Electrode Coating & Refurbishment Services
Q1: What electrode coatings solutions does INEOS Electrochemical Solutions provide?
We supply advanced anode and cathode coatings, complete electrode refurbishment services, and technical support for chlor-alkali electrolysers. Our solutions are designed to maximise efficiency, extend electrode life, and reduce total operating costs.
Q2: Which electrolyser technologies do INEOS coatings support?
Our coatings are optimised for most membrane cell technologies, either mono-polar or bi-polar, INEOS designed electrolysers as well as many alternative designs. We tailor coating formulations to match specific operating conditions and performance targets.
Q3: What are common materials used for electrolyser electrode coatings?
Electrode coatings are typically based on precious metal oxides and catalytic compounds applied to conductive substrates. Common materials include:
- Mixed Metal Oxide (MMO) coatings for anodes, often based on ruthenium, iridium, or other platinum group metals
- Nickel-based coatings for cathodes, sometimes enhanced with activators to improve hydrogen evolution performance
- Specialised catalytic layers tailored to optimise specific electrochemical reactions
The exact formulation is carefully engineered to balance activity, durability, and resistance to harsh operating environments such as high current densities.
Q4: How do INEOS coatings improve electrolyser efficiency?
Electrode coatings are critical to reducing the energy required for electrochemical reactions. They improve efficiency by:
- Lowering overvoltage at both anode and cathode
- Enhancing reaction kinetics (chlorine evolution and hydrogen evolution reactions)
- Maintaining stable performance over time, reducing efficiency losses due to degradation
In practical terms, this results in a lower cell voltage, which directly reduces electricity consumption—typically the largest operating cost in chlor-alkali or green hydrogen production.
Q5: What factors influence the lifespan of an electrode coating?
The operational life of electrode coatings depends on several key factors:
- Operating conditions: current density, temperature, and brine purity
- Process stability: fluctuations in load or shutdown/start-up frequency
- Mechanical handling: installation practices and physical wear
- Chemical environment: presence of contaminants or impurities
A well-designed coating, combined with optimised operating practices and regular monitoring, can significantly extend service life and maintain performance.
Q6: What are the latest INEOS advancements in electrode coating technology for water splitting?
Recent developments - particularly relevant as chlor-alkali and hydrogen markets increasingly converge - include:
- Reduced precious metal loading, lowering cost while maintaining performance
- Advanced nanostructured coatings to increase active surface area
- Improved catalyst stability under high current densities
- Tailored coatings for green hydrogen production, focusing on efficiency and durability in alkaline electrolysis
These innovations aim to deliver higher efficiency, longer lifetimes, and improved sustainability, all of which are increasingly important for customers targeting carbon reduction.
Q7: Do INEOS offer electrode coatings for hydrogen electrolysers?
Yes – INEOS offer coating services for alkaline water electrolysers producing green hydrogen. Get in touch for more information and to receive a quotation.
Anode Coatings
Q8: What are the benefits of INEOS anode coatings?
Our anode coatings are engineered to deliver:
- Low overvoltage, reducing energy consumption
- High durability, extending service life
- Stable performance, even under demanding operating conditions
- Optimised chlorine evolution efficiency
Q9: How do INEOS coatings improve energy efficiency?
By reducing the overpotential required for electrochemical reactions, our coatings lower the cell voltage, which directly reduces energy consumption - one of the largest cost drivers in chlor-alkali production.
Q10: How long do INEOS anode coatings typically last?
Coating life varies depending on operating conditions, but our anodes are designed for long operational lifetimes, with consistent performance across extended campaigns. We provide guidance based on your plant’s duty cycle and operating parameters.
Cathode Coatings
Q11: What advantages do INEOS cathode coatings offer?
Our cathode coatings provide:
- Reduced hydrogen evolution overvoltage
- Improved current efficiency
- Enhanced resistance to degradation and reverse currents
- Stable long-term operation
Q12: Can INEOS cathode coatings reduce operating costs?
Yes. By lowering energy requirements and maintaining high efficiency over time, our industry leading cathode coatings help reduce electricity costs and minimise maintenance-related downtime.
Electrode Refurbishment Services
Q13: What does INEOS electrode refurbishment service include?
Our refurbishment service typically includes:
- Electrode surface preparation
- Substrate inspection and repair (flange corrosion, mesh damage)
- Application of new high-performance coatings
- Quality assurance, testing, and inspection before return
Q14: How do chemical plant operators know when electrode refurbishment is needed?
