POWER


Harnessing hydrogen’s power: How ASICs enable reliable, efficient


hydrogen fuel cell operation The International Energy Agency predicts that hydrogen demand will surpass 100 metric tonnes in 2025, driven by increased use of hydrogen as a feedstock for industrial processes. Converting hydrogen into power is highly sensitive, relying on sensors to maintain stable, efficient operation. But harsh operating environments can degrade these sensor outputs.


By, Ross Turnbull, director of business development at application-specific integrated circuits (ASIC) specialist Swindon Silicon Systems.


G


lobal demand for fertilisers, industrial chemicals and low-carbon steel is driving growth in energy-intensive sectors such as refining, ammonia, methanol and fossil-based direct-reduced iron (DRI). These processes require continuous, reliable electricity and heat to maintain production efficiency. To meet this demand while reducing reliance on non-renewable energy, industrial sites are increasingly turning to hydrogen fuel cells to generate power. Hydrogen fuel cells produce electricity by splitting hydrogen molecules into protons and electrons. The positively charged protons pass through an electrolyte to a cathode, while the negatively charged electrons flow through an external circuit, creating an electric current. After passing through the electrolyte and circuit respectively, the electrons and protons meet at the cathode and combine with oxygen to produce water and heat, which can be captured to support chemical reactions, generate steam or heat plant facilities.


This reaction is extremely sensitive to changes in temperature, pressure, hydrogen concentration and fluid flow. To maintain safe and efficient operation, hydrogen fuel cells rely on a network of sensors that continuously monitor and regulate the process.


Sensor challenges


Temperature and pressure sensors monitor internal conditions, ensuring the cells remain within their optimal range of 50 to 100 degrees Celsius and one to three atmospheres, critical for stable electrochemical reactions. Hydrogen concentration sensors measure gas levels in real time, confirming sufficient fuel for


consistent electricity and heat output, while fluid-level and flow sensors track the fuel cell separators, maintaining stability and preventing interruptions.


In harsh industrial environments, high humidity, elevated temperatures, pressure fluctuations, vibration and electromagnetic interference (EMI) can degrade signals before they reach the processor. To ensure reliable sensor performance when signal degradation is a risk, robust integrated circuits (ICs) designed for precise signal acquisition are essential.


The case for ASICs


Unlike general-purpose processors, ASICs are designed from the ground up to perform a specific set of functions within a defined operating environment, making them ideal for the precise demands of hydrogen fuel cells.


Rather than relying on separate components and high-level processing


10 DECEMBER/JANUARY 2026 | ELECTRONICS FOR ENGINEERS


architectures, the full signal chain required for fuel cell monitoring can be integrated onto a single ASIC.


Integrating multiple functions onto a single chip also reduces processing overhead, allowing ASICs to consume less power than standard processors and reducing parasitic losses within the fuel cell system. Finally, ASICs can be engineered for environmental resilience, tolerating elevated temperatures, high humidity and EMI, with built-in compensation for thermal drift, component ageing and long-term parameter variation.


As hydrogen is increasingly adopted as an energy source, the reliability and efficiency of hydrogen fuel cells become critical. Purpose-built ASICs enable precise, reliable sensor processing under harsh conditions, supporting stable fuel cell operation and helping hydrogen scale as a viable industrial energy solution.


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