Technical ceramics for renewable energy applications

GAS-TIGHT, INSULATING, TEMPERATURE-STABLETechnical Ceramics for Renewable Energies

Fuel cells, solar thermal systems and wind power system technology place highly diverse loads on components: hydrogen atmosphere, molten salts above 500 °C, alternating loads and electrical insulation. Metallic and polymer materials reach their limits here. BCE manufactures ceramic components for all three areas — from material selection through to the finished geometry.

Gas-tight in hydrogen atmospheres up to over 1,600 °C
Electrical and thermal insulation in a single component
No hydrogen embrittlement – unlike many metals
Resistant to alternating loads and thermal shock
Manufacturing from quantity 1

Discuss stack component or insulator

Clarify material for hydrogen application

QUICK ACCESSWhere is your application case?

Fuel Cells and Hydrogen Technology

Stack plates, insulators and sealing surfaces in hydrogen atmospheres.

Go to the fuel cell section

Solar Thermal Energy and High-Temperature Absorbers

Thermally and electrically insulating components at molten-salt temperatures.

Go to the solar thermal section

Wind Power and System Technology

Ceramic materials for requirements in the drivetrain and power electronics.

Go to the wind power section

TYPICAL PROBLEMSChallenges in Hydrogen Technology, Solar Thermal Energy and Wind Power System Technology

Hydrogen embrittlement and gas tightness

Components must remain tight in hydrogen atmospheres and must not fail due to embrittlement.

Thermal and electrical insulation

In stacks, absorbers and inverters, insulation, temperature and mechanical loads come together.

Molten salts above 500 °C

Solar thermal components operate permanently at high temperatures and must reduce interfaces.

Alternating loads in field operation

Thermal cycling and cyclic loads must already be considered during material and geometry selection.

Preload and tight fits

High mechanical preload and precise fits require ceramic-compatible design.

Do you have a specific load case in a stack, absorber or inverter?

Tell us the medium, operating temperature, preload and required insulation values. We will evaluate material, geometry and feasibility.

Discuss requirements now

FUEL CELLCeramics in Fuel Cells: Gas-Tight, Insulating, Hydrogen-Stable

Ceramic components in fuel cell technology, flange, electrical insulating — Flange, electrical insulating

In fuel cell stacks, four requirements come together at the same time: electrical insulation between the cells, uniform pressure transfer across the stack surface, gas tightness and resistance in a pure hydrogen atmosphere. Many metallic materials are susceptible to hydrogen embrittlement — a form of material fatigue that leads to cracking and premature failure.

Typical Components

Stack plates as electrical insulators in the stack
Electrically insulating flanges
Plates with feedthroughs and bores

Ceramic components in fuel cell technology, plate with holes, electrical insulating — Plate with holes, electrical insulating

Material Assignment

Components made from Al₂O₃ A-997 (99.7% purity) and A-999 have proven themselves for years as stack plates. They withstand temperatures above 1,600 °C in pure hydrogen atmospheres and transfer stack preload evenly. With 0% open porosity and dielectric strength above 25 kV/mm, gas tightness and electrical insulation are verified by measurement.

Blanks are isostatically pressed at 2,000 bar, machined to geometry using CAD/CAM and 5-axis machining, and finished by grinding.

Discuss stack component

SOLAR THERMAL ENERGYCeramics in Solar Thermal Energy: Thermal and Electrical Insulation at the Absorber

Technical ceramics for wind and solar energy technologies

In parabolic trough solar power plants, absorber tubes operate with molten salts as the energy carrier. Nitrate salts have a melting temperature of around 400 °C and are operated permanently at 500 to 600 °C. In the focal line area, components must provide both thermal and electrical insulation — a material that is merely temperature-resistant is not sufficient.

Typical Components

Insulators and holders for absorber tubes
Thermally insulating elements on pipelines
Electrically separating connection components

Material Assignment

BCE uses ZrO₂ in quality Z-513 for this application. With a thermal conductivity of 2 W/mK (steel: 50 W/mK) and thermal shock resistance of 275 K, the material performs two functions in a single component — thermal and electrical insulation of the absorber tubes.

This reduces the number of components and interfaces in the critical focal line area.