Common indicators include:
- Rising cell voltage
- Reduced current efficiency
- Visual degradation of coatings
- Increased energy consumption
We can assist with condition assessment and recommend the optimal timing.
Performance & Reliability
Q15: How do INEOS ensure electrode coating quality and consistency?
We use proven coating technologies, stringent quality control processes, and extensive industry experience to ensure consistent, high-performance coatings. Additionally, we use our electrode coatings in our own electrolysis plants, so we know what it takes to ensure quality and reliable operations.
Q16: Do you provide technical support during operation?
Yes. We offer:
- Performance monitoring guidance
- Troubleshooting support
- Recommendations for operational optimisation
- On-site technical service visits, where required
Sustainability & Value
Q17: How do your solutions support sustainability goals?
Our coatings and refurbishment services help:
- Reduce energy consumption and carbon footprint
- Extend asset life and reduce waste
- Improve overall plant efficiency
Q18: What is the overall value proposition of INEOS electrode services?
We focus on delivering:
- Lower total cost of ownership
- High reliability and uptime
- Energy-efficient performance
- Long-term partnership and technical support
- Fast turn around
Getting Started with INEOS Electrochemical Solutions
Q19: How can I request a quotation or technical consultation?
You can contact our team with details of your electrolyser type, operating conditions, and current production challenges, and we will provide a tailored recommendation and proposal.
Ageing Plants & Retrofit Projects
Q20: Can INEOS coatings improve the performance of ageing electrolysers?
Yes. Our electrode coatings are specifically designed to restore and enhance performance in ageing plants, helping to reduce rising cell voltage, recover efficiency, and extend operational life without major capital investment.
Q21: What are the typical challenges in ageing chlor-alkali plants that INEOS solutions address?
Common issues include:
- Increased energy consumption (higher cell voltage)
- Reduced current efficiency
- Increased maintenance frequency
Our refurbishment and recoating services directly target these challenges.
Q22: Is electrode refurbishment a viable alternative to full electrolyser replacement?
Absolutely. For many plants, refurbishment offers a high-impact, low-capital solution that delivers:
- Significant energy savings
- Improved operational stability
- Extended asset life
This makes it an ideal step before considering full system upgrade or replacement.
Q23: How much performance improvement can be expected after refurbishment?
While results depend on operating conditions, customers typically see:
- Measurable reductions in cell voltage
- Improved efficiency and consistency
- Stabilised performance over extended operating campaigns
We can assess your current performance and provide a tailored projection.
Q24: Can refurbishment be carried out in stages to minimise downtime?
Yes. We work with operators to plan phased refurbishment programmes, enabling upgrades during scheduled maintenance windows and avoiding unnecessary production disruption.
New Builds & Greenfield Projects
Q25: How do INEOS coatings support new electrolyser installations?
For new builds, our coatings are engineered to deliver:
- Optimised start-up performance
- Low initial and long-term energy consumption
- High durability from day one
- Stable operation under design conditions
This ensures maximum return on investment from the outset.
Q26: Can INEOS tailor coatings to specific plant design or operating conditions?
Yes. We work closely with project teams to customise coatings based on:
- Electrolyser technology and design
- Target current density
- Brine quality and operating conditions
- Cellroom polarisation philosophy
- Customer performance priorities
Q27: How do INEOS solutions contribute to achieving efficiency targets?
Our coatings play a critical role in meeting:
- Energy consumption guarantees
- Production capacity targets
- Long-term reliability requirements
- Lower overvoltage directly reduces the plant’s power demand, supporting both cost and sustainability objectives.
Q28: Do INEOS support EPC contractors and project developers?
Yes. We collaborate with EPCs, technology licensors, and end-users to ensure smooth integration, including:
- Technical specifications
- Performance expectations
- Commissioning support
Q29: What long-term support can INEOS provide after start-up?
We offer ongoing partnership through:
- Performance monitoring
- Maintenance and recoating strategies
- Refurbishment planning for future campaigns
- Technical service visits
Q30: Can INEOS support both immediate improvements and long-term electrolysis plant strategies?
Yes. We often support customers with a dual approach:
- Short-term: electrode recoating and refurbishment to improve current performance
- Long-term: planning for future upgrades or new electrolyser installations
This ensures customers maximise value across the full lifecycle of their assets.