Stargate Hydrogen’s electrolyser stacks use PSU material replacing metals

Electrolyser manufacturer Stargate Hydrogen, Estonia, is now using German firm BASF’s polysulphone (PSU) materials to manufacture the frames in its stacks used for alkaline water electrolysers (AWE).

The materials replaces metals such as nickel, resulting in significantly lighter stacks. This substitution is possible because BASF’s high-performance thermoplastic offers high temperature and chemical resistance also in harsh alkaline conditions. It can withstand high stack pressures due to compression strength.

As Ultrason can be injection-moulded, it provides design flexibility for easier functional integration than metal. The collaboration between Stargate Hydrogen and BASF has yielded results such as long operational lifespans, supporting reliable hydrogen production, and reducing downtime and maintenance costs.

Alkaline electrolysers are the most robust and proven form of electrolysis for producing hydrogen from water.

Marko Virkebau, CEO of Stargate Hydrogen, says, “We deliver not only a piece of hardware but a partnership from day one until hydrogen is being produced reliably. We build upon the best aspects of AWE technology and complement it with breakthrough materials.”

The patent-pending design of the Stellar stacks incorporates frames with a diameter of 85 cm, incorporating BASF’s Ultrason. It withstands the extreme forces in AWE systems and shows excellent hydrolytic stability. Its stable mechanical properties make it suitable for current (90 °C) and future (>100 °C) electrolysers.