Automated electric reactor cell system and methods

Abstract

Electric reactor systems and methods are provided that utilize a plurality of electric reactor cells secured to an open skid. These systems and methods incorporate a programmable logic controller (PLC) in operative communication with system sensors that monitor reactor system settings and generate input signals. Based on the sensor input signals, the PLC automatically adjusts production settings to optimize performance or avoid hazardous operating conditions. The systems and methods support automated operations including reactor hot swaps using a hot swap algorithm, flow balancing through a flow balancing algorithm, and dynamic fluid flow control across both series and parallel reactor formations. These automation features enhance system reliability, reduce downtime, and improve operational efficiency and safety. The open skid architecture enables rapid maintenance, inspection, and modular scalability, offering a significant advantage over traditional combustion-based reactors, which are typically enclosed, less accessible and more difficulat to service.

Description

[0001] AUTOMATED ELECTRIC REACTOR CELL SYSTEM AND METHODS

[0002] RELATED APPLICATIONS

[0003]

[0001] The present application claims priority to and incorporates by reference the entireties of the following U.S. patent applications: U.S. Provisional Patent Application No. 63 / 703,517, filed on October 4, 2024, and U.S. Provisional Patent Application No. 63 / 703,526, filed on October 4, 2024.

[0004] FIELD OF INVENTION

[0005]

[0002] This disclosure relates to the field of industrial chemical production, and in particular, to chemical production systems and methods utilizing electric reactors.

[0006] BACKGROUND

[0007]

[0003] Chemical reactors or reactor cells are devices used to contain and control chemical reactions. They provide suitable conditions for reactions to occur, such as temperature, pressure, and mixing, to convert reactants into desired products. In industrial chemical production, conventional reactors frequently operate under hazardous conditions, including high temperatures, high pressures, and aggressive flow rates. These reactors typically rely on fossil fuel combustion to generate heat, resulting in the emission of harmful pollutants such as carbon dioxide (CO2), sulfur dioxide (SO2), nitrogen oxides (NOx), and particulate matter. These emissions pose significant environmental risks and contribute to unsafe operating environments. As production scales increase, so do the associated emissions and safety concerns. To mitigate these risks, conventional reactors are commonly enclosed within containment vessels, which restrict physical and visual access and complicate maintenance and automation procedures. Servicing or replacing conventional reactors typically requires a full system shutdown, resulting in costly downtime and production delays. Accordingly, there is a need for reactor systems and methods that enable safe and efficient maintenance or replacement operations without interrupting production. Furthermore, solutions that reduce reliance on fossil fuels are critical to achieving long-term sustainability in industrial chemical processing.

[0008]

[0004] Electric reactor systems offer a transformative alternative by utilizing electricity to drive chemical reactions, thereby reducing or eliminating the need for fossil fuel combustion. Beyond sustainability, electric reactors provide enhanced safety, operational flexibility, and automation capabilities. Unlike traditional systems, electric reactors do not require confinement within containment vessels, allowing for greater flexibility in system design and enabling configurations that improve accessibility and scalability. Additionally, electric reactors operate under safer conditions, making it feasible to replace individual reactor cells without interrupting production. In continuous chemical manufacturing, minimizing downtime is critical to maintaining efficiency and profitability. Therefore, systems and methods that incorporate automated control, real-time monitoring, and flexible reactor configurations are essential for advancing industrial chemical processing. Moreover, such systems that also reduce the consumption of fossil fuels is essential for advancing sustainable industrial practices.

[0009] SUMMARY OF THE INVENTION

[0010]

[0005] In general, in one aspect, embodiments relate to an electric reactor cell system that includes a reactant input transported by an input feed and a plurality of electric reactor cells secured to at least a first open skid, where the plurality of electric reactor cells are configured to transform the reactant input into a product output. The system also includes a plurality of system sensors configured to measure a reactor system setting and generate an input signal, and a programmable logic controller (PLC), configured to operatively communicate with the plurality of system sensors to receive the input signal and automatically adjust a production setting, based at least in part, on the input signal. Adjusting a production setting may include automatically adjusting the temperature, pressure, flow rate, production capacity, electric power, or a movement of valves in the reactor system. Adjusting a production setting may also include performing a hot swap using a hot swap algorithm programmed onto the PLC, balancing the reactant input flow using a flow balancing algorithm programmed onto the PLC, and controlling the flow of a start-up fluid and the flow of the reacant input.

[0011]

[0006] In general, in one aspect, embodiments relate to a method of adjusting at least one of a production setting for at least one of a plurality of electric reactor cells. This method includes operating, using a programmable logic controller (PLC), an electric reactor cell system having a plurality of electric reactor cells secured to at least a first open skid, where the electric reactor cells are configured to transform a reactant input into a product output. The method further includes measuring a reactor system setting using at least one of a plurality of system sensors and generating an input signal, transmitting the input signal to the PLC, which is in operative communication with the plurality of system sensors and automatically adjusting a production setting using the PLC, based at least in part, on the input signal. Adjusting a production setting may include automatically adjusting the temperature, pressure, flow rate, production capacity, electric power, or a movement of valves in the reactor system. Adjusting a production setting may also include performing a hot swap using a hot swap algorithm programmed onto the PLC, balancing the reactant input flow using a flow balancing algorithm programmed onto the PLC, and controlling the flow of a start-up fluid and the flow of the reacant input. BRIEF DESCRIPTION OF DRAWINGS

[0012]

[0007] The accompanying drawings are included to provide a further understanding of the systems, apparatus, devices, and / or methods of the disclosure, and are incorporated in and constitute a part of this specification. The drawings are not necessarily to scale, and sizes of various elements may be distorted for clarity and / or illustrated as simplistic representations to promote comprehension. The drawings illustrate one or more embodiments of the disclosure, and together with the description, serve to explain the principles and operation of the disclosure.

[0013]

[0008] Figures 1A - 1C show reactor cell system configurations, in accordance with one or more embodiments.

[0014]

[0009] Figure 2 shows a comparison table, in accordance with one or more embodiments.

[0015]

[0010] Figures 3A and 3B show a plurality of electric reactor cells in an open skid, in accordance with one or more embodiments.

[0016] [Oil] Figure d shows an electric reactor cell system, in accordance with one or more embodiments.

[0017]

[0012] Figure 5 shows a flowchart, in accordance with one or more embodiments.

[0018]

[0013] Figure 6 shows a flowchart, in accordance with one or more embodiments.

[0019]

[0014] Figure 7 shows a flowchart, in accordance with one or more embodiments.

[0020]

[0015] Figure 8 shows a flowchart, in accordance with one or more embodiments.

[0021]

[0016] Figures 9A - 9C show electric reactor cell system comparisons, in accordance with one or more embodiments.

[0022]

[0017] Figure 10 shows an electric reactor cell system, in accordance with one or more embodiments.

[0023]

[0018] Figure 11 shows a simplified block diagram illustrating an example computer system, in accordance with one or more embodiments.

[0024] DETAILED DESCRIPTION

[0025]

[0019] Example systems, apparatus, devices, and / or methods are described herein. It should be understood that the word “example” is used to mean “serving as an example, instance, or illustration.” Any embodiment or feature described herein as being an “example” is not necessarily to be construed as preferred or advantageous over other embodiments or features unless stated as such. Thus, other embodiments can be utilized, and other changes can be made, without departing from the scope of the subject matter presented herein. The aspects described herein are not limited to specific embodiments, apparatus, or configurations, and as such can, of course, vary. It should be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only, and unless specifically defined herein, is not intended to be limiting.

[0026]

[0020] Throughout this specification, unless the context requires otherwise, the words “comprise” and “include” and variations (e.g., “comprises,” “comprising,” “includes,” “including,” “has,” and “having”) will be understood to imply the inclusion of a stated component, feature, element, or step or group of components, features, elements, or steps, but not the exclusion of any other component, feature, element, or step or group of components, features, elements, or steps.

[0027]

[0021] Further, unless context suggests otherwise, the features illustrated in each of the figures may be used in combination with one another. Thus, the figures should be generally viewed as component aspects of one or more overall embodiments, with the understanding that not all illustrated features are necessary for each embodiment.

[0028]

[0022] As used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

[0029]

[0023] Ranges may be expressed herein as from “about” one particular value and / or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint and independently of the other endpoint.

[0030]

[0024] Any enumeration of elements, blocks, or steps in this specification or the claims is for purposes of clarity. Thus, such enumeration should not be interpreted to require or imply that these elements, blocks, or steps adhere to a particular arrangement or are carried out in a particular order. It is to be understood that one or more of the steps shown in the flowcharts may be omitted, repeated, and / or performed in a different order than described without deviating from the scope of the present disclosure. Throughout the application, ordinal numbers (e.g., first, second, third, etc.) may be used as an adjective for an element, (i.e., any noun in the application). The use of ordinal numbers is not to imply or create any particular ordering of the elements nor to limit any element to being only a single element unless expressly disclosed.

[0025] The term “electric reactor cell(s)” as used herein, broadly refers to any device or system that utilizes electrical energy to facilitate a chemical reaction or physical process. Electric reactor cells may include any reactors that use electricity as a source of energy or any reactor that may use electrical components to control or enhance the reaction process. Any electric reactor cell known in the arts may be utilized by the systems described throughout the disclosure including, but not limited to photoreactors, electrolytic reactor cells, plasma reactors, fuel cells, or any other electrochemical reactor cells.

[0031]

[0026] The term “photoreactor” used herein, also referred to as a “photocatalytic reactor cell,” broadly refers to one type of electric reactor cell. A photoreactor is a type of reactor that utilizes light to drive a chemical reaction. It is designed to provide controlled conditions for photochemical reactions, where light is used as an energy source for the reaction. While photoreactors may be described and illustrated in the present disclosure as one possible embodiment of electric reactor cell systems, it should be understood that any electric reactor cell may be used in the systems and methods described herein, without deviating from the scope of the disclosure. For at least some embodiments, a system element that relates specifically to photoreactors, may be replaced, omitted, or repeated by another system element from an alternative electric reactor cell, without deviating from the scope of the present disclosure. For example, those skilled in the art will understand that an electric reactor system that automatically controls a light source for a photoreactor, could easily be implemented on an electrically heated reactor, by automatically controlling the alternative heating element.

[0032]

[0027] The term “catalyst” as used herein, refers to a substance that increases the rate of a chemical reaction without being consumed in the process. It works by providing an alternative reaction pathway with lower activation energy, allowing the reaction to occur more efficiently than without the catalyst. Catalysts may be contained within a catalyst bed inside a reactor. In photochemical reactions, a particular type of catalyst may be used, referred to as a photocatalyst. The term “photocatalyst / s”, as used herein, refers to a substance that, when exposed to photons from a light source, increases the rate of a chemical reaction without being consumed in the process. The term “photocatalysis”, as used herein, refers to irradiating a chemical process with photons to accelerate the rate of chemical conversion of reactants to selectively form a desired product. Incident photons of sufficient energy and wavelength activate photo-induced reactions by unlocking reaction mechanisms that otherwise may not be accessible via thermally activated processes.

[0033]

[0028] The term “programmable logic controller (PLC)” as used herein, broadly refers to any industrial digital computer designed to control automated processes by receiving input signals, processing the data, and controlling outputs in a system. While the embodiments of the present disclosure may be described using a PLC, any device or system capable of performing automated control functions in a reactor system may be used without deviating from the scope of the disclosure. For example, a distributed control system (DCS), or a supervisory control and data acquisition (SCAD A) system could also be used to perform similar functions as the PLC.

