PCT

Premier Control Technologies

Flow, pressure, level and temperature solutions

Gas Mixing systems

Gas Mixing Key features

  • Vapour pressure compensated
  • User friendly and easy to use
  • Can be built to specific customer requirements
  • Extremely fast concentration step changes
  • Can include humidified gases

Static Gas Mixers

Calculations and specific design of static mixers can be offered for all types of gas regardless of concentration, material compatibility and pressure regime. As each application is different, the flow rates, pressures and nature of the gases are taken into account within the calculations such that panels and cabinets can be designed to fulfil exacting requirements from gas supply through to process delivery.

Gas Mixing 2

Tailor-made Gas Mixing Systems

The turnkey gas mixing system was developed and designed for industrial applications as a process equipment. Every system is custom-built according to customer’s specification, you can pick and pair high flow, medium flow and low flow channels for any gas mixing application, be it common gas mixing applications or bespoke applications. Our turnkey gas mixing system can be used by engineers, technicians, system designers and we will work together to design the perfect high precision gas mixer for you. Features include:

  • Custom-built
  • Rugged enclosure
  • Easy-to-use
  • Plug-n-play
  • High precision
  • Fast-response times < 50ms
  • NIST Traceable

The turnkey system is the go-to solution for gas mixing users who are looking for plug-n-play, effortless implementation of sophisticated gas mixing system. Once it is set up and running, you can be confident that no intervention would be necessary until process parameters need to be changed or when maintenance is required. The turnkey gas mixing system is perfect for mixing gas with high precision in a factory setting. The rugged enclosure protects internal components from dust and provides physical protection. The enclosure has been designed to ensure that technicians can get easy access to internal components when maintenance or service is required. All the gas mixing components including the mass flow controllers are calibrated using NIST traceable standards. We provide calibration certificates for every component to assure customers have high confidence in what they are purchasing.

We have advanced data logging capability to store data in different formats for any post-processing you may need. Several customers of 'Fusion Flow Technologies' have used the data-logging capability to maintain FDA approvals in critical gas mixing processes. Data can be logged in different industry standard formats to be seamlessly integrated with your internal processes. Our Gas Mixer offers custom digital or analog I/O boxes to integrate our gas mixing system with third part systems. Inputs from the third part system can be used as a feedback input through the Fusion Gas Mixing software. A typical case of this would be using a gas analyzer’s input as a feedback mechanism to control the component of a particular gas.

You can choose to have an industrial PC panel to interact with the software and finely control every aspect of the gas mixing process, find out more about Gas Mixing Software options. Optionally you can also use the software through your desktop or laptop. For gas mixing applications that do not need the advanced features of a software, we provide a lower-cost TFT display option as well. You can also choose to simply control the system with the master component called the mix-module. Mix-module is a pressure gauge with specialized firmware that communicates with every individual component 1000 times a second to ensure the gas mixing set points are maintained.

Our participation in your gas mixing application does not end with design and delivery of the products. We support our customers by providing easy step-by-step assistance to setup the system until it is functional. After setup, our world class engineers will be available on demand to help in case any unforeseen problems arise.

Fusion Gas Mixing Software

We have developed a rugged, advanced and intuitive software to easily manipulate every aspect of your gas mixing application. Current gas mixing software offerings in the market have limited capacity and do not have critical abilities required for a high performing gas mixing system. The gas mixing software displays individual channel data and overall gas mixture data live at all times for the user to monitor. You have several modes of operation, listed below, to choose from. In all the operational modes, you decide the individual gas composition for each channel. This can be changed during the process, and the response times for a change is generally below 50ms. The operational modes that Fusion Gas Mixing software offer are:

Tank fill mode: This mode is used for applications where a mixed gas fills a ballast tank. You choose the maximum and minimum tank pressure, and the gas mixer will fill the ballast tank and maintain the pressure between the limits all while consistently maintaining the mix ratios in the ballast tank. This is particularly useful in cases where usage of mixed gas varies over a time period. For instant in MAP food packaging, welding, gas sensor, etc. assembly lines, a constant supply of gas is required at multiple locations. When the usage amount decreases and becomes nil when staff leave for lunch break or at the end of the day, the gas mixer will continue to fill the tank till the upper limit and shut off automatically. This feature increases the efficiency of gas usage and ensure there is no wastage.

Constant flow mode: This mode is straight-forward and most used in gas mixing applications. You will just have to set the gas mix ratios and the desired flow rate of the final mixture which the gas mixer will maintain at all times.

