renewable source)
			\| $35,000–$84,000
			\|-
			\| Renewable power hardware
			\| ~$20,000
			\|-
			! Total system including stack + BoS + renewable source
			! ~$61,650 – $123,100
			\|}

			= Interpretation =

			The dominant non-stack cost items are typically:

			* power electronics / current control
			* gas handling and drying
			* piping, sensors, and safety systems
			* structural integration and commissioning

			The major insight is that for a 100 kW distributed alkaline system, the '''stack is not the only serious cost center'''. The non-stack systems can readily exceed stack cost, which is consistent with current alkaline system cost structure where BoP remains a very large share of total electrolyzer CAPEX. Representative 2025 European electrolyzer cost reporting still separates cost into '''stack, balance of plant, other utilities, and other CAPEX''', confirming that non-stack categories remain economically significant. :contentReference[oaicite:1]{index=1}

Marcin: /* Key Insight */

2026-03-17T05:21:47Z

Key Insight

← Older revision		Revision as of 05:21, 17 March 2026
Line 221:		Line 221:
	* simplified geometry		* simplified geometry
	* process standardization		* process standardization

			=Balance of System=
			(includes PV)

Marcin: /* Rough Stack Materials Budget */

2026-03-17T04:56:48Z

Rough Stack Materials Budget

@@ Line 129: / Line 129: @@
 = Rough Stack Materials Budget =
 {| class="wikitable"
-|+ 100 kW Stack Materials Budget
+|+ Detailed Stack Cost Breakdown (Prototype-Realistic)
 ! Category
-! Estimated Cost
+! Description
 |-
-| Nickel foam electrodes
+| Nickel Foam Electrodes
 | $600–$3,000
 |-
-| Separator
+| Separator (Zirfon)
 | ~$1,800
 |-
-| Structure + collectors
+| Electrolyte + Chemicals
 | $1,000–$3,000
 |-
-| Chemicals + electrolyte
+| Scrap, Yield Loss, Shipping, Contingency
-| $200–$600
+| Material losses, damaged parts, supplier overhead
 |-
-! Total estimated stack materials
+| High-friction prototype case
-! $10,000–$18,000
+| Inefficient sourcing, mistakes, iteration cycles
 |}

Marcin at 04:51, 17 March 2026

2026-03-17T04:51:05Z

@@ Line 7: / Line 7: @@
 $10-20k for a 100kW stack. Payback of one year with 6 hour solar, quicker with wind.
+=Materials Breakdown and Sourcing=
 {| class="wikitable"
 |+ 100 kW Open Source Alkaline Electrolyzer Stack – Bill of Materials
@@ Line 100: / Line 100: @@
 | Sigma-Aldrich
 | https://www.sigmaaldrich.com/US/en/product/sial/695092
 |}

Marcin at 04:49, 17 March 2026

2026-03-17T04:49:27Z

← Older revision		Revision as of 04:49, 17 March 2026
Line 1:		Line 1:
	https://chatgpt.com/share/69b78df5-6188-8010-8d76-08b5073da11a		https://chatgpt.com/share/69b78df5-6188-8010-8d76-08b5073da11a

			=No Exotic Materials Required=

			No exotic manufacturing is required - no exotic membranes outside of off-the-shelf Zirfon separator which appears to contribute 10% to the cost.

			$10-20k for a 100kW stack. Payback of one year with 6 hour solar, quicker with wind.


	{\| class="wikitable"		{\| class="wikitable"

Marcin at 04:59, 16 March 2026

2026-03-16T04:59:39Z

← Older revision		Revision as of 04:59, 16 March 2026
Line 1:		Line 1:
			https://chatgpt.com/share/69b78df5-6188-8010-8d76-08b5073da11a

	{\| class="wikitable"		{\| class="wikitable"
	\|+ 100 kW Open Source Alkaline Electrolyzer Stack – Bill of Materials		\|+ 100 kW Open Source Alkaline Electrolyzer Stack – Bill of Materials

Marcin: Created page with "{| class="wikitable" |+ 100 kW Open Source Alkaline Electrolyzer Stack – Bill of Materials ! Component ! Specification ! Quantity ! Typical Cost Range ! Example Supplier / Source ! Link |- | Nickel Foam (Cathode) | 1–2 mm thick, 20–60 PPI, >99% Ni | ~12 m² | $300–$1,500 | MTI Corporation | https://mtixtl.com/products/0-5-mm-thick-nickel-foam-for-battery-cathode-substrate-or-solid-state-electrolyte-support-l-1000-x-w-200-mm-eq-bcnf-05m |- | Nickel Foam (Anode sub..."