[0034]

[0029] Embodiments described herein relate to electric reactor systems and methods for automatically adjusting production settings, based at least in part, on a plurality of system sensors that monitor operational settings. The system includes a plurality of electric reactor cells secured to an open skid, which provides ready access to the reactor cell, such as on every side, including above. The open skid structure allows for the vertical stacking of multiple open skids for continous expansion, while conserving horizontal floor space. The enhanced operational safety provided by electric reactor cells, combined with the accessibility and inspection benefits of the open skid architecture, enables certain system operations to be automated within the system.

[0035]

[0030] The systems and methods disclosed herein include operating an electric reactor system using a programmable logic controller (PLC) that is in operative communication with a plurality of system sensors and the electric reactor cells. The sensors may be strategically positioned throughout the reactor system, including along fluid feed lines, at reactor inlets and outlets, within the reactor housing, or adjacent to temperature / pressure sensitive zones. These sensors communicate measured reactor system settings to the PLC. These measurable reactor system settings may include the measured temperature, pressure, flow rate, electrical power, feed flow or measured product output from the system. These measurements may have a predefined set of acceptable values for a given reactor system setting, based on empirical data, system modeling, safety standards, and performance benchmarks. Each metric defines upper and lower thresholds that represent safe and efficient operating conditions for an electric reactor cell and its system components. When a sensor detects that a measured value falls outside of its corresponding operational range, it generates an input signal indicating a potential fault, inefficiency, or safety concern. These metrics may be stored within the control system and used by the PLC or any other computing systems to trigger automated responses or alerts.

[0036]

[0031] These automated responses may include automatically adjusting the temperature, pressure, flow rate, production capacity, electric power, or a movement of valves in the reactor system. Adjusting a production setting may also include performing a hot swap usining a hot swap algorithm programmed onto the PLC, balancing the reactant input flow using a flow balancing algorithm programmed onto the PLC, and controlling the flow of a start-up fluid and the flow of the reacant input.

[0032] Embodiments disclosed herein also relate to reactor systems configured to integrate both parallel and series (or a combination of parallel and series) fluid flow processing and automated methods to switch from one form of fluid flow processing to the other. For example, the electric reactor systems described herein may be configured to receive a start-up fluid in a series formation, until a first or second predetermined start-up condition is met, before automatically initiating a reactant fluid flow process in a parallel formation. In these embodiments, a purging process using an inert fluid, such as nitrogen, may be initiated in series flow until a system sensor has indicated the process has finished, before initiating a reactant input processing in parallel flow. Such a system would have certain advantages pertaining to system efficiency. For example, a parallel configuration for reactors allows for a simultaneous processing of larger volumes of reactants, which increases overall production capacity. Automatically transitioning the chemical production process from the start-up phase to a production phase eliminates downtime associated with manually switching production operations.

[0037]

[0033] Overall, the disclosed automated electric reactor cell systems and methods offer significant advantages in improving system efficiency, minimizing downtime, increasing production output, and extending equipment lifespan. By automatically detecting and mitigating system issues before reaching unstable conditions, these systems enhance reliability and reduce operating costs. Additionally, electric reactor cells may be powered by renewable energy sources such as solar, wind, or hydropower, further improving environmental sustainability. By eliminating fossil fuel combustion, the systems described herein support both operational performance and alignment with modem sustainability goals in industrial chemical production.

[0038]

[0034] Figures 1A, IB, and 1C show reactor cell system configurations in accordance with one or more embodiments. In chemical production systems, a plurality of reactors may be configured in various ways to achieve different processing objectives. Three of these configurations are described and illustrated in the following section. Figure 1A shows a parallel formation (100), with a reactant input (101) being transported by an input feed (102) to a reactant manifold (104). A reactant input (101) describes the introductory supply of material that will undergo chemical reaction processes in a reactor cell (108a, 108b, 108c) to produce a product output (114). For example, in some embodiments, a reactant input (101) may be ammonia (NH3), and the corresponding chemical reaction process may be ammonia decomposition 2NH3->N2+3H2. There are many different reactant inputs (101) used in such systems, each having a unique corresponding chemical reaction process. The present disclosure is not limited to the type of reactant input (101) nor the corresponding chemical reaction process performed.

[0039]

[0035] In a parallel formation (100), the reactant manifold (104) partitions the reactant input (101), from the input feed (102) into a plurality of reactor channels (105a, 105b, 105c). As illustrated in Figure 1A, each reactor channel (105a, 105b, 105c) includes corresponding components. For example, the reactor channel (105a) may include a first channel element (106a), a reactor cell (108a), and a second channel element (110a). Identical components along reactor channel (105b) and (105c) are similarly labeled with the same base reference numberals followed by the letters “b” and “c” respectively. For brevity, these components will hereafter be referred to with their base reference numberls only (e.g., 106, 108), unless specific distinction between channels is required.

[0040]

[0036] Each reactor cell (108) in the parallel formation (100) receives an independent supply of the reactant input (101) along the reactor channels (105) and independently produces a channel product output. The channel product output produced from each of the reactor cells (108), is combined using a product manifold (111) and transported downstream in an exit feed (112). The combined channel product output is referred to as the product output (114). Shown in Figure 1A, the reactor channels (105) may respectively transport the reactant input (101) to a first channel element (106), the reactor cells (108) and a second channel element (110). A first channel element (106) describes an element operatively connected to the reactor channel (105), that interacts with the reactant input (101), before the reactor cell (108).

[0041]

[0037] A first channel element (106) may include a block valve, a back pressure controller, a flow transmitter, a pressure transmitter, and / or a temperature transmitter. The first channel element (106) may be any device capable of measuring and / or manipulating the flow of reactant input (101) to the reactor cell (108). For example, a block valve may be used to shut off the flow of reactant input (101) to a reactor cell (108) if dangerous conditions are encountered. Block valves may also be used to shut off the flow of product output (114). Block valves may be operated manually, or automated using pneumatic, hydraulic, or electric actuators. The first channel element (106) may also include other instruments or devices configured to thermally condition the reactant input (101) prior to being introduced to the reactor cell (108). Such conditioning may include heating or cooling the reactant input (101) to achieve a target temperature suitable for initiating or sustaining the desired chemical reaction, improving flow properties, or maintaining phase stability. In these thermal conditioning embodiments, the first channel element (106) may include heat exhangers, coolers, heat trace systems, or any other thermal control elements. The first channel element (106) may also include any system sensor known in the art, capable of measuring any number of reactor system settings, including a temperature, pressure, flow rate, an electrical power, a feed flow and / or a measured product output.

[0042]

[0038] Next, the reactant input (101) continues to the reactor cell (108), where it will undergo chemical reaction processes to produce the product output (114). The reactant input (101) may enter the reactor cell (108) at a reactor inlet (not shown). The term reactor cell (108) used herein, broadly describes any device or structure that contains and controls chemical reactions. There are many different types of reactor cells, each designed for different types of reactions using different reactant inputs (101). The term reactor cell (108) is inclusive, meaning it refers to any reactor known in the arts, including electric reactors. Where the desired chemical reaction is ammonia decomposition, the reactant input (101) is ammonia (NH3), and the corresponding chemical reaction process is 2NH3->N2+3H2. In this example embodiment, the reactor cells (108) would chemically transform ammonia into a mixture of nitrogen and hydrogen gases (N2 and H2). This mixture of nitrogen and hydrogen gases produced by each reactor cell (108), is combined at the product manifold (111), and referred to as the product output (114).

[0043]

[0039] While Figure 1A illustrates a reactor cell (108) having only a single input and a single output, described as a reactant input (101) and product output (114) respectively, it should be understood that the reactor cell (108) may be configured to receive multiple types of input fluids and produce multiple types of output fluids. For example, the reactor cell (108) may receive one or more reactant inputs (101), as well as cooling fluids, inert gases, water and / or steam as inputs. Each fluid input may be delivered through a dedicated inlet valve to allow for selective fluid introduction, and the reactor cell (108) may include separate outlets to direct distinct output streams.

[0044]

[0040] Once the reactor cell (108) has produced a channel product output, the flow continues to a second channel element (110). The second channel element (110) describes an element operatively connected to the reactor channel (105), that interacts with the channel product output. The second channel element (110) may include any of the elements previously described for the first channel element (106). The second channel element (110) interacts with the plurality of channel product outputs before it is combined using the product manifold (111).

[0045]

[0041] The reactor cell system may also include one or more bypass valves (113), configured to selectively redirect input fluids around one or more reactor cells (108). For example, in a parallel formation (100), some reactor cells (108) may require to be purged using a purging fluid, such as an inert gas, to remove residual reactants prior to reactant input (101) processing. In this example embodiment, a purging fluid may be introduced to the reactor cells (108) that need it, and for the reactor cells (108) that don’t need it, the bypass valve (113) may be activated to prevent this purging fluid from entering those reactor cells (108). Bypass valves (113) allow for selective fluid routing to improve process control across the reactor system. While only one bypass valve (113) is shown in Figure 1A, there may be one or more bypass valves (113) for each reactor cell (108) in the system.

[0046]

[0042] The reactor cell system may also include a programmable logic controller (PLC) (115). The PLC (115) may be a computer system configured to operatively communication with a plurality of system sensors. The PLC (115) therefore may be in operative communication with the first channel elements (106), the reactor cells (108), and the second channel elements (110). Any instrument, device, or sensor included in the reactor cell system may communicate with the PLC (115) in realtime. These instruments, devices, or sensors may communicate with computer systems in various ways, such as through analog signals, digital signals, or wireless communications including Bluetooth. For example, a temperature sensor can transmit an analog signal representing the temperature to a PLC’s analog-to-digital converter, which then converts the signal to a digital value that the PLC (115) can process. Alternatively, the system sensor could use a digital communication protocol, such as Modbus or Ethernet, to directly transmit the temperature data to the PLC (115). The PLC (115) may transmit the input signal to a readable screen where they are constantly monitored and evaluated by reactor system operators to determine optimum production settings. The PLC (115) receives communication, or an input singal, from the plutality of system sensors in real-time and at least one production setting may be automatically adjusted, based at least in part, on the input signal communications.

[0047]

[0043] Adjusting production settings may include changing reactor cell (108) conditions, including temperature, pressure, and flow rate, production capacity settings, or an electrical power supplied to the reactor cell (108). Adjusting production settings may also include the turning of valves to alter or change the fluid flow to the reactor cell (108). For example, block valves may be automatically activated to halt production along a particular reactor channel (105) whenever an input singal indicates dangerous reactor system conditions. Adjusting the valves may also include changing the type of fluid being input to the reactor cell (108), such as halting a purging fluid and initiating a reactant input (101).

[0048]

[0044] The PLC (115) is intended to encompass any computing device such as a server, smartphone, desktop computer, laptop / notebook computer, personal data assistant (PDA), wireless data port, tablets, one or more processors within these devices, or any other suitable processing devices. Any computer device capable of receiving an input signal and displaying that signal on a screen in realtime may be used in the reactor cell system as a PLC (115). The reactor cell system may also include a network of interconnected devices that may communicate and exchange data with one another over the internet, often referred to as the “Internet of Things (IoT)” related devices.

[0049]

[0045] Although a PLC (115) is provided as one example of a computer system in the reactor cell system, other types may also be utilized. For example, a distributed control system (DCS) may be used instead of, or in combination with the PLC (115). A DCS may be used in industrial controlling systems to partition larger systems into more manageable subsystems, each having its own controller. Using a DCS may be advantageous for controlling subsystems associated with individual reactor cells (108) or a particular reactor channel (105). Each controller of a DCS system may be in communication with one another to enable the sharing of data across reactor cell systems. A DCS may be advantageous for parallel reactor formations (100) that require independent monitoring of each reactor channel (105).