Pressure match: we are the only company that offers this operational mode. The gas mixing system allows the user to control the pressure of the gas mixture and therefore control the process pressure. Several applications in R&D, vacuum industry, laser industry, etc. need this feature and currently employ exorbitant costs to obtain this capability.

You can switch from one operational mode to another with ease based on your requirements. Apart from the ability to change the basic parameters, our software provides several critical features that allow users to maximize their efficiency. Some of the advanced features are listed below. One or a combination of the following features can be used to implement full-fledged automation of the gas mixing process:

Gas Mix Pre-sets: You can save the parameters like gas mix ratios and flow rates/pressures you typically use and call upon them at any time. This minimizes occurrences of human-error by more than 15%.

Automation using pre-sets: You can choose a gas mix pre-set to run for a specific period of time and change the pre-set and time period on-the-fly, infinite times. For use cases where a constant change is required, you can interpolate between several gas mix pre-sets by choosing time and ramp rates. Integrating with downstream/upstream process control instruments: Components like mass flow controllers, mass flow meters, pressure gauges and pressure controllers external to the gas mixing system can be controlled with gas mixing software. Based on your requirement, you can use the software from a desktop remotely or use an industrial PC panel that we offer. Data is the most valuable asset in present day, with the Fusion Flow Technologies Gas Mixer, you will be able to save all the gas mixing data that you need for post processing. Several customers of ours have been using the gas mix data from our gas mixer for FDA and quality audits. Since all our instruments are NIST traceable, you can be assured that you will maintain highest standards in the industry.

We understand that some applications may not need a complete software package to perform gas mixing and we have options for those scenarios as well. In cases where this software is not required, you can choose to have a simple TFT display to control the gas mixer by setting simple set points like gas mix ratios and flow rates and keep your costs down.

Modular Gas Mixing System – Component Level Supply

The modular gas mixing system was developed to empower users of gas mixers to embrace the researcher in them. It gives you the ability to pick and choose each parameter that goes into designing the gas mixing system. You can pair high flow channels, medium flow channels and low flow channels for any bespoke gas mixing application. Our engineering team developed this customer-led solution to give utmost control of the gas mixer system in the hands of the customer. In case you are not fully aware of what is needed to design a gas mixing system, contact us at what goes into gas mixing system design and we will help you figure it out.

Features include:

  • Custom-built
  • Freedom to determine placement of components
  • Modular
  • Low-cost
  • Easy upgrades
  • High precision
  • Fast- response times <50 ms
  • NIST Traceable

With the modular gas mixing system you will get the individual components along with supporting accessories required for a functional gas mixer setup.

You get the freedom to choose the orientation and setup of the gas mixing system. We give you the choice to decide how the entire system needs to be plumbed.

Gas Mixer users who need very small footprint can place individual components right next to each other. If your cylinders and process equipment are placed far away from each other, you can even choose to place individual components in different rooms and have a fully functional gas mixing system.

Freedom is not the only benefit you get with a modular gas mixing system, the price become more attractive as a result of minimizing the number of external components required to make a gas mixing system. This option eliminates the need for metal components or cumbersome enclosure.

Since there is no enclosure, you can access individual mass flow controllers; minimizing effort that goes into servicing and replacements. Access to individual mass flow controllers can be used as an additional point of reference to increase confidence in readings. As a user of a gas mixing system, your needs might change over time. Cases where a 3-channel gas mixing system needs to be upgraded to a 4-channel or 5-channel system is common. As a customer of Fusion Flow Technologies, you will only have to pay for the extra component as opposed to upgrading to a whole new system. This option keeps costs down, and significantly increases the time it takes to upgrade.

Users who need the dynamic gas mixer to have automation capability, advanced data logging capability, integration with external systems and an easy way to manipulate the gas mixing system can use the Fusion Gas Mixing software. The software allows to control the system centrally. You can purchase a dedicated industrial PC panel to control the entire setup, the PC panel can be fixed to a cabinet or be placed in any customer-preferred location. Optionally you can also use the software through your desktop or laptop. If the gas mixing setup is going to simple with minimal changes to set points. You can also choose to simply control the system with the master component called the mix-module. Mix-module is a pressure gauge with specialized firmware that communicates with every individual component 1000 times a second to ensure the gas mixing set points are maintained.

Our participation in your gas mixing application does not end with design and delivery of the products. We support our customers by providing easy step-by-step assistance to setup the system until it is functional. After setup, our world class engineers will be available on demand to help in case any unforeseen problems arise.