10-10-2024

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 electrolyzers, BASF offers a unique partnership to the energy sector: a tailored portfolio of polyarylethersulfones (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. Backed by BASF’s deep understanding of complex injection-molding 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. This can be experienced first-hand at the BASF booth at Fakuma 2024, Germany where an electrolyser frame sample will be exhibited.

Ultrason is ideally suited for metal replacement in various components of alkaline water (AWE), proton exchange membrane (PEM) and anionic electrolyte membrane (AEM) electrolyzers. 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.

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

Ultrason accelerates green hydrogen production

With bigger, long-lasting and robust electrolysers the efficiency of green hydrogen plants can be increased. “You want to develop parts for water electrolyzers with special focus on higher operating temperatures and longer lifetime? We support all interested companies with choosing the right Ultrason grade and offer our experience during part and tool design, up to final serial manufacturing”, says Erik Gubbels from Global Business Development Ultrason at BASF. “We are a global partner but act locally when it comes to developing high-quality injection-molded parts and high-performance separator membranes. With more than 30 years of know-how in plastic processing, material performance and membrane production, we at BASF are the perfect match for your electrolyser project saving you time and costs so that you can become a frontrunner in the electrolyser market.”

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: BASF has profound application and process know-how in this field and is the ideal partner for bringing the technology to the next level in hydrogen applications.

Ultrason is the trade name for BASF’s product range of polyethersulfone (Ultrason E), polysulfone (Ultrason S) and polyphenylsulfone (Ultrason P). The high-performance thermoplastic is used to manufacture water filtration membranes, stylish, durable and safe household and catering applications as well as lightweight components for the automotive and aerospace industries. Ultrason brands can substitute thermosets, metals and ceramics in many applications because of their extraordinary property profile.