Stargate Hydrogen uses BASF’s Ultrason

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 excellent compression strength. As Ultrason can be injection-molded, it provides greater design flexibility for easier functional integration than metal. The collaboration between Stargate Hydrogen and BASF has yielded an exceptional result: the pressurised stacks of the Stellar series are designed for long operational lifespans, supporting reliable hydrogen production, and reducing downtime and maintenance costs. This durability enhances the economic feasibility of green hydrogen production, making it a cost-effective solution.

Alkaline electrolysers are the most robust and proven form of electrolysis for producing hydrogen from water. “Stargate Hydrogen manufactures electrolyser stacks to empower system integrators with the most flexible and scalable technology,” said Marko Virkebau, CEO of Stargate Hydrogen. “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. This is why we chose BASF’s Ultrason for the frames in our Stellar electrolyser series: it combines light weight with outstanding performance, thus helping us to improve the efficiency and lower the cost of alkaline electrolysers.” This results in a new class of electrolysers with high current densities, offering an innovative approach to decarbonising sectors such as heavy transport, steel manufacturing, and the chemical industry.

Tailored Ultrason portfolio for scaling up hydrogen production

The patent-pending design of Stargate Hydrogen’s Stellar stacks incorporates frames with a diameter of 85 cm. BASF’s specialty plastic Ultrason enables these frames to be large, robust, and durable, with a focus on higher operating temperatures and extended lifetimes. 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.

“With Ultrason, our customers can upscale green hydrogen production, thus advancing the transformation to clean energy,” said Jochen Schmid from Global Business Development Ultrason® at BASF. “Its excellent performance under the harsh conditions of water electrolysis makes it the ideal material for various electrolyser technologies and applications. We are proud to support Stargate Hydrogen in its scale-up strategy – from selecting the appropriate Ultrason grade to part and tool design and final frame production."

BASF offers a tailored Ultrason portfolio to meet the specific performance requirements of alkaline water (AWE), proton exchange membrane (PEM), and anion exchange membrane (AEM) electrolysers. Supported by BASF’s application expertise and local technical support, the material range for electrolyser components includes polyarylethersulfones (PSU, PESU, PPSU) for frames, gaskets, and separator membranes.

Read the article online at: https://www.globalhydrogenreview.com/hydrogen/11092025/stargate-hydrogen-uses-basfs-ultrason/