Optimized electrode material for higher efficiency in electrolysis

Hydrogen is seen as the key to decarbonizing industry and reducing CO2 emissions, which amounted to 37.4 gigatonnes worldwide in 2023. In order to produce the necessary amount of hydrogen sustainably, it is crucial to make the electrolysis processes more efficient. This requires not only the expansion of infrastructure, but also the optimization of efficiency in hydrogen production, especially through innovative electrode materials.

More efficient electrolysis thanks to optimized materials

The efficiency of electrolysers depends largely on the electrode materials used. Nickel foams, nonwovens, expanded metals and fabrics are traditionally used in alkaline electrolysers (AWE). Square mesh, also known as flynet, has become particularly well established in the industry. The anode side of these materials is usually coated, which significantly improves efficiency. However, it is not only the coating but also the choice of mesh that has a significant impact on efficiency.

Innovative TELA fabric for better gas bubble management

An innovative product in this area is the asymmetrical TELA mesh from GKD. This new mesh offers a promising opportunity to further optimize the electrolysis process. Thanks to specially developed drainage channels, gas bubble management is significantly improved, allowing hydrogen to be removed more efficiently. Despite a smaller surface area compared to traditional meshes, the optimized TELA shows better overall performance.

Increase in efficiency by up to 25 percent

Tests with alternative substrate materials have shown that GKD’s optimized TELA mesh, which is additionally coated with nickel, can increase efficiency by up to 25 percent compared to other coated media, such as expanded metals and square meshes. This increase in performance underlines the potential of the new mesh in hydrogen production.

Growing demand and expanded production capacities

As the demand for high-performance mesh for electrolysis increases, so do the requirements for cutting and size. GKD is responding to this with its own laser and plasma cutting technology and can even offer round mesh with a diameter of up to four meters. In order to meet global demand, GKD is expanding its production capacities worldwide and minimizing supply chain risk at the same time.

You can find out more about our electrode fabric for electrolysis here: