Upscaling of green hydrogen production with specialty plastic Ultrason

Efficient electrolysers are key in advancing the green hydrogen economy. For the development of larger, more efficient and durable electrolysers, German chemical firm BASF says it offers a unique partnership to the energy sector: a tailored portfolio of polyarylethersulphones (PSU, PESU, PPSU) for components in water electrolysers used for producing green hydrogen – combined with application know-how and reliable local technical support for part design.

It adds that backed by its deep understanding of complex injection-moulding applications and membrane casting, BASF helps customers in upscaling electrolyser technology, thus pushing the transformation to clean energy. BASF’s portfolio for electrolyser parts includes Ultrason grades for frames, gaskets and separator membranes.

Ultrason is ideally suited for metal replacement in various components of alkaline water (AWE), proton exchange membrane (PEM) and anionic electrolyte membrane (AEM) electrolysers. The amorphous polymer shows outstanding temperature and chemical resistance. Its excellent performance under highly demanding conditions includes thermoplastic processing for structural parts and constant high purity for separator membranes. Ultrason’s temperature-independent mechanical properties make it suitable for current (90 °C) and future (> 120 °C) electrolysers.

The PEF material is also said to enable long lifetime of electrolysers: it withstands the high compressive forces of electrolyser systems and shows great hydrolytic stability. BASF adds the thermoplastic can be used for small as well as large injection-moulding and extrusion components. All these advantages lead to lower-weight electrolysers and higher freedom of design for different construction needs when compared to metal.

Especially for membranes, Ultrason is well-known for its superior advantages like low cyclic dimer content and a constantly high material quality enabling stable spinning solutions for membrane casting. This is the reason why Ultrason is considered the market standard in membranes used in the water filtration and dialysis industry for more than 25 years, according to BASF.

The thermoplastic is used to manufacture water filtration membranes, as well as lightweight components for the automotive and aerospace industries. Ultrason brands can substitute thermosets, metals and ceramics in many applications.