[0046] Additionally, a supervisory control and data acquisition (SCAD A) system may be utilized in the reactor systems described herein. SCADA systems incorporate a comprehensive network of computer systems designed to remotely monitor and control processes using supervisory computers. These supervisory computers can receive data from any of the instruments, devices, or sensors across multiple reactor cell systems, enabling efficient real-time data collection and processing. This data can then be leveraged for historical analysis, providing useful insights into a system’s performance over time. The SCADA system network may include multiple PLCs (115) for implementing control commands in a specific reactor cell system. SCADA systems may be advantageous for remote monitoring and control over multiple dispersed locations. Any other computer systems, known or used in the arts, may also be employed in the systems and methods described herein without departing from the scope. While only a single PLC (115) is illustrated in the reactor cell system configurations, it should be understood that a reactor cell system may incorporate more than one. The PLC (115), as it functions as a computer system, will be described further in Figure 10.

[0050]

[0047] A reactor cell system utilizing parallel formations (100) offers flexibility in terms of upscaling or downscaling the system. Reactor cells are easily added or removed from the system to match production demands, provided production is halted during the installation or removal. Parallel formations (100) also mitigate downtime risk. If one reactor cell (108) fails, the impact on total production is limited compared to a series formation, where an entire reactor system may be affected by a reactor cell (108) failure. Parallel formations (100) are often used to meet high production demands as they allow for the simultaneous processing of larger volumes of reactions, which may increase overall production capacity. Parallel formations (100) may also allow for the heat load of the system to be distributed evenly across multiple reactor cells (108), improving the thermal system management. Operating reactor cells (108) in a parallel formation (100) may also reduce the pressure drop experienced across individual reactor cells (108). By distributing the input reactant (101) flow among multiple reactor channel (105), the system minimizes flow resistance within each reactor cell (108), thereby enhancing energy efficiency, improving process control, and reducing mechanical stress on upstream components.

[0051]

[0048] Figure IB shows a reactor cell system in a series formation (120), in accordance with one or more embodiments. In Figure IB, the reactor cells (108), are connected in a sequential line and may be utilized when the chemical reaction needs to occur in multiple steps within multiple series reactor cells (108). In a series formation (120), the input reactant (101) enters the first series reactor cell (108a) to undergo a chemical reaction, and the first series output (124a) may then be channeled into the second series reactor cell (108b) for a subsequent reaction to take place. This subsequent reaction uses, at least in part, the first series output (124a) and produces a second series output (124b). The second series output (124b) produced by the second series reactor cell (108b) is then channeled to the third series reactor cell (108c) for a final reaction to take place. In some embodiments, the final reaction may include the chemical transformation into a product output (114). In alternative embodiments, the final reaction may include the separation, purification, or extraction of a product output (114). A reactor cell system in a series formation (120) may also include any of the additional components that have been described and illustrated in Figure 1A, including channel elements (106, 110), PLCs (115), or any other system sensors. Figure IB may also include any additional components that have not been described in Figure 1 A. For brevity, the additional system elements and associated figures are not repeated in the context of Figure IB. While Figure IB shows three reactor cells (108) connected in a series formation (120), it should be understood that a series formation (120) only requires at least two series reactors connected along the same reactor channel (105). The use of reactor cells (108) in series allows for better control over the reaction conditions at each stage, leading to higher yields and purity of the product output (114). Series formations (120) may also lead to higher efficiency and productivity when compared to batch processes, and typically require a reduced amount of system instrumentation. A reduction of reactor system instrumentation reduces the system complexity, lowering operational costs.

[0052]

[0049] In some embodiments, ammonia decomposition may be performed using reactor cells (108) in a series formation (120). In these example embodiments, a reactant input (101) comprising ammonia (NH3) is introduced into the sequence of reactor cells (108). Each reactor cell (108) is configured to promote the catalytic decomposition of ammonia into hydrogen and nitrogen (2NH3->N2+3H2). As the reactant stream progresses through the series, the concentration of hydrogen and nitrogen progressively increases, while residual ammonia is gradually diminished. Such a configuration may also enable the use of bypass valves (113) to selectively divert the reactant input (101) around one or more reactor cells (108b). These bypass valves (113) enable continuous production even when a reactor cell (108b) is offline or experiencing failures.

[0053]

[0050] Figure 1C shows a reactor cell system in a hybrid formation (130), in accordance with one or more embodiments. A hybrid formation (130) integrates elements of both parallel formations (100) and series formations (120). Shown in Figure 1C, the hybrid formation (130), presents manifolding operations that are closely related to a parallel formation (100) with a reactant manifold (104) partitioning the reactant input (101) into a plurality of reactor channels (105). However, unlike the parallel formation (100) shown in Figure 1A, there are more than one reactor cells (108, 132) included in each reactor channel (105) connected in series. Reactor cells (108a, 108b, 108c), receive an independent supply of the reactant input (101) along the reactor channels (105a, 105b, 105c) and independently produce a plurality of first series outputs (124a, 124b, 124c).

[0054]

[0051] The first series outputs (124a, 124b, 124c) are channeled to a second reactor cell (132a, 132b, 132c) in each reactor channel (105) where it undergoes a second reaction to generate a plurality of second series outputs (125a, 125b, 125c). Shown in Figure 1C, the second series output (125a, 125b, 125c) from the reactor channels (105) are channeled to a product manifold (111) to be combined. The combined product is referred to as the product output (114) and is channeled away from the system in an exit feed (112).

[0055]

[0052] In a hybrid formation (130), each eactor channel (105) includes multiple reactor cells (108, 132) connected in a series formation (120) allowing sequential reaction stages to occur within a single reactor channel (105). At the same time, multiple reactor channels (105) are operating in parallel to increase the overall production capacity of the system. This dual arrangement is particularly advantageous for processes where certain reaction steps benefit from a series formation (120), while parallelization enables efficient scaling. By integrating both series and parallel architectures, the system achieves enhanced control over reaction conditions, improved scalability, and greater operational flexibility.

[0056]

[0053] A reactor cell system in a hybrid formation (130) may also include any of the additional components that have been described and illustrated in Figure 1A, including channel elements (106, 110), PLCs (115) or any other system sensors. Figure 1C may also include any additional components that have not been described in Figure 1A. For brevity, descriptions of the additional system elements are not repeated in the context of Figure 1C. Figure 1C shows three parallel reactor channels (105), each having two reactors (108, 132) connected in series. For brevity, such a reactor system may be referred to as a 3p2s hybrid configuration. Other hybrid formations (120) are possible that are not shown, including 2p3s configurations that describe two parallel reactor channels (105a, 105b), each having three reactors connected in series. In Figure 1C, a bypass valve (113) is illustrated and may be configured to selectively redirect input fluids around a particular reactor cell, such as reactor cell (108a) or (132a). Additionally, the bypass valve (113) may be activated to divert input fluids around an entire series of reactor cells within a given reactor channel (105), such as reactor cells (108a) and (132a). This functionality enables the system to maintain continous operation while isolating one or more reactor cells (108) that are offline, undergoing purging, or otherwise inactive.

[0057]

[0054] Figures 1A, IB and 1C are illustrated with a single input feed (102) and a single exit feed (112); however, in alternative embodiments, the reactor cells (108) may be equipped with multiple feedlines to accommodate various fluid inputs. These additional input and output feedlines may include a cooling fluid line for thermal regulation, a purging or catalyst activation fluid line to support start-up operations prior to introducing the primary reactant input (101), and a secondary reactant input line for delivering additional reactants required for the intended chemical transformation. While Figures 1A, IB, and 1C illustrate the generation of a single product output (114), in other example embodiments, this output may serve as an intermediate rather than the final desired product. There may be at least one downstream production unit (not shown) configured to produce a second product output using, at least the product output (114). For example, in an ammonia decomposition system, the product output (114) may comprise a mixture of H2 and N2. This mixture, transported in the exit feed (112) may be channeled to a product gas membrane (not shown) configured to separate the H2 and N2. In these example embodiments, the isolated H2 constitutes the final desired product, referred herein as the second product output. The N2 may then be stored, disposed of, or recycled back into the system. Figures 1A, IB, and 1C are meant for illustration purposes only, and to introduce different reactor formations; many optional components have therefore been omitted.

[0058]

[0055] Various reactor configurations have been illustrated in the preceding figures to demonstrate various structural arrangements in reactor systems. Each configuration may offer distinct operational advantages depending on the specific production goals and process conditions. Figure 2 presents a comparison table (200) of simulated performance data comparing operational efficiency metrics (202) across different reactor configurations. Specifically, the operational efficiency metrics (202) were simulated using six electric reactor cells (108) for the decomposition of ammonia (or ammonia e- cracking), at three operating temperatures (Tl, T2, T3). The operating temperatures (Tl, T2, T3) represent the temperature of the fluids exiting through the outlet of the electric reactor cells (108) where T3 > T2 > T1.

[0059]

[0056] The electric reactor cells (108) used for the comparison in Figure 2 were photoreactor cells (or “photoreactors”), more specifically Rigel™ reactor cells developed by Syzygy Plasmonics Inc. Rigel reactor cells feature an internal light source designed to emit photons uniformly onto a photocatalyst bed, enabling photocatalysis and and facilitating chemical conversion. The light housing converts electrical energy to light energy, which is utilized by the photocatalyst contained within the electric reactor cell (108). The simulations were conducted using Rigel reactor cells arranged in parallel, 2p3s hybrid, and 3p2s hybrid formations to compare and analyze these various configurations. A group of Rigel reactor cells operating in a particular configuration is referred to herein as a Rigel™ cell stack or a reactor cell stack. The operational efficiency metrics (202) evaluated include cumulative conversion percentage, energy consumption (kWh / kg FL), cumulative production rate (kg / day), pressure drop (psid), and bulb assembly power (kW). These metrics provide insight into the performance, scalability, and reliability of each configuration for ammonia e-cracking under industrial operating conditions across three different operating temperatures.

[0060]

[0057] The cumulative conversion percentage reflects the proportion of ammonia converted into hydrogen over time, serving as a key indicator of reactor efficiency. Energy consumption (kWh / kg H2) measures the energy required to produce one kilogram of hydrogen, with lower values indicating higher energy efficiency. Low energy consumption values are helpful in reducing production costs and have a lower environmental impact. Cumulative production rate (kg / day) quantifies the system’s output capacity, with higher production rates being more desirable for maximizing system production and meeting output demands. Pressure drop (psid) is the decrease in pressure that occurs as fluid flows through a reactor cell (108), revealing the flow resistance characteristics. Minimizing pressure drop is important for ensuring proper reactor cell (108) performance and avoiding issues such as flow disruptions or equipment damage. Bulb assembly power (kW) indicates the energy demand of the photoreactor’s light source, which affects both operating temperature and component longevity. Typically, the higher the Bulb assembly power (kW), the greater operating temperature of the light source and related electrical components. Precautions may be taken to ensure the electrical components of the light source do not overheat and damage the electric reactor cell (108). Efficient use of light energy reduces overall Energy consumption (kWh / kg EL) and increases the efficiency and longevity of the photoreactor.

