Sakhalin Scientists Develop a Serviceable Fuel Cell for Hydrogen Energy

July 29, 2026

Researchers at Sakhalin State University are developing a prototype modular fuel cell featuring a serviceable design based on titanium bipolar plates. The solution will allow the membrane electrode assembly to be replaced without damaging the unit’s most valuable component.

Unlike welded foreign counterparts, which may become completely unusable in the event of a malfunction, the new architecture allows individual components to be repaired and replaced. The prototype is designed to remain leak-tight at pressures of up to two atmospheres, while the sealing elements are expected to operate for more than 10,000 hours of continuous use.

The researchers are using computational fluid dynamics modelling to optimise the gas and cooling channels. Their objective is to achieve at least 90% uniformity in heat distribution, reduce the risk of local overheating and improve equipment reliability.

Particular attention is being paid to hydrogen embrittlement, a process in which hydrogen penetrates the metal structure and makes the material brittle. Special coatings have been applied to titanium plates up to 3 mm thick to prevent hydrogen penetration and the subsequent deterioration of the metal. The technology has reached TRL 4–5, representing the transition from a laboratory prototype to testing under conditions close to industrial operation.

The new fuel cells are expected to be used in mining dump trucks, railway and marine transport, autonomous power systems for remote and Arctic territories, and as backup power sources at industrial facilities.

According to A. Ognev, Acting Rector of Sakhalin State University, the development of a domestically produced serviceable fuel cell is aimed at creating independent hydrogen technologies adapted to a wide range of climatic conditions and offering high economic efficiency and maintainability. The Sakhalin Region, which is developing a pilot hydrogen cluster, is expected to serve as a testing ground for these solutions.

The training of engineering personnel for the hydrogen energy sector is planned to be discussed at the upcoming international Energy of Sakhalin Forum. The discussion will bring together representatives of the university, employers and public authorities.

The project is being implemented as part of the Priority 2030 programme, with support from a Russian Science Foundation grant. Its planned results include a complete set of design and process documentation and three experimental fuel cell units.

The project’s industrial partners are the InEnergy Group, the Federal Research Centre for Problems of Chemical Physics and Medicinal Chemistry of the Russian Academy of Sciences, and the Engineering Environment for the Transfer of Educational Competencies company.

The Sakhalin Region has been implementing a hydrogen cluster development project since 2020. Sakhalin State University is one of the initiative’s key research participants and is developing technologies for low-carbon energy.

Source: Neftegaz.RU

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