This paper discusses development of new materials for alkaline electrolysers and assesses the impact of large penetrations of electrolysis plants on the electrical grid. New electrolyser electrodes were produced by a synthesis method of Nickel electroplated with carbon catalyst consisting of Molybdenum-Resorcinol-Formaldehyde (Mo RF), and carbon aerogel of surface area >700 m(2)/g and pore size of 4 nm, followed by an impregnation of molybdenum as a catalyst before deposition on nickel thus creating Ni-Mo RF electrodes. Another electrode made from Vulcan-Carbon-Platinum powder was used to produce Ni-C-Pt electrodes. The different electrodes were compared by analysis of kinetic reaction measurements using polarisation techniques and electrochemical impedance methods. An experiment was carried out to measure the AC and DC harmonics and the efficiency of the electrical parts of an operational 1 Nm(3)/hr electrolyser. In addition, the power system impact analysis of two Alkaline Electrolysis plants connected to the IEEE30 standard power system model was studied in MATLAB environment. (C) 2012 Elsevier Ltd. All rights reserved.