[0061]

[0058] From the comparison table (200), it may be observed that the 6 electric reactor cells in a parallel formation (100) generally exhibit a lower cumulative conversion percentage and production rates compared to the hybrid formations (130). This suggests that hybrid configurations, at least for ammonia decomposition, may be more effective for maximizing hydrogen output. However, the parallel formation (100) demonstrates superior performance in terms of energy efficiency and reduced bulb assembly power, which are critical for minimizing operating costs. Photoreactor failures often result from excessive heat buildup within the bulb assembly, which can damage the light source itself or degrade internal reactor components such as the photocatalyst bed. Therefore, operating in a configuration that reduces bulb assembly power can extend equipment life and significantly lower the risk of reactor failure.

[0062]

[0059] Additionally, the parallel formation (100) shows significantly lower pressure drop when compared to hybrid configurations (130). In series-connected reactors, fluid flows sequentially through each reactor cell (108), accumulating pressure loss at each stage. In contrast, parallel processing divides the flow among multiple reactors, each experiencing pressure drop through only one reactor cell (108), resulting in lower overall system pressure drop. As previously mentioned, minimizing the pressure drop across the reactor system is imperative for ensuring proper reactor cell performance and avoiding issues such as flow disruptions or equipment damage. Futher, higher pressure drops across the reactor system necessitate system pumps and / or compressors to work harder, thereby increasing the enery consumption and operating costs of the system. High pressure differentials can also stress equipment, leading to wear and maintenance issues. Accordingly, when evaluating the entirety of the operational efficiency metrics (202), the parallel formation (100) may be more advantageous in terms of longevity and reliability, which is crucial for industrial scale chemical processing.

[0063]

[0060] While the comparison table (200) focuses on operational metrics related to the chemical transformation of a reactant input (101) into a desired product output (114), different reactor configurations may also enhance other system functions. For example, operating reactors in a series formation may be advantageous for thermal management applications, such as running a cooling fluid through reactor cells (108) connected in series to progressively reduce temperature across stages. This can help maintain controlled temperature gradients, protect sensitive components, and improve downstream reaction stability. Additionally, reactor startup procedures, such as reactor purging with inert gases or introducing catalyst activation fluids may also benefit from series configurations. Sequential purging can ensure thorough removal of residual reactants or contaminants, while staged catalyst activation may allow for controlled ramp-up of catalytic activity, reducing thermal shock and improving catalyst longevity. These examples demonstrate that selecting an appropriate reactor configuration is important not only for production efficiency but also for enhancing system safety, reliability, and scalability.

[0064]

[0061] The previous figures have demonstrated various reactor configurations possible and highlighted their respective advantages in chemical conversion and system operations. To illustrate how these configurations may be physically implemented in a scalable and modular format, Figures 3A and 3B instroduce an open skid (304) structure. This structure is designed to securely house electric reactor cells (302) in a manner that facilitates easy access, integration into pre-existing systems, and maintenance operations.

[0065]

[0062] Figures 3A and 3B show a plurality of electric reactor cells (302) secured to an open skid (304), in accordance with one or more embodiments. Any of the reactor cells (108) previously described in Figures 1A-1C, including the six reactor cells referenced in the comparison table of Figure 2, may be secured to an open skid (304). An open skid (304) described herein, refers to a modular framework or platform designed to support various system components, including electric reactor cells (302), pumps, valves, instrumentation, sensors, and any other equipment needed for a particular chemical production process. In some example embodiments, an open skid (304) may be pre-assembled and pre-tested prior to being installed at the production site, enabling rapid deployment and efficient integration into chemical production systems.

[0066]

[0063] Conventional reactors used in chemical manufacturing typically operate under extreme conditions, often exceeding 1000°Celcius and 50 atmospheres of pressure. These systems frequently rely on fossil fuel combustion for heat generation, resulting in the emission of carbon dioxide (CO2), sulfur dioxide (SO2), and other pollutants. Due to these hazardous conditions, physical inspection of reactors during operation, or even in close proximity to other active reactors are generally unsafe. Additionally, reactors are often confined within a reactor containment vessel, which restricts external access and direct visual inspection and further complicates maintenance procedures. A reactor containment vessel typically surrounds one or more reactors and is designed to contain and protect the reactor and their surroundings.

[0064] The combination of high-risk operating conditions and containment vessel confinement renders inspection and access to conventional reactors impractical during active production. When a reactor requires replacement or a new reactor is introduced into a formation, a full ystem shutdown is typically necessary to ensure safe handling. This process involves extensive downtime to allow fluids to evacuate and temperatures to stabilize, resulting in signification operational delays and reduced system productivity. The associated downtime related to a shutdown is costly and overall production of the system suffers.

[0067]

[0065] Electric reactor cells (302) on the otherhand, present a sustainable and operationally superior alternative to these traditional fossil fuel-based systems. By utilizing electricity as the driving force in chemical reactions, these electric reactor cells (302) eliminate the need for burning fossil fuels, reducing greenhouse gas emissions and reliance on finite resources. Notably, electric reactor cells (302), such as the Rigel™ cell stack, do not require confinement within a containment vessel and operate under safer conditions conducive to visual or physical inspection, even when active or while nearby other active electric reactor cells (302). This transition to electric heating supports environmental goals while offering benefits sucfh as precise temperature control, improved process efficiency, and reduced downtime.

[0068]

[0066] Figure 3A illustrates an example emobidment where a plurality of electric reactor cells are secured to one open skid (304). The open skid is demonstrated as a versatile and efficient platform for organizing multiple electric reactor cells (302) compatible with any reactor system formation. Electric reactor cells (302) mounted on an open skid (304) may be arranded in a parallel (100), sereies (120), or hybrid (130) formations, depending on system requirements. The open skid design provides full visibility and accessibility from all sides and above, facilitating maintenance and integration. While Figure 3A shows three electric reactor cells (302), any number may be mounted to the skid and incorporated into a reactor cell system. Furthermore, electric reactor cells (302) secured to an open skid (304) may be retrofitted into any existing chemical production systems with minimal modification. While Figure 3A illustrates a plurality of electric reactor cells (302) mounted to one open skid (304), the open skid structure is designed to support vertical stacking of multiple skids, enabling scalable system configurations.

[0069]

[0067] Figure 3B demonstrates emboidments where multiple open skids are vertically stacked to increase production capacity while conserving horizontal floor space. In these system emobidments shown in Figure 3B, a first plurality of electric reactor cells (302a) are secured to at least a first open skid (304a) and a second plurality of electric reactor cells (302b) are secured to a second open skid (304b). The second open skid (304b) may be stacked on top of the first open skid in some example embodiments. This configuration allows for the continous system expansion without requiring additional floor space. While Figure 3B illustrates a first open skid (304a) and a second open skid (304b), any number of open skid structures may be stacked vertically to meet production and scalability demands. In these example embodiments, where open skids (304) are stacked vertically, access to the tops of an underlyind skid may be limited. However, overall, the open skid design ensures that all sides of each electric reactor cell (302) remain accessible, enabling seamless integration into any preexisting plants, especially when horizontal floor space is limited.

[0070]

[0068] Additionally, the modular design of the open skid (304) allows for easy removal or replacement of reactor cells. In some embodiments, an electric reactor cell (302) may be removed and replaced without requiring a full system shutdowen or breaching any containment vessel, referred to as a “reactor hot swap”. This flexibility is particularly valuable in dynamic production environments, where minimizing downtime is critical to efficiency. Implementing reactor hot swaps through automated systems, such as remote-controlled mechanisms, would even further improve operational safety, reduce manual labor, and minimize downtime for a reactor system. Automation in this context allows for faster, more precise reactor cell exchanges, making the system even more adaptable to high-throughput chemical production environments. As chemical production systems become increasingly complex and demand greater flexibility, the ability to maintain continuous operation without full system shutdown becomes critical. To meet these evolving operational needs, automation plays a key role in managing reactor performance, optimizing system conditions, and reducing downtime. Figure 4 further expands on this concept by introducing system elements that enable automated control and monitoring of electric reactor cells (302), supporting scalable, efficient, and uninterrupted chemical processing.

[0071]

[0069] Figure 4 shows an electric reactor system (400) in accordance with one or more embodiments. The electric reactor system (400) includes a reactant input (101) transported by an input feed (102) to a plurality of electric reactor cells (302) in a parallel formation (100) secured to at least a first open skid (304a). The system (400) may be designed to accommodate a wide range of reactant inputs (101), including liquids, gases, or combinations therof. In certain embodiments, the reactant input (101) may include natural gas or its components, such as methane, ethane, biogas or propane as well as other gases such as ammonia or hydrogen. The reactor system (400) may include multiple reactant inputs (101) such as reactant fluids, cooling fluids, inert gases, water and / or steam. Each reactant input (101) may be delivered via a dedicated inlet valve to allow for selective fluid introduction.

[0072]

[0070] The plurality of electric reactor cells (302) may be configured to transform a reactant input (101) into a product output (114). The system (400) further includes a reactant manifold (104) configured to partition the reactant input (101) into each one of the plurality of electric reactor cells (302) in a parallel formation (100) along at least one of a reactor channel (105) to transform the reactant input (101) into a plurality of channel product outputs. The chanel product output produced from each of the electric reactor cells (302), may be combined using a product manifold (111) to an exit feed (112). The combined channel product output is referred to as the product output (114).

[0073]

[0071] The electric reactor system (400) may also include a plurality of system sensors disposed along various components of each reactor channel (105), configured to measure a reactor system setting. The reactor system setting may include a temperature, a pressure, a flow rate, an electrical power, a feed flow, a measured product output, any combination thereof, or any other reactor system condition. These plurality of system sensors monitor these key operating parameters and genrerate an input signal that may be transmitted to and read by a programmable logic controller (PLC) (115). The PLC (115) may be in operative communication with the plurality of system sensors and configured to receive the input signal and automatically adjust at least one of a production setting, based at least in part, on the input signal. The plurality of system sensors may include a block valve (408), a back pressure controller (410), a flow transmitter (412), atemperature transmitter (414), a leak detection sensor (416), a bypass valve (113), a start-up condition sensor (418), or a product analyzer (420). The plurality of system sensors may also be any other sensor known in the arts for monitoring reactor system operational settings. The plurality of system sensors may also include one or more devices described by the first or second channel element (106, 110). The start-up condition sensor (418) and / or the product analyzer (420) may include any number fluid analysis instruments, including but not limited to gas chromatographs and mass spectrometers configured to analyze the product output (114) or the channel product outputs based on chemical or physical properties. The production setting may be a temperature, a pressure, a flow rate, a production capacity, an electrical power, a movement of valves, or any other system setting. The PLC (115) may adjust these production settings automatically in real-time based, at least in part, on the sensor input.

[0074]

[0072] The electric reactor cells (302) used in the system (400) may include the Rigel™ reactor cell stack developed by Syzygy Plasmonics Inc. In these emobidments, the electric reactor cells (302) are photoreactors secured to a first open skid (304a) having a light housing (402) internal or external to the reactor housing. These photoreactors utilize light to drive a chemical reaction. The following applications provide further description of photoreactors, including various embodiments that describe the photocatalytic reactor cell developed by Syzygy Plasmonics. These photoreactors and associated systems are hereby incorporated by reference in their entireties: International Application No. PCT / US2018 / 039470, International Application No. PCT / US2018 / 039476, International Application No. PCT / US2020 / 013190, International Application No. PCT / US2020 / 013206, International Application No. PCT / US2021 / 042448, International Application No. PCT / US2022 / 031444, and PCT / IB2023 / 060737. The light housing (402) may contain a bulb assembly and associated electrical components. The light housing (402) may broadly be any energy-emitting device with associated electrical components required for accepting a required Bulb Assembly Power (kW) from an electrical power source. The associated electrical components typically have the lowest temperature rating of anything found inside the electric reactor cell (302) and preventative measures are needed to ensure the electrical components do not overheat and cause a reactor shutdown. The bulb assembly may include all types of photon emitting devices, both artificial (e.g., IR bulbs, ultraviolet (UV) lamps and voltaic arc lamps) and natural (e.g., utilizing solar radiation). In general, to promote efficient operation for a photoreactor, the photon emitters are selected to emit photons having a sufficient energy and wavelength to activate desired photo-induced gas-phase reactions. While Figure 4 shows the light housing external to the electric reactor cell (302), the light housing (402) may alternatively be integrated within the reactor cell structure itself.

