Fuel Cell Research - Energy Industries

Fuel Cell Research and Tests

Fuel cell technology is driving the transition to clean energy, and precision in gas flow and pressure control is critical for efficiency, safety, and performance. From hydrogen supply to dynamic load simulation, every process demands accurate instrumentation that can handle reactive gases, high pressures, and hazardous environments.

Premier Control Technologies offers a comprehensive range of mass flow controllers, Coriolis meters, pressure regulators, and back pressure solutions tailored for fuel cell R&D, testing, and production. Our products help UK manufacturers and research facilities achieve consistent results, meet compliance standards, and scale innovation.

Typical applications and solutions

Hydrogen Supply and Pressure Regulation for Fuel Cell Stacks

Hydrogenation is a critical step in API synthesis, requiring precise hydrogen flow and pressure control to ensure safety and consistent yield. Variations in gas delivery can compromise reaction efficiency and product purity. Maintaining stable conditions is essential for compliance with GMP and safety standards.

Relevant products:

Alicat Pressure Controllers (PC Series, IS-PC Series): Closed-loop pressure control with fast response and ATEX-certified options for explosive atmospheres.
Key benefits:
- Rapid response for dynamic pressure changes
- Intrinsically safe variants for hazardous zones
- Digital communication for automation
Drastar Precision Regulators: High-purity regulators for stable hydrogen pressure in supply lines.
Key benefits:
- Corrosion-resistant internals for hydrogen service
- Wide pressure range for stack requirements
- Compact design for skid integration

Air Flow Control to the Cathode Side of PEM Fuel Cells

Precise air flow to the cathode ensures optimal oxygen supply for electrochemical reactions. Variations in flow can impact efficiency and stack durability. Equipment must deliver stable flow under changing load conditions and integrate with control systems for automated testing.

Relevant products:

Alicat Mass Flow Controllers (MC Series): High-accuracy flow control for air supply with fast response times.
Key benefits:
- ±0.6% accuracy for consistent air delivery
- Multi-gas calibration for flexibility
- Digital protocols for integration
High-Flow Alicat MFCs: For large-scale stacks requiring higher air volumes.
Key benefits:
- Handles large flow ranges without sacrificing accuracy
- Robust design for continuous operation

Reformate Gas Conditioning and Delivery

Reformate gas streams in fuel cell systems often contain hydrogen mixed with CO, CO₂, and other components. Conditioning these gases requires precise flow and pressure control to maintain stack performance and prevent contamination. Equipment must handle variable compositions, high temperatures, and corrosive elements while ensuring safety and compliance. Integration with automated systems is essential for dynamic operation and data logging.

Relevant products:

CODA Coriolis Flow Meters: Provide direct mass flow measurement unaffected by gas composition changes.
Key benefits:
- High accuracy for mixed gas streams
- Handles corrosive gases and high pressures
- ATEX-certified options for hazardous zones
Drastar Precision Regulators: Maintain stable pressure for reformate delivery under varying conditions.
Key benefits:
- Corrosion-resistant internals for reformate gases
- Compact design for skid integration
- Wide pressure range for flexible operation

Back Pressure Control in Fuel Cell Test Loops

Maintaining consistent back pressure in test loops is critical for simulating real-world operating conditions. Variations in back pressure can affect stack efficiency and durability. Equipment must respond quickly to dynamic changes and provide stable control across a wide flow range.

Relevant products:

Equilibar Back Pressure Regulators: Deliver ultra-stable pressure control with minimal hysteresis.
Key benefits:
- Precise control under variable flow conditions
- Handles reactive and high-purity gases
- Ideal for dynamic load cycling in R&D environments

Dynamic Load Simulation for Fuel Cell Performance Testing

Fuel cell performance testing requires rapid changes in gas flow and pressure to simulate real-world load conditions. Controllers must offer fast response times and maintain accuracy during transitions. Integration with automation systems ensures repeatability and data capture for analysis.

Relevant products:

Alicat IS Series Controllers: Intrinsically safe for hazardous environments with fast response.
Key benefits:
- Certified for explosive atmospheres
- Multi-gas calibration for flexibility
- Rapid response for dynamic testing
High-Flow Alicat MFCs: Handle large flow changes for air and hydrogen supply.
Key benefits:
- Accurate control across wide flow ranges
- Robust design for continuous operation
- Digital protocols for test bench integration

High-Flow Gas Control for Stack Durability Testing

Durability testing involves prolonged operation under high-flow conditions to evaluate stack longevity. Equipment must deliver stable, accurate flow over extended periods without drift. Reliability and ease of integration are key for automated test rigs.

