CORE APPLICATION
CORE APPLICATIONAlkaline Water Electrolysis with IONZERA Membrane
The separator membrane is the heart of every alkaline electrolyser. IONZERA delivers 3x lower ionic resistance than Zirfon PERL, enabling more efficient hydrogen production at lower cell voltages.
Membrane Cross-Section
PSU-TiO₂-GO3x Lower Cell Voltage Drop
Area resistance of 0.09-0.1 ohm-cm2 vs Zirfon's 0.30 ohm-cm2 reduces the voltage penalty across the membrane by approximately 0.08V per cell at typical operating current densities.
Drop-In Stack Compatibility
IONZERA is fully compatible with standard AWE operating conditions: 30 wt% KOH electrolyte, temperatures up to 45 degrees C, and current densities from 0.2-0.6 A/cm2. No frame modifications required.
Mesh-Free Uniform Performance
Without PPS mesh reinforcement, IONZERA provides more consistent pore distribution across the entire active area, reducing localized hot spots and non-uniform current distribution in large-format cells.
Compact Stack Design
At 350-410 um, IONZERA is 20-30% thinner than Zirfon, enabling higher cell density per stack length and reducing overall stack weight and footprint.
The Separator's Role in Alkaline Electrolysis
In alkaline water electrolysis (AWE), the separator membrane sits between the cathode and anode, immersed in concentrated potassium hydroxide electrolyte. It must allow hydroxide ions to pass freely while blocking hydrogen and oxygen gas crossover. The separator's ionic resistance is the single largest contributor to the voltage drop beyond the thermodynamic minimum, making it the most impactful component for energy efficiency improvements.
IONZERA was purpose-built for AWE from the ground up. Its PSU-TiO2-GO nanocomposite architecture delivers an area resistance of 0.09-0.1 ohm-cm2 in 30 wt% KOH, roughly three times lower than Zirfon PERL UTP 500. This translates directly to lower cell voltages and reduced electricity consumption per kilogram of hydrogen produced.
Performance Under Real AWE Operating Conditions
IONZERA has been characterized under conditions that mirror actual alkaline electrolyser operation. In 30 wt% KOH at room temperature, the membrane achieves gas crossover below 0.5% hydrogen in oxygen, meeting the safety thresholds required for commercial AWE systems. The bubble point pressure exceeding 1.3 bar provides an additional safety margin against differential pressure events.
The membrane's mechanical strength of 2.7 MPa ensures reliable operation during stack assembly and pressurized electrolysis, while its elongation at break provides the flexibility needed to accommodate thermal expansion and stack compression cycles over years of continuous service.
Nanocomposite Structure
PSU-TiO₂-GOLower Resistance
Thinner Profile
Scaling AWE with a Better Separator
As alkaline electrolysis scales from MW-class pilot plants to multi-GW facilities, the separator membrane becomes a critical cost and performance lever. IONZERA addresses this scaling challenge on multiple fronts:
Area Resistance
3x LOWERThickness
20% THINNEREXPLORE MORE
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