[0075]

[0073] In Figure 4, a temperature transmitter (414) is shown positioned adjacent to the bulb assembly to monitor the temperature of its electrical components, which typically have the lowest thermal tolerance of all the system components. Detecting the temperature of these electrical components is critical to avoid reactor failure. In some emboidments, the light housing and the temperature transmitter (414) may also be in operative communication with the PLC (115). The PLC (115) may receive an input signal indicating a temperature of an electrical component of a bulb assembly and automatically adjust a production setting based, at least in part, on the input signal in real-time.

[0076]

[0074] For example, the PLC (115) may receive an input signal from a temperature transmitter (414) that indicates that the electrical components of the bulb assembly exceed a safe threshold. To adjust a production setting based on this reading, the PLC (115) may automatically initiate some corrective actions. For example, the PLC (115) may be configured to initiate or increase the flow of cooling fluid directed to the electric reactor cell (302) or the light housing (402), thereby actively regulating the temperature of the electrical components. Furthermore, the PLC (115) is also in electrical communication with the bulb assembly, and may decrease the electrical power to bulb assembly, thereby decreasing the temperature of the electrical components of the bulb assemblies until a safe operational range is detetected by the temperature transmitter (114). These automation techniques serve to protect the most sensitive system components, prolonging the lifespan of the electric reactor system (400) as it reacts in real-time to varying reactor system settings. While example embodiments have been provided that describe photoreactors having a bulb assembly, temperature sensors may also be used in different example electric reactor systems that employ different energy -emitting devices without deviating from the scope of the disclosure.

[0077]

[0075] The PLC (115) may be programmed with any number of reactor system setting threshold values to determine when a production setting should be automatically adjusted. In some embodiments, the plurality of electric reactor cells (302) may be secured to at least a first open skid (304a). In other emboidments, the electric reactor system (400) may also include a second plurality of electric reactor cells (302b) secured to a second open skid (304b) stacked on top of the first open skid (304a). Incorporating an open skid structure in the electric reactor cell system (400) enables hot swapping capabilities. In some embodiments, the PLC (115) may be programmed with a hot swap algorithm and adjusting a production setting may include performing a hot swap, using the hot swap algorithm. In some example embodiments, the PLC (115) may be programmed with a flow balancing algorithm and adjusting a production setting may include balancing the reactant input (101) flow between each reactor channel (105), using the flow balancing algorithm. The hot swap and flow balancing functionality is discussed in greater detail in the context of Figures 6-9.

[0078]

[0076] While not shown, the electric reactor system (400) may further include an integrated electric control system designed to supply power and transmit electronic signals to various components within the system. Power supplies can be manifolded and distributed to each of the electric reactor cells (302) via multi-pair cables, with each electric reactor cell (302) connected to a dedicated junction box. These junction boxes serve as connection hubs for reactor cell instruments and sensors, such as thermocouples and pressure transmitters, which are linked to remote input / output (I / O) cards. By routing sensor data through remote I / O cards, the system enables centralized data acquisition and communication with a central control unit or a PLC (115). This architecture significantly reduces wiring complexity, streamlines installation, and minimizes the risk of wiring errors or signal interference.

[0079]

[0077] Figure 5 shows a flowchart (500) describing a method of adjusting at least one of a production setting for at least one of a plurality of electric reactor cells (302) in an electric reactor system (400) in accordance with one or more embodiments. In Step 502, the electric reactor cell system (400) is operated using a PLC (115). The system (400) may include a plurality of electric reactor cells (302) secured to at least a first open skid (304a) configured to transform a reactant input (101) into a product output (114). The system (400) may further include any of the components previously described in Figures 1 - 4, such as an input feed (101) configured to transport the reactant input (101) and a reactant manifold (104) configured to partition the reactant input (101) into each one of the plurality of electric reactor cells (302) along at least one of a reactor channel (105). The plurality of electric reactor cells (302) may be in a parallel formation (100) and a plurality of system sensors may be disposed on each reactor channel (105) to monitor operational parameters. The system (400) may also include a product manifold (111) configured to combine a plurality of channel product outputs to an exit feed (112), where the combined plurality of channel product outputs are referred to as the product output (114). The reactor system (400) may further include a second plurality of electric reactor cells (302b) secured to a second open skid (304b) and stacked on top of the first open skid (304a), enabling scalable configurations.

[0080]

[0078] In accordance with one or more embodiments, the plurality of electric reactor cells (302) may be configured to transform a reactant input (101) into a product output (114). For example, the transformation may involve converting biogas into syngas or performing ammonia e-cracking. The systems and methods described herein are not limited to any specific chemical reaction and may be adapted to accommodate a wide range of transformation processes depending on the application.

[0081]

[0079] The method continues to Step 504, where a reactor system setting is measured using at least one of a plurality of system sensors. These sensors may include any one of the system sensors described in Figure 1 or 4 and are configured to measure reactor system settings such as a temperature, a pressure, a flow rate, an electrical power, a feed flow, or a measured product output. In Step 506, an input signal is generated, using the plurality of system sensors. The input signal represents a real-time measurable value corresponding to a specific reactor system setting being monitored. These signals may be analog or digital, depending on the sensor type and system architecture, and may be time-stamped to support historical tracking, trend analysis, and predictive control. In some embodiments, the input signal may be part of a multi-variable control strategy, where signals from multiple sensors are aggregated and analyzed to assess complex system behaviors, such as reaction kinetics, thermal gradients, or flow imbalances.

[0082]

[0080] In Step 508, these input signals are transmitted to the PLC (115), which is in operative communication with the plurality of system sensors. The PLC (115) may receive these input signals using a wired or wireless communication channel. As previously discussed, the PLC (115) may be a computer system capable of accepting, displaying and interpreting the input signal. In some example embodiments, input signals may be displayed on a screen in real-time and monitored by a reactor system operator. Further, the PLC (115) may alternatively be a (DCS), or (SCAD A) system without departing from the scope of this method. In Step 510, a production setting is automatically adjusted using the PLC (115), based at least in part, on the input signal. These adjustments may include changes to temperature, pressure, flow rate, electrical power, or a movement of valve positions. The PLC (115) may be configured to compare current reactor system settings against predefined thresholds or setpoints, initiate alarms or safety protocols if values exceed acceptable limits, and dynamically modify system parameters to maintain optimal performance.

[0083]

[0081] The method outlined in Figure 5 describes general automation techniques that may be employed by the electric reactor system (400) described herein. In further embodiments, the PLC (115) may execute more advanced control routines using pre-programmed algorithms. For example, in some example embodiments, adjusting the production setting may include performing a hot swap, using at least a hot swap algorithm programmed on the PLC (115). In other example embodiments, adjusting the production setting may include performing a flow balancing, using at least a flow balancing algorithm programmed onto the PLC (115). These algorithms and methods will be discussed in greater detail with reference to Figures 6-9.

[0082] Figure 6 shows a flowchart (600) describing a method to perform a hot swap in accordance with one or more embodiments. A hot swap is one specific example of a production setting being adjusted, where an electric reactor cell (302) is replaced without requiring a complete system shutdown. This approach is designed to minimize downtime and maintain continuous production. Hot swaps may be performed for various reasons, including preventative maintenance, component upgrades, or in response to a detected failure.

[0084]

[0083] In some example embodiments, the method includes utilizing a hot swap algorithm, programmed onto a PLC (115) to automatically identify an electric reactor cell (302) requiring removal. Upon identification, the system may automatically isolate the target reactor cell by halting fluid flow to that cell, while simultaneously increasing the production capacity of the remaining reactor cells (302) to compensate for the loss. This dynamic adjustment enables a reactor system (400) to maintain a consistent level of output. Once a replacement reactor cell is installed, the hot swap algorithm may automatically rebalance the system by reducing the output of the remaining cells to restore the system to its original production configuration.

[0085]

[0084] In the context of flowchart (600), Steps 602-614 are executed using a PLC (115) programmed with a hot swap algorithm. In alternative embodiments, the control system may be implemented using a distributed control system (DCS), a supervisory control and data acquisition (SCAD A) system, or any other computer-based control system capable of communicating with the plurality of system sensors and automatically adjusting production settings. Steps 606 and 610 may involve manual or automated actions to physically remove and replace the identified electric reactor cell (302), depending on the system configuration and operational requirements. The electric reactor cell system (400) used in this method may be the system described by Figure 4, comprising a plurality of electric reactor cells (302) connected to at least a first open skid (304a).

[0086]

[0085] In Step 602, an electric reactor cell system (400) is operated at a first production capacity, to obtain a cell stack benchmark production. The cell stack benchmark production comprises the sum value of a measured product output (114) from each of the plurality of electric reactor cells (302) operated at the first production capacity. The product output (114) may be measured using a product analyzer (420), including gas chromatographs and / or mass spectrometers configured to analyze the output based on chemical or physical properties. The product analyzer (420) may be any other sensor or device capable of measuring chemical or physical properties of a fluid to determine or measure its contents. In some example embodiments where ammonia e-cracking is being performed, the cell stack benchmark production may represent the total amount of hydrogen or nitrogen measured by the product analyzer (420).

[0087]

[0086] The first production capacity represents a modelled value that represents the optimal production rate over an extended period, taking into account the longevity of the electric reactor system components. The first production capacity may refer to the optimal rate at which an electric reactor cell (302) is capable of transforming a given reactant input into a desired product output under defined operating conditions. This may be expressed in units such as kilograms per day (kg / day), standard liters per minute (SLPM), or any other relevant metric depending on the chemical process. The first production capacity is less than the maximum production capacity for the electric reactor system (400), as operating at maximum production capacity for extended periods could lead to increased wear, overheating, and reduced lifespan of the electric reactor cell components. Further, operating below maximum capacity allows for gradual increases in flow rate to account for catalyst degradation. Operating the electric reactor system (400) at the first production capacity that prioritizes long-term reliability may reduce maintenance frequency and enhance overall system uptime. This approach supports a sustainable and cost-effective operation by balancing performance with equipment durability.

[0088]

[0087] In Step 604, at least one of a target electric reactor cell is detected from the plurality of electric reactor cells (302). Detecting the target electric reactor cell may include receiving an input signal from at least one of the plurality of system sensors and evaluating the input signal against an operational range metric. When an input signal falls outside a safe operational range, the corresponding electric reactor cell (302) may be identified as a target electric reactor cell, in need of a hot swap. The term “operational range metric” refers to a predefined set of acceptable values for a given reactor system setting, including temperature, pressure, flow rate, electrical power, feed flow, or a measured product output. These metrics are established based on empirical data, system modeling, safety standards, and performance benchmarks. Each metric defines upper and lower thresholds that represent safe and efficient operating conditions for the electric reactor cell (302) and its system components. When a sensor detects that a measured value falls outside of its corresponding operational range, it generates an input signal indicating a potential fault, inefficiency, or safety concern. These metrics may be stored within the control system and used by the PLC (115) or other computing systems to trigger automated responses or alerts.

