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Fuel cell testing through automation – A cleaner Hydrogen powered future

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.

Validation process challenges in the hydrogen industry

Within the hydrogen industry, some challenges that were faced with the validation process are as follows:

  • Complex and the absence of automation: The test stands were a nest of wiring and tubing. It lacked the ability to be fully automated, making the testing process awkward and inefficient.
  • Long-term testing requirements: Multi-year tests are conducted on several cells, making it necessary for them to be reliable and repeatable for long-term testing.

Developing the custom test stands

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.

Key features of the custom test stands

Precision

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.

Automated and remote testing

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 are helping to drive this innovation in automated testing

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:

  • Time efficiency: By having the on-board Composer software, it allows a catalogue of up to 130 Pre-calibrated gasses and an additional 20 custom gas blends on the meters and controllers. This allows the engineers to switch or create custom blends quickly without manual calculations, streamlining the transition between tests.
  • Flexibility: Alicat MFC’s (and meters) offer up to 10,000:1 turn down ratio which enables each device to handle a wide range of process conditions, allowing a reduction in the required number of devices. Additionally, the ability to easily change engineering units facilitates customised reporting for clients.
  • Optimised performance: End users can adjust custom gas blends and settings, to obtain true mass flow measurements in situ, thus ensuring accurate control over the process.

In summary

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.

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Get in touch

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.