- Stargate Hydrogen presents Starbase and Aurora systems that further accelerate industrial green hydrogen production
- Aurora offers a compact, outdoor-ready design, maximizing efficiency and minimizing space requirements
- Starbase stacks deliver high performance and durability, reducing the cost of hydrogen generation
- Jointly, these systems provide scalable, next-generation solutions for heavy industry decarbonisation
This October, Stargate Hydrogen—the well-known Estonian innovator in next-generation alkaline electrolysers for cost-effective green hydrogen—announced the launch of its two new major product families: Starbase, the 5 MW Electrolyser Stack, and Aurora, the 10 MW Electrolyser System module.
Stargate Hydrogen in a Nutshell and Its New Products at a Glance
Founded in 2021, Stargate Hydrogen is a Tallinn-based deep-tech company developing next-generation alkaline electrolysers that make green hydrogen production more efficient, durable, and cost-effective. Its core innovation lies in ceramic-based materials that enhance system performance and longevity.
By expanding manufacturing and R&D, Stargate Hydrogen aims to accelerate industrial decarbonisation and enable large-scale adoption of renewable hydrogen. The company’s scalable, high-efficiency electrolysis solutions are designed to support heavy industries in achieving sustainability goals while maintaining operational reliability and economic competitiveness.
Stargate Hydrogen’s new Starbase and Aurora systems are engineered to accelerate industrial decarbonisation by enabling refineries, chemical plants, and steel manufacturers to produce green hydrogen on-site efficiently and affordably. The Aurora system, a 10 MW outdoor-ready electrolyser, sets a benchmark in space efficiency with a footprint of only 14.4 m2 per MW—the most compact alkaline electrolyser available. It integrates two 5 MW Starbase stacks, achieving an exceptional stack consumption below 49 kWh/kg. Together, Starbase and Aurora deliver scalable, high-performance, and cost-effective solutions tailored for large-scale industrial hydrogen production and the transition to clean energy.
New Electrolyser Systems for Driving Industrial Decarbonisation
ITKeyMedia approached Stargate Hydrogen’s senior business development and sales manager Aniket Choudhari to find out more about the new products, how they came to be, what they bring to the table, and what’s next.
A stack consumption of less than 49 kWh/kg for the Aurora system was cited. What are the specific assumptions behind that figure?
Aniket Choudhari, Senior Business Development and Sales Manager at Stargate Hydrogen
Aniket Choudhari: This efficiency figure is the result of several engineering optimizations, including an improved stack design, novel electrode materials, and pressurized operation. These advancements collectively reduce internal losses and enhance gas separation, which contributes directly to lower specific energy consumption. The Aurora system’s performance therefore reflects not only design innovation but also Stargate Hydrogen’s continuous work on material and process refinement.
The Aurora module claims a footprint of just 14.4 m2 per MW, making it ‘most space-efficient.’ What design trade-offs did you make to achieve that compactness?
AC: The compactness of the Aurora module comes from its modular and vertically stackable design. Thanks to the lightweight 5 MW Starbase stack, we can effectively utilize space above the ground plane, enabling construction in a vertical configuration. Importantly, this compactness does not compromise accessibility—critical equipment remains easily reachable for service and maintenance.
For Starbase and Aurora, how modular are the systems in actual field deployment?
AC: Both systems have been engineered for maximum modularity and fast deployment in real-world conditions. Prefabricated modules minimize on-site installation time and complexity, allowing customers to scale up production with minimal civil works. The modular architecture, combined with the fact that no dedicated building is required, ensures easier maintenance and flexible scaling as hydrogen demand grows.
What lessons from your earlier smaller-scale stacks influenced Starbase and Aurora?
AC: Our previous generation of smaller stacks provided valuable insights into optimizing flow distribution and electrode performance. These learnings directly informed the development of the Starbase 5 MW stack, resulting in more uniform operation and higher overall efficiency. The Aurora system, in turn, builds upon this foundation—integrating all of these lessons into a robust, industrial-scale product.
How are you addressing integration challenges for industrial users?
AC: Integration has been simplified by providing a comprehensive documentation package to EPCs and system integrators, making project implementation smoother and faster. Because large-scale plants typically operate on stable power supplies, fluctuating renewable input is less of a concern for them. Our approach ensures that even complex industrial environments can incorporate the Aurora system seamlessly into existing infrastructures.
Aurora is described as ‘outdoor-ready.’ What environmental testing has it undergone before rollout?
AC: We have extensive experience designing systems for both harsh Nordic climates and saline coastal environments. The Aurora system has been developed based on knowledge gained from previous executed projects in these challenging conditions. This means its engineering already accounts for durability against temperature fluctuations, corrosion, and environmental exposure expected in outdoor operation.
Are the new modules manufactured at your Tallinn facility?
AC: Yes, production of the new modules will take place at our manufacturing facility in Tallinn, Estonia. This site already hosts the production of our electrolysers and will continue to serve as our main hub for upscaling. Centralizing manufacturing there allows us to ensure consistent quality control and efficient logistics as we expand to larger-scale deployments.
How do you foresee the cost of green hydrogen evolving using Starbase or Aurora?
AC: The levelized cost of hydrogen (LCOH) is largely dependent on electricity pricing and system CAPEX. Because the Aurora system offers both high efficiency and competitive cost, we expect it to play a key role in driving down overall hydrogen production costs. Its efficiency gains and modular scalability make it a strong enabler of affordable green hydrogen at industrial scale.
What feedback metrics will you use to validate industrial readiness, and what are your priority markets?
AC: We are focusing on real-world operational data and customer feedback from initial deployments to validate industrial readiness. Key metrics include system efficiency, uptime, and ease of integration into existing industrial operations. Our primary target markets for these launches are the EU, MENA region, and India, where demand for large-scale hydrogen systems is rapidly accelerating.
Do you have a roadmap for next-generation sizes beyond 10 MW?
AC: Yes, we already have a roadmap in place for systems larger than 10 MW. We see containerized, modular solutions as optimal up to roughly 50 MW, beyond which we recommend implementing our 5 MW stacks in a building or warehouse format. This approach balances scalability and efficiency, allowing clients to expand economically while maintaining flexibility in plant design.
Marko Virkebau, Co-Founder and CEO at Stargate Hydrogen
Concluding in the words of Stargate Hydrogen’s co-founder and CEO Marko Virkebau, ‘Starbase and Aurora are addressing the two main barriers for industrial hydrogen adoption: cost of hydrogen and space constraints at industrial sites. Delivering the most compact and high-efficiency 10 MW electrolyser system on the market empowers industries to integrate green hydrogen production directly into their existing operations, marking a critical step forward for hard-to-abate industries seeking to decarbonise at scale.’
Stargate Hydrogen’s new products drive industrial decarbonisation by allowing refineries, chemical plants, and steel manufacturers to generate green hydrogen directly on-site. The Aurora module offers a compact, outdoor-ready design that maximises space efficiency while maintaining excellent durability and performance. Powered by advanced Starbase stacks, the system delivers high efficiency and reliability, helping to significantly reduce the cost of green hydrogen. Together with the Aurora module, these new technologies provide scalable, next-generation solutions that support the global shift toward cleaner industrial energy production.
Kostiantyn is a freelance writer from Crimea but based in Lviv. He loves writing about IT and high tech because those topics are always upbeat and he’s an inherent optimist!