[0089]

[0088] Sensors may be positioned at multiple locations throughout the electric reactor system (400), including inlets and outlets of electric reactor cells (302), along the input and exit feeds, within the catalyst bed of the reactor, and near seal locations. Monitoring seal integrity is critical, as seals maintain internal pressure and prevent leakage of hazardous materials. In embodiments involving photoreactors having a light housing (402), temperature sensors or temperature transmitters (414), may be placed adjacent to the electrical components of the bulb assembly. These components typically have the lowest thermal tolerance in the system, making temperature monitoring essential for avoiding reactor failure.

[0089] While example embodiments have been provided that describe photoreactors having a bulb assembly, temperature sensors may also be used in different example reactor systems that employ different energy-emitting devices without deviating from the scope of the disclosure. Similar to temperature sensors, pressure transmitters, flowmeters or flow transmitters (412), may be strategically positioned throughout the electric reactor cell system, including within individual electric reactor cells (302) and along the input and output feeds. These transmitters may monitor and control pressure within the electric reactor cell (302) to ensure safe and efficient operations. Furthermore, flowmeters may be installed at various locations within the system to meausre the flow rate of fluids. A detected reduction in flow rate may indicate a blockage, leak, or malfunction within a reactor cell or elsewhere upstream in the system.

[0090]

[0090] Measurement of a product output (114) from each one of the plurality of electric reactor cells (302) may also be used to determine a target electric reactor cell requiring a hot swap. As previously mentioned, there may be a product analyzer (420) or any number of gas analysis instruments disposed on each reactor channel (105) configured to measure the channel product output. Alternatively, mass flow meters, volumetric flow meters, or weighing scales may be employed to quantify product output. A sudden decline in output from a specific reactor channel may signal a failure or inefficiency upstream, prompting further investigation or cell replacement

[0091]

[0091] In Step 606, the target electric reactor cell is disabled while the remainder of the plurality of electric reactor cells continue to operate. As used herein, “the remainder of the plurality of electric reactor cells” refers to all electric reactor cells (302) within the system that have not been designated as the target electric reactor cell. Disabling the target electric reactor cell may involve activating a block valve (408) to the reactor channel (105), thereby prohibiting the flow of the reactant input (101) to the target electric reactor cell and the channel product output from the target electric reactor cell. Additional steps may include cooling the target electric reactor cell and purging the target electric reactor cell with an inert fluid, such as nitrogen, to remove residual oxygen and prepare the target electric reactor cell for safe removal. Disabling may also encompass any other procedure necessary to facilitate safe extraction or servicing of the target electric reactor cell from the open skid (304).

[0092]

[0092] In some embodiments, once the target reactor cell is disabled, all associated connections may be disengaged, and the cell may be physically removed from the open skid (304). Removal may be performed using equipment such as forklifts, cranes, or lifting jacks. The primary advantage of this approach is that fluid flow is only interrupted for the target cell, while the remaining cells, connected in a parallel formation (100), continue uninterrupted production. While in some embodiments, the target electric reactor cell is removed from the open skid (304), in other embodiments the target electric reactor cell may remain on the skid and undergo maintenance while still mounted. This flexibility allows for both full removal and in-place servicing, depending on operational needs and system design.

[0093]

[0093] In Step 608, the first production capacity of each of the remainder of electric reactor cells is increased by a maintenance capacity factor to return the electric reactor cell system (400) to the cell stack benchmark production. This increase is to compensate for the disabled cell. Calculating the maintenance capacity factor includes determining a cell maintenance production by measuring the product output (114) of the remaining electric reactor cells, subtracting the cell benchmark production by the cell maintenance production, to obtain a difference of production, and dividing the difference of production by the number of the remaining electric reactor cells to obtain the maintenance capacity factor. The maintenance capacity factor represents the additional output required from each of the remaining reactor cells to restore system performance. The maintenance capacity factor calculated should then be added to the first production capacity of each of the remainder of electric reactor cells to return to the original cell benchmark production, despite missing the target electric reactor cell. This new production capacity for each of the remainder of electric reactor cells will be referred to herein as the restored production capacity.

[0094]

[0094] The restored production capacity may exceed the original first production capacity but should remain below the system’s maximum production capacity to avoid excessive wear. In cases where the calculated value exceeds the maximum allowable capacity, the system may operate at its maximum, and full recovery of the benchmark production may not be achievable. This step ensures that the reactor system undergoing a hot swap maintains near-continuous production with minimal loss. The restored production rate, which is an elevated production capacity when compared to the first production capacity, may be achieved in the system by adjusting one or more of the production settings, using the PLC (115). For example, production settings may be adjusted including increasing the flow rate of the reactant input (101), elevating the operating temperature or pressures of the reactant input (101), or enhancing the energy input to the electric reactor cell (302) (e.g., increasing the electrical power to heating or lighting -emitting components). The system may estimate the expected increase in production capacity by referencing predefined performance models, historical production data, or real-time sensor feedback. These inputs allow the control system, including the PLC (115) to predict how changes in flow rate, temperature, energy input, or reactor configuration will impact overall system output, enabling informed adjustments that maintain system efficiency and reliability.

[0095]

[0095] In Step 610, a replacement electric reactor cell is activated to the electric reactor cell system (400). In embodiments where the target electric reactor cell was physically removed from the open skid (304), the replacement cell may be inserted into the vacant position while the remaining reactor cells continue operating at an elevated production capacity. The replacement reactor cell may be a newly manufactured unit of the same design, a unit of an alternative design, or the original target reactor cell following completion of maintenance procedures. Activating the replacement electric reactor cell may include purging the replacement electric reactor cell with an inert fluid (e.g., nigrogen), introducing a catalyst reaction fluid, elevating the temperature of the electric reactor cell to operational levels, and initiating the flow of reactant input (101).

[0096]

[0096] In Step 612, once the replacement reactor cell has been installed and prepared for operation, it is brought online and operated at the first production capacity. In some embodiments, the replacement cell may be preconditioned prior to installation by performing start-up procedures off- skid. Operating the replacement reactor cell at the first production capacity ensures alignment with the system’s long-term performance targets and supports sustained production efficiency. With the activation of the replacement electric reactor cell in Step 612, the hot swap process is complete, and the system is restored to its original number of active electric reactor cells (302). However, additional steps are required to ensure the system does not continue operating at elevated production levels, thereby preserving reactor longevity and maintaining overall system stability.

[0097]

[0097] In Step 608, each of the remaining electric reactor cells had its production capacity temporarily increased by applying the maintenance capacity factor, allowing the system to compensate for the offline target reactor cell by operating at elevated output levels. This step is performed to maintain a consistent product output (114) despite the temporary removal of an electric reactor cell (302), making it particularly beneficial for maintenance or replacement procedures. However, prolonged operation of the remaining electric reactor cells at elevated production capacities may adversely affect system longevity, potentially leading to overheating, accelerated component wear, and increased risk of future downtime.

[0098]

[0098] Thus, in Step 614 once the replacement reactor cell begins producing a measurable channel product output, the restored production capacity for each of the remainder of electric reactor cells is decreased by the maintenance capacity factor to return the electric reactor system (400) to the cell benchmark production. The fundamental objective of this step is to reestablish balanced production across the system, ensuring consistent throughput and maintaining optimal operating conditions throughout the reactor system’s lifecycle. Steps 602-614 are executed using, at least a PLC (115) programmed with a hot swap algorithm.

[0099]

[0099] Figure 7 shows a flowchart (700) describing a hot swap algorithm, in accordance with one or more embodiments. The hot swap algorithm may be programmed onto the PLC (115), to automate electric reactor system processes, including the hot swap process. The hot swap algorithm may be performed on an electric reactor system (400) having a plurality of electric reactor cells (302) secured to an open skid (304). The hot swap algorithm automates steps 602-608 from the hot swap method previously discussed. The hot swap algorithm begins with Step 702 when the PLC (115) receives an input signal from at least one of the plurality of system sensors. In Step 704, the input signal is evaluated to determine whether it falls within a safe operational range, based on predefined operational range metrics. If the input signal is within this safe operational range, Step 706 verifies whether the reactor system has met a minimum operational time constraint. This constraint ensures that the electric reactor cells (302) have ramped up to their first production capacity and are operating under stable conditions. The minimum operational time may be pre-programmed into the PLC (115) prior to initiating production.

[0100]

[0100] In Step 708, if the system has met the minimum operational time constraint, the cell stack benchmark production is calculated. As previously mentioned, the cell stack benchmark production comprises the sum value of a measured product output (114) from each of the plurality of electric reactor cells (302) operated at the first production capacity. Given the dynamic nature of chemical production systems, operational parameters may fluctuate overtime. Therefore, in some embodiments, the benchmark production may be recalculated at regular intervals. Steps 702-708 may be repeated periodically until an input signal falls outside the safe operational range. If the system has not met the minimum operational time constraint, no cell stack benchmark production is calculated.

[0101]

[0101] When an input signal falls outside a safe operational range, the corresponding electric reactor cell (302) may be identified as a target electric reactor cell, in need of a hot swap. Some examples of input signals falling outside a safe operational range have been provided when describing the hot swap method in Figure 6. Examples of such measurements include elevated temperature readings at critical locations within the reactor system, such as the catalyst bed, bulb assembly, or feedlines. Additional indicators may include pressure spikes or drops within the reactor cell or associated piping, irregular flow rates through reactor channels, and a measurable decline in product yield. Each reactor system setting may have its own predefined operational range metric, which is programmed into the PLC (115) to enable automated detection of deviations from safe operating conditions.

[0102]

[0102] In Step 710, the target electric reactor cell is removed from the open skid (304), while continuing to operate the remainder of telectric reactor cells. The PLC (115) may display a message on a system monitor identifying which reactor requires removal, while simultaneously disabling fluid flow to that reactor. The physical removal of the target electric reactor cell from the open skid (304) may be accomplished using equipment such as forklifts, cranes, or lifting jacks. Step 712 verifies whether a cell stack benchmark production has been previously calculated. If not, the system did not meet the minimum operational time constraint, and the remaining reactor cells continue operating at their first production capacity during hot swap operations. If the cell stack benchmark production has been calculated, Step 714 calculates a maintenance capacity factor, based at least in part, on the remainder of electric reactor cells. In Step 716, the first production capacity of each remaining reactor cell is increased by the maintenance capacity factor to compensate for the offline target cell and restore the system to the benchmark production level. The remainder of electric reactor cells are now operating at a restored This adjustment ensures that the total system output remains consistent despite the temporary removal of one or more reactor cells.

[0103]

[0103] In Step 718, the system calculates a restored production capacity based on the output of the remaining reactor cells. Although the goal is to match the benchmark production, variations in system dynamics may result in a restored rate that is slightly lower. In Step 720, the restored production capacity is evaluated against a predetermined threshold. The predetermined threshold may include a percentage of the cell stack benchmark production, e.g., if the restored production capacity is at least 90% of the cell stack benchmark production, the restored production capacity meets this predetermined threshold. If such is the case, the electric reactor cell system (400) is considered to have successfully compensated for the loss of the target electric reactor cell. If the restored production capacity does not meet the predetermined threshold, the algorithm returns to Step 714 to recalculate the maintenance capacity factor. Steps 714-720 may be repeated iteratively until the restored production capacity satisfies the threshold. While the hot swap algorithm shown in Figure 7 focuses on the removal and compensation process, the algorithm may also be programmed to incorporate steps 610-614 from the hot swap method. These steps include the automated procedures for insterting the replacement electric reactor cell back into formation, while ramping down production of the remainder of the electric reactor cells to return the system back to the benchmark level.

