Raising Safety and Efficiency in Hydrogen: Modcon’s In-Situ Analyzer and AI Approach
Hydrogen is no longer just about feasibility—it’s about making production safe, efficient, and economically sustainable. Electrolyzers sit at the entry point of the hydrogen value chain, where water is split into hydrogen and oxygen using renewable electricity. Yet traditional approaches often rely on long sampling lines and slow, maintenance-heavy measurement systems. The result? Delayed responses, added costs, and elevated safety risks.
Why This Approach Matters
By moving to in-situ analyzers reinforced with Advanced Process Control (APC) and Artificial Intelligence (AI), operators can cut both Capex and Opex, while elevating safety to a new level:
No sampling lines → fewer leaks, faster responses, simpler installation.
Safe and reliable operation → continuous H₂, O₂, and dew point monitoring inside the stack environment.
Fast response times → real-time detection of gas crossover, oxygen ingress, or humidity imbalance.
Prolonged stack lifespan → AI keeps operation inside safe envelopes, reducing hotspots and extending catalyst/membrane life.
Stable hydrogen costs → controlled LCOH, independent of water quality fluctuations or renewable power disturbances.
APC + AI: From Control to Optimization
Traditional PID control reacts only after disturbances occur. By contrast, Modcon’s APC + AI platform anticipates deviations and optimizes in real time:
Advanced Process Control stabilizes crossover, pressure differentials, and humidity balance.
AI with Deep Reinforcement Learning (DRL) adapts continuously, predicting degradation, adjusting load, and maximizing hydrogen output.
Digital Twins mirror electrolyzer behavior, running “what-if” scenarios to test control strategies before deployment.
This isn’t just theoretical. Plants using this combined approach routinely see 3–5% lower energy consumption, 1–2 years longer stack life, and millions saved per MW installed in avoided downtime and maintenance.
Safety and Business Case
Safety is not an add-on—it’s integral. Continuous monitoring of H₂ in O₂ and O₂ in H₂ prevents explosive mixtures long before they reach dangerous levels. Compliance with ISO 14687, SAE J2719, ASME B31.12, and NFPA 2 is baked in, ensuring purity and system reliability.
From a business standpoint, the impact is direct:
Lower electricity cost (up to 70% of Opex) through efficiency gains.
Extended stack value by $200k–$300k per MW.
Protection against off take penalties that can exceed $100k per out-of-spec event.
Added revenue from vaporizing oxygen by-products.
From Vision to Reality
It sounds like a dream—safe, reliable electrolyzer operation at lower cost, shielded from renewable fluctuations and water quality issues. But this isn’t the future. It’s reality today with Modcon’s AI-guided, in-situ analyzer approach.
Join our upcoming webinar to see how in-situ analyzers and AI optimization are transforming electrolyzer operations into safer, more efficient, and more profitable assets.
Process Optimization and Safety of Green Hydrogen Production
Event by Modcon Systems Ltd.
Wed, Sep 10, 2025, 9:00 AM - 10:00 AM (your local time)
https://www.linkedin.com/events/processoptimizationandsafetyofg7361757306881032193/