Supporting reliable hydrogen recovery with intelligent valve control

A leading chemical processing company in USA relies on Pressure Swing Adsorption (PSA) technology to recover hydrogen from process gas streams. The recovered hydrogen is then used in other processes throughout the plant, making reliable PSA operation essential to production performance.

Because the PSA system plays an important role in supporting downstream operations, minimizing unplanned interruptions and maintaining high availability are critical priorities.

Addressing operational challenges

The customer was looking for a more reliable and user-friendly valve control solution for its PSA units.

The existing installation required multiple pneumatic accessories and manual adjustments to achieve the fast cycle times needed for the application. This increased maintenance requirements and introduced additional potential failure points that could affect system availability.

With hydrogen from the PSA system supporting other plant processes, improving reliability and simplifying maintenance were key objectives.

A solution tailored to the application

After discussing the customer's challenges and reviewing the application requirements, Valmet’s flow control experts recommended the Neles™ NDX™ intelligent valve controller.

Drawing on extensive experience in PSA applications, the experts proposed a solution that helped reduce system complexity, simplify maintenance, and provide the performance required for fast-cycling service.

The project began with the installation of two Neles NDX intelligent valve controllers in the PSA system. Following successful implementation, the customer expanded the scope to additional valve assemblies throughout the unit. The installation program subsequently grew to 30 NDX controllers across both rotary and linear valve assemblies.

The NDX's high-capacity design can reduce the need for additional pneumatic accessories, depending on valve size and application requirements. Compatibility with both linear and rotary valve assemblies also provides flexibility across different valve configurations.

Key benefits of the solution include:

  • Reduced reliance on pneumatic accessories and associated leak points
  • Simplified maintenance
  • Faster calibration and commissioning
  • Linkage-less magnetic position sensing with fewer mechanical components
  • Built-in diagnostics without additional diagnostic packages
  • Reduced risk of accessory-related failures

Delivering long-term value

Based on positive operating experience and the results achieved in the PSA application, the customer continued to expand the use of Neles NDX intelligent valve controllers.

The collaboration also helped identify opportunities to support other process areas within the facility, further strengthening a relationship that has continued for more than 15 years.

Expertise that supports better outcomes

Successful PSA operation requires more than the right technology. It requires an understanding of the process, operating conditions and valve performance requirements.

By combining intelligent valve control technology with application expertise, we helped the customer improve maintainability, reduce potential failure points and gain greater visibility into valve performance. What began as a small installation evolved into a broader partnership supporting the customer's reliability and operational goals.

Back to top