[0104]

[0104] For example, once the restored production capacity meets the predetermined threshold, operators may begin inserting a replacement reactor cell into the open skid (304). After completing all necessary connections and start-up procedures, the replacement reactor cell is operated at the first production capacity. The system then recalibrates by subtracting the restored production capacity of the remaining reactor cells by the maintenance capacity factor, thereby returning the system to the original cell stack benchmark production. Regardless the step beign performed, the PLC (115) will continuously receive input singals from the system sensors. In some embodiments, a second target electric reactor cell or more may be identified in the electric reactor cell system (400) .

[0105]

[0105] The PLC (115) may be programmed with any number of other algorithms configured for automated control of the reactor cell system (400). Another such example is illustrated in Figure 8, which demonstrates a flow balancing algorithm in accordance with one or more embodiments. A flow balancing algorithm may be configured to automatically adjust the flow rate across multiple reactor channels (105) to achieve a balanced system flow. Maintaining uniform flow conditions is advantageous for improving process stability, improving performance consistency, and reducing the impact of pressure drop variation between reactor channels (105). The following steps described in Figure 8 may be performed using at least the PLC (115).

[0106]

[0106] The flow balancing algorithm of Figure 8 begins in Step 802, where the PLC (115) receives an input signal from at least one of the plurality of system sensors from each reactor channel (105). In certain embodiments, the input signal corresponds to a flow rate, and the system sensor comprises a flow transmitter (412). In Step 804, a noise signal is fdtered from the input signal to determine a true signal for each reactor channel (105). System sensors employed in electric reactor cell systems (400) may introduce signal noise, which can distort measurements and adversely affect control accuracy. Filtering the noise yields a more reliable signal, thereby enhancing measurement accuracy.

[0107]

[0107] In Step 806, an average system signal is calculated based, at least in part, on the true system signal for each reactor channel (105). Continuing with the flow rate example emobidment, after step 804, a flow rate and / or total flow for each individual reactor channel (105) is determined. For an electric reactor system (400) with 3 electric reactor cells (302) connected in a parallel formation (100), the total system flow is expressed as QI + Q2 + Q3. Thus, the average flow per reactor channel (105) or the average system signal is calculated as Qavg = Q / 3.

[0108]

[0108] In Step 808, for each reactor channel (105), a deviation between the average system signal and the true system signal is calculated and in Step 810, each deviation is evaluated to determine if it satisfies a predetermined condition. In some example embodiments, the predetermined condition may be defined as a percentage or fraction of the average system signal (Qavg). For example, a predetermined condition may be expressed as: [deviation < Qavgx .1 ] indicating that the deviation must be less than 10% of Qavg. If the deviation satisfies the condition, no corrective action is taken, and the PLC (115) continues to receive input signals. If the deviation exceeds the threshold, the PLC (115) initiates a corrective response, and the algorithm proceeds to the next step. Using the deviation example provided, if the deviation is greater than 10% of the Qavg this indicates that the PLC (115) will need to adjust a production setting, and the algorithm continues to the next Step. In Step 812, the deviations are sorted by absolute value and in Step 814, a proportional coefficient is selected, based at least in part, on the sorted deviation value.

[0109]

[0109] The proportional coefficient determines how aggressively the PLC (115) responds to the error between the desired setpoint and the actual process variable. A higher proportional coefficient will result in a stronger corrective action for a given setting, while a lower proportional coefficient will yield a more moderate response. Proper tuning of the proportional coefficient is essential to achieve the desired performance and stability in a control system. Overall, the calculation of the proportional coefficient involves a balance between achieving the desired control performance (e.g., response time, stability) and avoiding oscillations or instability in the system.

[0110] In Step 816, the proportional coefficient is applied to the production setting. For example, if QI, Q2, and Q3 are assigned a proportional coefficient of 1, .5, and 2 respectively, the PLC (115) would respond with a corrective action by decreasing the flow rate of Q2 by .5 units, increasing the flow rate of Q2 by a factor of 2, and leaving the flow rate of QI unchanged. This adjustment would achieve a balanced flow across all individual reactor channels (105), which would ensure that each electric reactor cell (302) receives an equal share of reactants, leading to a more uniform reaction conditions across all reactors. Balanced flow contributes to consistent reaction conditions, improved reactor efficiency, and reduced maintenance frequency. Disproportionate flow to a single reactor channel (105) may accelerate wear on the system components and necessitate more frequent servicing. Moreover, balanced flow enhances system safety by mitigating risks such as localized hot spots or other non-ideal operating conditions. Collectively, the flow balancing algorithm facilitates efficient and uniform operation of parallel formations (100), thereby improving overall system performance.

[0110]

[0111] Although Steps 802-816 describe a flow balancing algorithm primarily in the context of realtime flow rate adjustments, the algorithm may be similarly applied to other reactor system settings. For example, temperature readings from each reactor channel (105) may be monitored, and production system settings, such as power to the bulb assembly or cooling fluid flow rate may be adjusted by the PLC (115) to restore system balance. In further embodiments, the flow balancing algorithm may incorporate machine learning techniques to enhance performance. An artificial intelligence (Al) system employing trained models may optimize flow distribution across the reactor system. These models, trained on historical and real-time data from electric reactor cells (302), can identify optimal operating conditions and predict performance degradation. By forecasting expected performance trends, the system may generate deviation metrics based on projected rather than realtime values. This predictive capability enables more precise adjustments to flow and operating conditions, maintaining consistent performance even as individual reactor cells evolve over time.

[0111]

[0112] Figures 9A -9C illustrate the flow balancing capabilities of an electric reactor cell system (400) utilizing the disclosed flow balancing algorithm. In Figure 9A, three electric reactor cells (Rl, R2, R3), are shown with a pressure drop (PSI) plotted on the vertical axis against a production time (minutes) shown on the horizontal axis. The electric reactor cells (Rl, R2, R3) are arranged in a parallel formation (100), with each cell receiving an independent stream of reactant fluid (101) through its respective reactor channel (105). The pressure drop variation across the three cells is depicted, with Rl exhibiting the highest pressure drop values (indicated by oval 902), and R2 the lowest. Each reactor cell includes a trendline representing the pressure drop behavior over time. The three electric reactor cells (Rl, R2, R3) in Figure 9A demonstrate a large pressure drop variation (904).

[0113] Such pressure differentials can lead to increased flow velocity due to fluid acceleration from regions of higher to lower pressure, consistent with Bernoulli’s principle. This increase in flow velocity can affect the behavior of the fluid and the performance of the system. Therefore, a larger pressure drop variation (904) may result in an increased flow imbalance between the electric reactor cells (302). Consequently, a significant pressure drop variation (904) between electric reactor cells (302) may induce flow imbalance across the cells, potentially impacting system performance.

[0112]

[0114] Figure 9B presents the measured flow rates of the reactor cells Rl, R2, and R3 over time, with the flow rate (SLPM) on the vertical axis and a production time (minutes) on the horizontal axis. In Figure 9B, the flow balancing algorithm was deactivated to illustrate a flow rate variation (908) during periods of high pressure drop variation (904). The data shows that as pressure drop fluctuates, as illustrated in Figure 9A, the flow rates to each reactor cell vary independently. Each reactor cell includes a trendline that illustrates the flow rate trajectory over time, emphasizing the divergence in flow behavior when the algorithm is inactive. Notably, Rl reaches a peak flow rate of approximately 6.5 SLPM around the 50-minute mark, corresponding to the maximum pressure drop variation (904), highlighting the impact of unregulated pressure dynamics on flow distribution.

[0113]

[0115] Figure 9C demonstrates the effect of activating the flow balancing algorithm across reactor cells Rl, R2, and R3 via a PLC (115). As discussed herein, the PLC (115) may be programmed with a flow balancing algorithm that automatically adjusts the flow rate across multiple reactor channels

[0114] (115) to achieve a balanced system flow. Each reactor cell Rl, R2, and R3 includes a trendline giving the flow rate trajectory overtime. With the flow balancing algorithm activated, the trendlines for all three reactor cells are closely aligned, indicating that the system maintained near-identical flow characteristics across channels. This alignment demonstrates the effectiveness of the flow balancing algorithm in achieving its primary objective: consistent and uniform fluid distribution throughout the parallel reactor system. As the reactor system experiences total flow changes due to pressure drop, the flow balancing algorithm will automatically compensate for these changes. By executing the flow balancing algorithm, the system can actively maintain uniform flow conditions between reactor cells, thereby enhancing process stability, improving performance consistency, and reducing the impact of pressure drop variations.

[0115]

[0116] Figures 9A-9C illustrate advantages that electric reactor system automation may offer. By integrating sensor feedback with a PLC (115), the electric reactor cell system (400) can automatically respond to a wide range of operational anomalies or inefficiencies identified by system sensors. This automation enables real-time adjustments to production settings, including flow rate balancing, reactor hot-swapping, or any other number of production setting adjustments. These automatic adjustments may be advantageous to prevent equipment damage, reduce unplanned downtime, and improve overall system reliability. As demonstrated in the flow balancing figures, automation not only enhances performance but also contributes to cost efficiency by maintaining optimal operating conditions. These capabilities underscore the broader value of automated control in electric reactor systems, which may be extended to additional functionalities as described in the previous sections.

[0116]

[0117] Figures 7-9 depict specific embodiments of electric reactor system automation that may be implemented by the electric reactor system (400) described herein. However, the automation techniques and algorithms illustrated are not limited to this particular system configuration and may be applied to alternative electric reactor cell systems without departing from the scope of the present disclosure. Figure 10 presents a hybrid electric reactor cell system (1000), which enables the implementation of additional automation techniques beyond those previously discussed. In certain embodiments, the configuration shown in Figure 10 may incorporate features similar to those described in Figure 4, while introducing further enhancements and optional embodiments to expand system functionality and automation capabilities.

[0117]

[0118] Specifically, Figure 10 shows a hybrid reactor cell system (1000) utilizing a plurality of electric reactor cells (302) having both parallel and series type connections. Many components described in Figures 1 and 4 are reused in Figure 10 to illustrate parallel processing of the reactant input (101). For brevity, embodiments related to manifolding and reactor channel (105) elements are not repeated in this section. The plurality of electric reactor cells (302) in the hybrid reactor cell system (1000) may be configured to receive a start-up fluid (1002) in a series formation (120) while having the reactant input (101) configured to enter the plurality of electric reactor cells (302) arranged in a parallel formation (100) to produce the product output (114). As demonstrated in the comparison table (200) of Figure 2, a parallel formation (100) may offer distinct advantages for reactant input (101) processing. However, it may be advantageous for certain reactor systems to incorporate seriesbased operations for specific processes, such as start-up procedures. The plurality of electric reactor cells (302) may have multiple dedicated inlets and outlets for channeling different fluid types to achieve different objectives. Controlling the fluid flow of these different fluid types may be automated by the hybrid reactor cell system (1000).