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WIND POWERCeramics in Wind Power: Hybrid Bearings and System Technology

Special ceramics for wind and solar power, thermal insulation of pipelines — Thermal insulation of pipelines

Special ceramics for renewable energy, thermal insulating components — Thermal insulating components

Modern wind power in its current form would not be possible without ceramic hybrid bearings. Rolling elements made from Si₃N₄ in main bearings are a specialized segment served by only a few manufacturers. In addition, other requirements for ceramic materials arise in wind turbine system technology: electrical insulation, dimensional stability under alternating loads and tightness. If you are designing ceramic components for wind power system technology, talk to us.

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TYPICAL WRONG DECISIONSThe Most Common Mistakes in Material Selection for Renewable Energy Applications

Component designed for permanent load while alternating load cycles are not considered
Material selected based on temperature resistance while the hydrogen atmosphere is not assessed
Gas tightness and electrical insulation treated as separate requirements, although they can be solved in one component
Metal geometry transferred 1:1 to ceramic instead of designing in a ceramic-compatible way

Those who evaluate alternating load, medium and preload together at an early stage avoid expensive material replacement after the first field phase.

MATERIALSSuitable Materials for Renewable Energy Systems

Zirconium Oxide (ZrO₂)

When useful:
High-strength sealing surfaces, positioning and absorber supports, e.g. Z-513 in solar thermal energy, as well as mechanically loaded components under alternating loads.

Less suitable:
Continuous operation above 900 °C; phase transformation during thermal cycling must be considered.

Aluminium Oxide (Al₂O₃)

When useful:
Stack plates and insulators in fuel cells (A-997, A-999), electrical insulation in inverters and system technology – stable even at high temperatures and in hydrogen atmospheres.

Less suitable:
Highly dynamic impact or bending loads; hydrofluoric acid attacks Al₂O₃.

Mixed Oxides (ATZ / ZTA)

When useful:
When Al₂O₃ is too brittle and ZrO₂ is too expensive – for components with combined strength and toughness requirements.

Special Materials (SiC, Si₃N₄, AlN, B₄C)

When useful:
AlN where heat dissipation and electrical insulation are required at the same time; SiC under combined corrosion and wear loads.

Less suitable:
More complex to manufacture than oxide ceramics – only use when the properties are truly required.

Compare materials

Open comparison table

KEY FACTSTechnical Values at a Glance

>1,600 °C

Dimensionally stable in pure hydrogen atmospheres – application range of A-997/A-999 in fuel cell stacks.

Open porosity for A-997 – measurable basis for gas-tight components in the stack.

2,000 bar

Isostatic pressing pressure of the blanks – homogeneous density as the starting basis.

>25 kV/mm

Dielectric strength of A-997 – electrical insulation in stacks and inverters.

2 W/mK

Thermal conductivity of Z-513 (steel: 50 W/mK) – thermal insulation in solar thermal energy.

Whether ceramic is suitable for your application can be clarified in a short conversation.

Describe the medium, temperature and load — we will provide an initial technical assessment.

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FAQFrequently Asked Questions About Ceramic Components in Energy Technology

Answers to typical questions about inquiries, prototypes, documentation and the feasibility of ceramic components in renewable energy systems.

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How does an inquiry for BCE energy technology components work?

You describe your application case – ideally with a drawing, specification sheet or at least the central requirements: medium, temperature, preload and required insulation values. We will respond with a feasibility assessment including material recommendation and possible risks. Only once this basis is in place will a quotation be prepared.

Does BCE manufacture prototypes and individual parts for renewable energy applications?

Yes. Especially in fuel cell and solar thermal development, prototype and small-batch capability is crucial: new stack designs or absorber geometries must be tested before series production makes sense. BCE Special Ceramics manufactures from quantity 1, with no minimum quantities and without high tooling costs. Prototypes go through the same quality process as series parts.

What documentation does BCE provide?

BCE is certified according to ISO 9001. If your project has requirements for documentation, traceability or test reports, we will agree the scope before production starts.

How does BCE assess the reliability of ceramic components under alternating load?

We do not speak in terms of general service life, but in terms of probability of failure under the specific load profile. This means: alternating load cycles, medium, thermal cycling and preload are included in material and geometry selection. Blanket statements about durability would not be technically sound – which is why we clarify the load case before manufacturing.

How do I know whether ceramic is useful for my application at all?

Describe the operating conditions: medium, temperature, type of load and required insulation values. BCE will assess whether ceramic offers a verifiable advantage over a metallic or polymer material. If not, we will say so. Ceramic makes sense where conventional materials reach their limits — not before.

Do you have a stack, absorber, inverter or open material decision?

We will tell you whether ceramic is the right choice – and if so, which material.