Lab and industry collaborate to develop the next generation of advanced electrode materials - Part 2
About the Author
Alise-Valentine Prits is a PhD researcher in sustainable energetics at the University of Tartu and a Junior Scientist at Stargate Hydrogen. Her work focuses on developing the next generation of advanced electrode materials for alkaline water electrolysis, contributing to the advancement of green hydrogen technologies. With a strong foundation in chemistry and materials engineering, Alise-Valentine combines academic insight with hands-on experience in R&D. She is also a teacher and is passionate about making science accessible to everyone.
Introduction
This two-part article by guest contributor Stargate Hydrogen aims to provide a practical overview of the findings from the study "Electrochemical characterisation of Raney nickel electrodes for alkaline water electrolysis: From laboratory to industrial scale" by Alise-Valentine Prits, et. al. Published with unrestricted access in the International Journal of Hydrogen Energy.
You can access the full study here.
What measurement setups can be used to study advanced electrode materials?
To evaluate advanced electrode materials for alkaline water electrolysis, researchers can choose from a variety of electrochemical setups. These setups differ in complexity, scale, and how closely they reflect the configuration of the cells in actual electrolysers.
In the study discussed here, four types of setups were used to evaluate Raney nickel electrodes. To make the comparison easier to follow, we refer to them using simplified names. The corresponding setup codes from the original study are also included for reference:
Basic lab cell (3E) – a three-electrode system commonly used in academic research
Simple flow cell (2EP) – a two-electrode system with plastic tubing and circulating electrolyte
Advanced flow cell (2EMC1 and 2EMC2) – a two-electrode system with metal piping, capable of operating at higher temperatures and pressures
Industrial stack (S) – a full-scale 17-cell electrolysis stack used for performance validation
Image ©Stargate Hydrogen
How do you choose the measurement setup?
The choice of measurement setup for characterising AWE electrodes should depend on the specific focus of the study. For example, while all four setups can be used to study advanced electrode materials, they serve different purposes depending on the research question, available resources, and desired level of industrial relevance.
Basic Lab Cell
The three-electrode system is ideal for fundamental research. It allows separate analysis of the oxygen and hydrogen evolution reactions (OER and HER), making it especially useful for understanding reaction mechanisms and evaluating catalyst activity. However, it does not include electrolyte circulation or pressure control, and measurements are typically done at room temperature with diluted electrolytes. While it's excellent for early-stage screening, it may not reflect industrial performance.
Simple Flow Cell
This two-electrode setup with plastic tubing introduces electrolyte circulation and a diaphragm, making it more representative of real electrolysis cells. It allows for controlled iron content in the electrolyte and is relatively easy to assemble and modify. The flexibility of using different gaskets makes it suitable for testing various electrode and separator thicknesses. However, this flexibility can also introduce variability between experiments. Although the setup used in this study did not support elevated temperatures, it could be modified to do so. Among all setups, the simple flow cell is the most practical for long-term testing and is recommended for initial screening of advanced electrode materials.
Advanced Flow Cell
This metal-piped two-electrode system is designed for testing under industrially relevant conditions, including elevated temperatures and pressures. In this study, two configurations of the setup were used:
2EMC1: A simpler design without elastic elements, easier to assemble
2EMC2: A more complex configuration that includes elastic elements and expanded metal sheets, closely mimicking the design of the industrial stack
The fixed geometry of the anode and cathode compartments helps ensure consistent assembly between experiments. The system also supports pressurised operation and can be equipped with gas analysers to study gas purity and crossover. However, it is more complex and time-consuming to use, and the electrolyte composition cannot be precisely controlled due to iron and chromium leaching from stainless steel components. This setup is best suited for secondary screening of promising materials and for estimating stack-level performance without the need for full-scale testing.
Industrial Stack
The full-scale 17-cell stack is used to validate electrode performance under real-world operating conditions. While it provides the most accurate performance data, it requires significantly more resources and is not practical for early-stage testing. Stack testing is essential for evaluating system-level effects such as shunt currents, which cannot be replicated in single-cell setups.
Quick Guide to Setup Selection
Basic lab cell - Best for mechanistic studies and early-stage catalyst development.
Simple flow cell - Ideal for initial screening and long-term testing, especially when precise control over electrolyte composition is important.
Advanced flow cell - Suitable for testing under industrial-like conditions and for secondary screening of promising materials.
Industrial stack - Well-suited for final validation and for studying effects that cannot be captured in single-cell setups.
How do the results measured with laboratory-scale setups correlate with industrial-scale setups?
The study demonstrates that results from laboratory-scale setups can closely reflect the performance of full-scale electrolysis systems when the lab configuration is appropriately designed.
The advanced flow cell, which incorporates metal piping and elastic elements, showed a strong alignment with the industrial stack under identical operating conditions (30% KOH, 70 °C, 16 atm). The voltage difference between the two setups was less than 20 mV at low current densities and around 60 mV at higher current densities.
In comparison, the other configuration of the advanced flow cell, which did not include the elastic element, exhibited greater deviation from the industrial stack. This suggests that, in addition to industrially relevant measurement conditions, replicating mechanical and flow characteristics is important for improving the accuracy of lab-scale predictions.
While the advanced flow cell provides a practical and resource-efficient method for estimating industrial performance, full-stack testing remains necessary for evaluating system-level phenomena such as gas crossover and shunt currents.
Conclusion
Bridging the gap between lab-scale experimentation and industrial performance is no longer a theoretical challenge; it is a practical necessity. Developing advanced electrode materials is the key to more efficient electrolysers, but testing them under the right conditions is what turns academic results into scalable industrial solutions. As demonstrated in the research by Alise-Valentine Prits and team, each test setup, from three-electrode systems to pressurised two-electrode cells, has a role to play in a structured R&D program.
By applying the right tools in the right order and paying attention to conditions like Fe content, temperature, and KOH concentration, researchers and engineers can build a dependable bridge between lab results and megawatt-scale hydrogen production.
By investing in novel catalysts like Stargate Hydrogen’s Stardust and refining testing protocols to reflect real-world environments, the industry moves closer to delivering scalable, affordable, and high-efficiency alkaline electrolysers. In doing so, we not only improve technological performance but also take a critical step toward decarbonising heavy industry and accelerating the global energy transition.
Working Together
Stargate Hydrogen take pride in bringing technical expertise and industrial realism to every electrolysis project. If you’re looking to kickstart hydrogen production, get in touch with us today. We’re here to help turn proven lab research into real-world hydrogen output.
To find out more about Stargate Hydrogen, visit www.stargatehydrogen.com.