2026-03-16T04:56:44Z

Created page with "{| class="wikitable" |+ 100 kW Open Source Alkaline Electrolyzer Stack – Bill of Materials ! Component ! Specification ! Quantity ! Typical Cost Range ! Example Supplier / Source ! Link |- | Nickel Foam (Cathode) | 1–2 mm thick, 20–60 PPI, >99% Ni | ~12 m² | $300–$1,500 | MTI Corporation | https://mtixtl.com/products/0-5-mm-thick-nickel-foam-for-battery-cathode-substrate-or-solid-state-electrolyte-support-l-1000-x-w-200-mm-eq-bcnf-05m |- | Nickel Foam (Anode sub..."

New page

{| class="wikitable"
|+ 100 kW Open Source Alkaline Electrolyzer Stack – Bill of Materials
! Component
! Specification
! Quantity
! Typical Cost Range
! Example Supplier / Source
! Link
|-
| Nickel Foam (Cathode)
| 1–2 mm thick, 20–60 PPI, >99% Ni
| ~12 m²
| $300–$1,500
| MTI Corporation
| https://mtixtl.com/products/0-5-mm-thick-nickel-foam-for-battery-cathode-substrate-or-solid-state-electrolyte-support-l-1000-x-w-200-mm-eq-bcnf-05m
|-
| Nickel Foam (Anode substrate)
| same spec as cathode
| ~12 m²
| $300–$1,500
| Goodfellow
| https://www.goodfellow.com/usa/nickel-sizes-foam-group
|-
| Separator (Zirfon-type diaphragm)
| ~0.3–0.5 mm polysulfone + zirconia composite
| ~12 m²
| ~$1,800
| Agfa Zirfon PERL
| https://www.agfa.com/zirfon/
|-
| Cell Frames / Spacers
| HDPE / polypropylene plates
| ~100 pieces
| $500–$1,500
| McMaster-Carr plastic sheet
| https://www.mcmaster.com/polypropylene-sheets/
|-
| End Plates
| Carbon steel or stainless plate
| 2 pieces
| $200–$600
| Online Metals steel plate
| https://www.onlinemetals.com/
|-
| Gaskets
| EPDM or PTFE sheet 1–2 mm
| ~100 sets
| $100–$400
| McMaster-Carr gasket sheet
| https://www.mcmaster.com/epdm-rubber/
|-
| Current Collectors
| Nickel sheet or nickel mesh
| ~2–4 m²
| $200–$800
| Alfa Aesar nickel sheet
| https://www.fishersci.com/shop/products/nickel-foil/AA43098
|-
| Busbars
| Copper bar stock
| ~3–5 kg
| $100–$300
| McMaster copper bar
| https://www.mcmaster.com/copper-bars/
|-
| Electrolyte
| Potassium hydroxide (KOH), 25–30 wt%
| ~100–150 L solution
| $200–$500
| Lab Alley KOH
| https://www.laballey.com/products/potassium-hydroxide-koh
|-
| Anode Catalyst Bath Chemical
| Nickel sulfate (NiSO₄)
| ~1–2 kg
| $50–$200
| Sigma-Aldrich
| https://www.sigmaaldrich.com/US/en/product/aldrich/656895
|-
| Anode Catalyst Bath Chemical
| Ferrous sulfate (FeSO₄)
| ~1 kg
| $20–$80
| Fisher Scientific
| https://www.fishersci.com/shop/products/ferrous-sulfate-heptahydrate
|-
| Anode Catalyst Bath Chemical
| Boric acid (H₃BO₃)
| ~1 kg
| $10–$40
| Sigma-Aldrich
| https://www.sigmaaldrich.com/US/en/product/sial/695092
|}