
Tuesday, 28th January 2025
Within the manufacturing process of electrochemical hydrogen pumps, there have been some significant validation issues, the biggest one being how labour-intensive the process is.
One client tackled this challenge by developing a custom solution that integrates Alicat Mass Flow Controllers (MFCs). The result? Automated fuel cell test stands that have transformed efficiency in fuel cell research. These advanced test stands have proven so effective that they’re now being sold to competitors within the industry, driving progress and innovation across the hydrogen sector.
Within the hydrogen industry, some challenges that were faced with the validation process are as follows:
The key to fixing this was a little In-House Development to allow enough space for the Alicat MCS series to be integrated, offering high accuracy and repeatability compared to the previously used technology of variable area flowmeters. After testing the MFC’s they then further changed the schematics so the Alicat PCS series with downstream valves could replace the mechanical back pressure regulators (BPR). This then allowed them to swap all manual readings & controls to be integrated into a PLC for live readings and automated control.
The advantages of these custom test stands were so profound that competitors began enquiring about them. Over time, these test stands became a core product for the client.
The stands maintain strict control over critical factors such as ‘mass flow’ and ‘pressure’. A unique pressurisation option that is available for components sensitive to extreme differential pressures. Two Alicat BPR’s are supplied to precisely manage the differential pressure across the cathode and anode, keeping them within the optimal range.
The system includes low and high voltage cabinets, which are equipped with hydrogen sensors, mass flow controllers and back pressure regulators. All of which are connected and communicating with the PLC allowing a fully automated process that can handle two tests simultaneously, 24/7, minimising human error.
Alicat controllers (both mass flow and pressure) have greatly enhanced the precision and reliability of the tests. With an easy-to-use display and integration-friendly protocols such as EtherNet/IP, these controllers are known for the following benefits:
By transitioning from complex, manual stands to their own bespoke solution, the end user has not only improved their processes but has also provided innovative tools for other fuel cell manufacturers.
Premier Control Solutions and Alicat Scientific are proud to partner with pioneers in driving the global shift toward a cleaner, hydrogen-powered future.
If you would like to know more about our range of mass flow controllers and back pressure regulators please do contact us by email sales@pctflow.com, or by phone 01953 609930.
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