Dynamic gas blending for industrial process applications

Precise control of gas mixtures is vital in industrial processes that require repeatability and accuracy, including combustion control, catalyst testing, food packaging, and calibration of gas analysis instruments. In such scenarios, depending on pre-mixed gas cylinders is often impractical because of limited storage, lengthy lead times, and the need for flexibility. Dynamic gas blending, using real-time control systems, provides a more efficient and adaptable alternative.

Mass Flow Controllers (MFCs) are often used to dynamically generate custom gas mixtures by precisely measuring and regulating gas flow rates. However, switching between different gases introduces variability that can hamper performance. Enhancing these systems with automation, data acquisition, and traceability to national standards, particularly those of the National Institute of Standards and Technology (NIST), is critical for improving consistency and productivity.

The FlexMixer™ Multi-Gas Mixing and Dilution system by KIN-TEK Analytical, Inc. addresses these needs through the integration of differential pressure-based MFCs, an extensive pre-configured gas library, and user-friendly software. Designed to run on a standard PC, the system supports both manual operation and ‘Profile Mode’, which enables users to schedule timed mixing sequences with up to ten gas channels. Data from these sequences can be logged and archived for future reference.

FlexMixer™ systems are offered in two configurations: a standard model with up to four channels and an expanded version supporting ten. Each channel is independently calibrated and delivered with a NIST-traceable certificate. Source gases are introduced through standardized ¼-inch front panel connections, and output pathways can be specified in stainless steel, coated stainless steel, or inert Teflon. Standard configurations include a 5 slpm balance gas channel and 500 sccm component channels, with optional upgrades to 10 slpm as required.

With its flexibility, ease of operation, and documented traceability, the FlexMixer™ system is an ideal tool for laboratories and production environments that require fast, accurate, and customisable gas blending solutions.