Relevant products:

Alicat High-Flow MFCs: Designed for large-volume air and hydrogen supply.
Key benefits:
- Handles high-volume flows with precision
- Durable construction for long-term testing
CODA Coriolis Meters: Provide mass flow accuracy for critical measurements.
Key benefits:
- Independent of gas composition
- High accuracy for performance validation

Precise Gas Blending for Synthetic Reformate Mixtures

Creating synthetic reformate mixtures for testing requires accurate ratio control of multiple gases. Errors in blending can compromise test validity and stack performance. Equipment should support automated recipe changes and maintain purity.

Relevant products:

Alicat MCQ Series MFCs: Multi-gas capability for flexible blending.
Key benefits:
- ±0.6% accuracy for precise blending
- Digital communication for recipe control
Fusion Flow Gas Mixers: Automated ratio control for complex blends
Key benefits:
- Compact design for OEM integration
- Automated ratio adjustment for efficiency

Pressure Management in Hydrogen Recirculation Systems

Hydrogen recirculation improves fuel efficiency and reduces waste in fuel cell systems. Stable pressure control prevents stack damage and ensures consistent performance. Equipment must handle high-purity hydrogen and operate reliably under dynamic conditions.

Relevant products:

Drastar Regulators: Provide precise pressure control for recirculation loops.
Key benefits:
- High-purity design for hydrogen service
- Wide pressure range for flexibility
Equilibar Back Pressure Regulators: Maintain consistent back pressure during variable flow.
Key benefits:
- Ultra-low hysteresis for stable control
- Ideal for dynamic recirculation systems

Controlled Delivery of Reactive or Corrosive Gases

SOFC development and other advanced fuel cell technologies often involve reactive or corrosive gases. Equipment must resist chemical attack and maintain accuracy under harsh conditions. Safety and compliance are critical for these applications.

Relevant products:

CODA Coriolis Meters: Corrosion-resistant for aggressive gases.
Key benefits:
- Handles corrosive gases without drift
- High accuracy for critical processes
Alicat IS Series Controllers: Intrinsically safe for hazardous environments.
Key benefits:
- Certified for explosive atmospheres
- Fast response for dynamic control

Calibration and Verification of Gas Flow for Fuel Cell R&D

Accurate calibration ensures reliable test data and compliance with industry standards. Equipment should provide traceable measurements and integrate easily with lab systems. High precision and repeatability are essential for research environments.

Relevant products:

CODA Coriolis Meters: Provide direct mass flow measurement for calibration accuracy.
Key benefits:
- Independent of gas composition
- High accuracy for calibration standards
Alicat BASIS OEM Controllers: Compact units for integration into calibration rigs.
Key benefits:
- Small footprint for OEM integration
- Digital outputs for automated calibration

Application Selection Guide

Application	Recommended Technologies	Why It Helps
Hydrogen Supply & Pressure Regulation	Alicat PC/IS-PC Series, Drastar Regulators	Safe, accurate pressure control for hydrogen lines
Air Flow Control for PEM Cathode	Alicat MC Series, High-Flow MFCs	Stable air flow for efficient electrochemical reaction
Reformate Gas Conditioning	Alicat CODA Coriolis, Drastar Regulators	Accurate flow and pressure for mixed gas streams
Back Pressure Control in Test Loops	Equilibar Back Pressure Regulators	Maintains consistent operating conditions
Dynamic Load Simulation	Alicat IS Series, High-Flow MFCs	Fast response for performance testing
High-Flow Gas Control for Durability Testing	Alicat High-Flow MFCs	Handles large flows for stack stress tests
Precise Gas Blending	Alicat MC/MQ Series, CODA Coriolis	Ratio control for synthetic reformate
Hydrogen Recirculation Pressure Management	Drastar Regulators, Equilibar Back Pressure Regulators	Stable pressure for recirculation loops
Reactive Gas Delivery for SOFC	Alicat CODA Coriolis, IS Series	Corrosion resistance and intrinsic safety
Calibration & Verification	Alicat CODA Coriolis, BASIS OEM Controllers	High accuracy for R&D compliance