Alkaline Electrolyser — Bipolar Design, Green Hydrogen Production

An alkaline electrolyser is an electrochemical device that splits water into hydrogen and oxygen gas using DC electricity and a liquid alkaline electrolyte (KOH or NaOH). DC current is applied across a bipolar cell stack — at the cathode, water molecules are reduced to produce hydrogen gas and hydroxide ions; at the anode, hydroxide ions are oxidised to produce oxygen gas. A porous diaphragm separates the two gases while allowing ions to pass, maintaining gas purity and safety.

Brise Chemicals Pvt. Ltd., based in Pune, Maharashtra, is an Indian manufacturer of bipolar alkaline electrolysers for green hydrogen production. They design and fabricate proprietary bipolar stacks with in-house electrode coating technology, offering systems from small pilot scale to multi-MW industrial capacity. They are ISO 9001, ISO 14001, and ISO 45001 certified.

Brise Chemicals' alkaline electrolyser stacks achieve a specific energy consumption of 3.8 to 4.4 kWh per Nm³ of hydrogen — placing them among the most efficient industrial alkaline electrolysers available in India. Lower kWh/Nm³ directly reduces hydrogen production cost per kilogram.

Alkaline electrolysers use a liquid KOH/NaOH electrolyte and conduct hydroxide ions (OH⁻), use non-precious nickel-based catalysts, and have lower CAPEX — making them ideal for large-scale, continuous industrial hydrogen production. PEM electrolysers use a solid polymer membrane, conduct protons (H⁺), use expensive platinum/iridium catalysts, and respond better to rapidly variable power — making them preferred for smaller-scale renewable energy integration where dynamic response is critical.

Brise Chemicals' alkaline electrolysers produce hydrogen at 99.99% (4N) to 99.9999% (6N) purity after passing through the complete gas purification train: gas-liquid separator, scrubber, catalytic De-Oxo unit, and molecular sieve dryer. Oxygen content in the hydrogen stream is maintained below 2 ppm(v) and moisture below 2 ppm(v).

The cost of an alkaline electrolyser in India depends on capacity (kW/MW), operating pressure, purity requirements, and site conditions. At commercial scale, alkaline electrolyser systems range from ₹2.5 crore to ₹8 crore per MW depending on configuration. For a precise quotation customized to your project, contact Brise Chemicals at sales@brisechemicals.com or +91 8956727434.

Yes. Brise Chemicals' alkaline electrolysers are fully compatible with solar PV and wind energy as power sources. The integrated Siemens PLC control system uses an equal distribution control strategy to safely manage variable DC power inputs from renewable sources, routing power to active stacks while placing others in hot-standby during low generation periods.

Brise Chemicals' alkaline electrolysers operate at 1 to 30 barg (gauge pressure). Pressurized operation produces hydrogen at elevated pressure directly from the stack, eliminating the need for a separate low-pressure compressor in many applications, reducing CAPEX and energy consumption.

Current density (measured in A/cm² or mA/cm²) is the electrical current applied per unit of active electrode area in the electrolyser cell. Brise Chemicals' stacks operate at 0.2 to 0.8 A/cm². Higher current density increases hydrogen production rate but also increases cell voltage (and energy consumption). Operating at the optimal current density (typically 0.4–0.6 A/cm²) balances production rate with energy efficiency.

Theoretically, 9 liters (9 kg) of pure water produce 1 kg of hydrogen. In real industrial systems, this rises to 10–11 liters to account for losses in water treatment and purification. For project water planning, Brise Chemicals recommends budgeting 15–18 liters per kg H₂ when including closed-loop cooling circuit makeup water.