Breakthrough in real-time monitoring and intelligent process optimization unlocks safer, more efficient high-pressure green hydrogen systems—without gas extraction.
The global race toward decarbonization relies heavily on one element: scalable, cost-effective, and safe green hydrogen production. Electrolyzers powered by renewable energy sources are key to this vision. But until now, a critical obstacle has remained unresolved—how to monitor and control gas composition at high pressure in real time, without relying on hazardous and expensive sample extraction systems.
Modcon Systems Ltd. has introduced a transformative solution to this longstanding challenge, delivering a technology that combines in-situ gas analyzers with AI-driven optimization frameworks, fundamentally redefining how we manage high-pressure hydrogen systems.
Eliminating the Weak Link: Extraction-Based Monitoring
Traditional electrolyzer setups monitor gas composition by extracting samples, reducing pressure, and venting them before analysis. While functional, this method presents several problems:
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Safety risks due to pressurized hydrogen and oxygen handling
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Inaccurate data due to time delays and sample degradation
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High capital and maintenance costs for extraction and pressure-reduction hardware
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Limited responsiveness under dynamic load conditions (e.g., variable solar or wind power)
With these challenges in mind, Modcon developed a revolutionary in-situ gas analysis solution for hydrogen systems, designed to operate safely and accurately at up to 200 barg, even in corrosive environments containing KOH and water vapor.
Advanced In-Situ Oxygen and Hydrogen Analyzers
At the heart of Modcon’s innovation are two flagship analyzers optimized for high-pressure green hydrogen applications:
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MOD-1040 Optical Oxygen Analyzer: A state-of-the-art industrial oxygen analyzer using quenched fluorescence optical technology. It delivers contact-free, high-precision oxygen measurements directly within the electrolyzer, making it ideal for challenging industrial environments.
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MOD-1060 Thermal Conductivity Hydrogen Analyzer: A leading hydrogen gas analyzer designed for continuous real-time measurements of hydrogen in binary gas mixtures. Its thermal conductivity-based technology excels in scenarios with high variability in gas composition.
When deployed together, these process gas analyzers support fusion-based compensation, cross-validating each other to enhance accuracy in real-world hydrogen production systems.
Both analyzers are certified for ATEX / IECEx zones and meet SIL-2 safety integrity level, ensuring industrial reliability and compliance in hazardous areas.
Real-Time Optimization with AI-Driven Control
Modcon goes beyond precision gas measurement by embedding its analyzers into a deep reinforcement learning (DRL) framework, enabling autonomous optimization of electrolyzer systems through its Modcon.AI software.
Key features include:
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Real-time data ingestion from oxygen and hydrogen analyzers, along with voltage, temperature, current, and pressure readings
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Dynamic control of input power, feed water rates, and pressure modulation
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Adaptive learning based on renewable power variability and system wear
This AI-enabled system transforms traditional monitoring into an intelligent control loop, ensuring continuous optimization of hydrogen output, energy consumption, and equipment longevity.
Fusion Modeling and Digital Twin Platform
To address the complexity of fluctuating gas matrices, Modcon implements sensor fusion modeling—leveraging the combined readings of its oxygen and hydrogen analyzers for unparalleled measurement accuracy. For example, the system can correct for shifts in gas composition, such as rising moisture or variable oxygen levels, by integrating contextual signals into a unified measurement framework.
This is reinforced by a hybrid modeling platform, blending:
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Electrochemical simulation models
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Historical performance-based machine learning models
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Mechanistic and analytical predictors
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Digital twin representations of electrolyzer stacks and processes
With these tools, Modcon delivers a complete ecosystem—from sensor to software—for smart hydrogen plant optimization.
Shaping the Future of Green Hydrogen
By removing the need for sample extraction and enabling real-time gas analysis, Modcon is solving the industry’s core bottleneck in green hydrogen production.
Benefits include:
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Improved safety: No hazardous gas venting required
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Increased efficiency: AI optimizes power-to-gas conversion in real time
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Reduced operational costs: No pressure reducers or sampling lines
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Scalability: Modular integration into electrolyzer systems of any size
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Sustainability: Intelligent systems that extend component life and reduce energy waste
“As the global demand for clean hydrogen surges, process intelligence and safety are no longer optional—they are foundational,” said Gregory Shahnovsky, CEO of Modcon Systems Ltd. “By uniting advanced sensors with intelligent control systems, we’re not just improving hydrogen production—we’re making it economically and environmentally sustainable at scale.”
About Modcon Systems Ltd.
Founded in 1972, Modcon Systems Ltd. is a leading developer of online process analyzers, including oxygen analyzers for industrial applications and hydrogen analyzers for green energy systems. The company integrates in-situ sensors, AI control systems, and digital twin platforms to support the hydrogen and hydrocarbon industries in their transition toward a smart, sustainable, and decarbonized future.
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