[0118]

[0119] The hybrid reactor cell system (1000) may be configured to adjust production settings using a PLC (115) by controlling the flow of the start-up fluid (1002) and the flow of the reactant input (101). In these embodiments, the plurality of electric reactor cells (302) may be configured to receive the start-up fluid (1002) until at least one of a first predetermined start-up condition is met, prior to receiving the reactant input (101). The start-up fluid (1002) may be an inert fluid, including nitrogen (N2), and the first predetermined start-up condition may be a purging indicator, such as an oxygen purging indicator. Prior to initiating parallel reactant input (101) processing, the plurality of electric reactor cells (302) are preferably purged with the inert fluid to remove any oxygen, moisture, or volatile compounds, which may adversely affect the chemical transformations occurring within the electric reactor cells (302). In some conventional reactor systems, this purging step may be performed for a predetermined amount of time and may continue long after the reactor has been successfully purged. This practice may result in lost production time. Automating the process to proceed with reactant input (101) processing directly after the reactors have been successfully purged may increase overall system production and efficiency.

[0119]

[0120] In some example embodiments, the plurality of electric reactor cells (302) may be further configured to receive a second start-up fluid (1004) that enters the cells in a second series formation until a second predetermined start-up condition is met, prior to introducing the reactant input (101). In these example embodiments, adjusting a production setting includes controlling the flow of the second start-up fluid (1104). The second start-up fluid (1004) may include a catalyst activation fluid and the second predetermined start-up condition may include a catalyst activation indicator. The system (1000) may also include a plurality of system sensors, including at least one of a start-up condition sensor (418) configured to identify when at least one of the first predetermined start-up condition or the second predetermined start-up condition is met.

[0120]

[0121] These start-up condition sensors (418) may include gas analysis instruments, such as gas chromatographs and mass spectrometers, capable of analyzing the output stream for chemical of physical properties. For example, to determine if a first predetermined start-up condition is met, the output stream may be analzed by a gas analysis instrument to confirm the removal of oxygen, moisture, volatile compounds, or other impurities. In the example embodiments where the purging indicator is an oxygen purging indicator, if no oxygen is detected by the start-up condition sensor (418), the system is deemed to have satisfied the first start-up condition and the flow of the second start-up fluid (1004) or the reactant input (101) may be automatically initiated. Given the series formation (120) of the start-up fluid flow, the start-up condition sensors (418) are preferably positioned at the exit feeds following the final reactor in the series.

[0121]

[0122] The PLC (115) included in the system is configured to automatically regulate the flow of both the start-up fluid (302) and the reactant input (101). The start-up condition sensors (418) may communicate directly with the PLC (115), enabling it to identify when a start-up condition such as a purging indicator is met and to actuate system valves, accordingly, thereby halting the flow of the start-up fluid (302). At that point, the PLC (115) may initiate the flow of a second start-up fluid (1004) until a second predetermined start-up condition is met or initiate the flow of the reactant input (101). The second predetermined start-up condition may be related to catalyst activation or reduction.

[0122]

[0123] As is typical in chemical reactor systems, catalysts are housed within the reactor cells to accelerate reaction rates without being consumed. Catalysts function by lowering the activation energy required for the reaction under specific conditions. To achieve optimal catalytic performance, activation or reduction steps may be necessary for use by making its surface more reactive. These activation or reduction steps may include removing impurities or oxides from the catalyst. Therefore, the second start-up fluid (1004) may include a catlyast activation agent, such as hydrogen (H2), which acts as a strong reducing agent to eliminate residual oxygen or oxidized species from the catalyst surface, thereby restoring its active sites. Catalyst activation is often conducted at elevated temperatures and the PLC (115) may initiate heating elements within the electric reactor cells (302) prior to introducing the second start-up fluid (1004).

[0123]

[0124] The PLC (115) may continue to distribute the second start-up fluid (1004) to the plurality of electric reactor cells (302) until the second predetermined start-up condition is identified by the startup condition sensors (418). A catalyst activation indicator may include a temperature threshold, as catalysts often have a known required activation temperature. Furthermore, the catalyst activation indicator may be determined through gas analysis via a gas chromatograph. During activation, gases may be released as impurities or oxides and removed from the catalyst surfaces. Start-up condition sensors, such as gas analysis instruments, may be able to detect the appropriate changes in the gas composition. Upon detecting the appropriate conditions, the PLC (115) may automatically actuate system valves to terminate the flow of the second start-up fluid (1004).

[0124]

[0125] Operating the start-up fluid processes in a series configuration allows unreacted or unused materials from one electric reactor cell (302) to pass to the next, thereby improving material utilization efficiency. This approach significantly reduces the volume of start-up fluids (1002, 1004) required, which is particularly advantageous when using costly reactants or operating in remote locations. Furthermore, series formations (120) reduce the need for complex manifold systems and associated instrumentation. Once the first and / or second predetermined start-up conditions have been identified using the PLC (115) and the start-up condition sensors (418), the start-up flow processes are transitioned into reactant input (101) flow processes, operating in parallel. As illustrated in Figure 2, parallel processing offers several benefits, including reduced energy consumption, lower pressure drop (psid), and improved energy efficiency. These advantages contribute to lower production costs, extended system longevity, and operational flexibility, such as the ability to scale production by adding additional reactor cells (302).

[0125]

[0126] By utilizing parallel flow for the reactant input (101) and series flow for the start-up fluids (1002, 1004), the system (1000) avoids the complexity and instrumentation burden associated with parallel start-up configurations. Parallel fluid processing typically requires intricate manifold systems, which increase the likelihood of equipment failure and elevate operational costs. These systems may be necessary for high-throughput reactant processing but are not essential for start-up operations. Additionally, automation of series-based start-up processes is inherently less complex than parallel configurations, which may require independent control systems for each reactor channel (105). Series processing reduces the number of independent flow paths, simplifies control architecture, and minimizes the volume of start-up fluid required, resulting in lower operational costs.

[0126]

[0127] While the system (1000) has been described as automatically transitioning from a series processing of a first and second start-up fluid (1002, 1004) to a parallel processing of the reactant input (101), alternative embodiments may reverse this configuration. In such embodiments, start-up fluids (1002, 1004) may be processed in parallel, while the reactant input (101) is processed in series. The selection of series (120) or parallel formations (100) may vary depending on system inputs, desired chemical reactions, and operational objectives. Figure 10 also illustrates a cooling fluid supply (1008) configured to enter the plurality of electric reactor cells (302) to regulate temperature sensitive zones. Although shown in a parallel configuration (100), the cooling fluid supply (1008) may alternatively operate in a series formation (120). A series arrangement may reduce the total volume of cooling fluid required and minimize piping infrastructure. In some embodiments, the cooling fluid supply (1008) may be configured to be in operation simultaneously with the input reactant (101) processing. Any number of series and parallel processing may be implemented in the current system (1000) without deviating from the scope of this disclosure. While the system (1000) has been described as initiating a start-up fluid (1002) and a second start-up fluid (1004) prior to reactant input (101) processing, the system may only initiate one of these start-fluids, or in a different order than described without deviating from the scope of this disclosure.

[0127]

[0128] It is to be understood that all features, functionalities, and variations described in connection with the hybrid reactor cell system (1000) are expressly incorporated into method embodiments, related to adjusting at least one of a production setting for at least one of a plurality of electric reactor cells (302). For example, using the hybrid reactor cell system (1000), the method of adjusting the production setting using the PLC (115) may include controlling the flow of the start-up fluid (1002) and the flow of the reactant input (101). This method may be employed whenever the plurality of reactor cells are configured to receive a start-up fluid (1002) in a series formation (120) and the reactant input (101) in a parallel formation (100). The method may include having the plurality of electric reactor cells (302) receiving the start-up fluid until at least one of a predetermined start-up condition is met, prior to receiving the reactant input (101). The first predetermined start-up condition used in the method may be a purging indicator, including an oxygen purging indicator. The method may also include having the plurality of electric reactor cells (302) configured to receive a second start-up fluid that enters the plurality of electric reactor cells (302) in a second series formation until a second predetermined start- up condition is met. In thse embodiments that make use of the second start-up fluid, adjusting a production setting may also include controlling the flow of the second startup fluid, using the PLC (115). The method may employ a pluratliy of system sensors, including startup condition sensors configured to identify at least one of the first predetermined start-up condition or the second predetermined start-up condition, where the second start-up fluid includes a catlyast activation fluid and the second predetermined start up condition includes a catalyast activation indicator.

[0128]

[0129] Figure 11 shows a simplified block diagram illustrating an example computer system ( 1100) that may be utilized in one or more example embodiments. The PLC (115) described in one or more example embodiments may be an example computer system (1100). In alternative embodiments, a distributed control system (DCS), or a supervisory control and data acquisition (SCAD A) system may be an example computer system (1100). The computer system (1100) can form part of or implement any of the systems and / or devices described above. The computer system (1100) such as the PLC (115), may be used to provide computational functionalities associated with described algorithms, including the hot swap algorithm and the flow balancing algorithm, methods, functions, processes, and any other procedures as described in this disclosure.

[0129]

[0130] The computer system (1100) can include a set of instructions (1145) that the processor (1105) can execute to cause the computer system (1100) to perform any of the operations described above. The computer system (1100) can operate as a stand-alone device or can be connected, e.g., using a network (1150), to other computer systems or peripheral devices, for example.

[0130]

[0131] In a networked example, the computer system ( 1100) can operate in the capacity of a server or as a client computer in a server-client network environment, or as a peer computer system in a peer-to-peer (or distributed) environment. The computer system (1100) can also be implemented as or incorporated into various devices, such as a PLC (115), a personal computer or a mobile device, capable of executing instructions (1145) (sequential or otherwise), causing a device to perform one or more actions. Further, each of the systems described can include a collection of subsystems that individually or jointly execute a set, or multiple sets, of instructions to perform one or more computer operations.

[0131]

[0132] The computer system (1100) can include one or more memory devices (1110) communicatively coupled to a bus (1120) for communicating information. In addition, code operable to cause the computer system (1100) to perform operations described above can be stored in the memory (1110). The memory (1110) can be random -access memory, read-only memory, programmable memory, a hard disk drive, or any other type of memory or storage device.

[0132]

[0133] The computer system (1100) can include a display (1130), such as a light-emitting diode (LED) display, liquid crystal display (LCD), a cathode ray tube (CRT), or any other display suitable for conveying information. The display (1130) may act as a human machine interface (HMI) for the user to visualize, monitor, and manipulate processing results produced by processor ( 1105). Additionally, the computer system (1100) can include an input device (1125), such as a keyboard or mouse or touchscreen, configured to allow a user to interact with components of system ( 1100).

[0134] The computer system (1100) can also include a disk or optical drive unit (1115). The drive unit (1115) can include a computer-readable medium (1140) in which the instructions (1145) can be stored. The instructions (1145) can reside completely, or at least partially, within the memory (1110) and / or within the processor (1105) during execution by the computer system (1100). The memory

[0133] (1110) and the processor (1105) also can include computer-readable media as discussed above.

[0134]

[0135] The computer system (1100) can include a communication interface (1135) to support communications via a network (1150). The network (1150) can include wired networks, wireless networks, or combinations thereof. The communication interface (1135) can enable communications via any number of communication standards, such as 802.3, 802.11, 802.12, 802.20, WiMAX, cellular telephone standards, or other communication standards.

[0135]

[0136] Accordingly, methods and systems described herein can be realized in hardware, software, or a combination of hardware and software. The methods and systems can be realized in a centralized fashion in at least one computer system or in a distributed fashion where different elements are spread across interconnected computer systems. Any kind of computer system (1100) or other apparatus adapted for carrying out the methods described herein can be employed.

[0136]

[0137] The methods and systems described herein can also be embedded in a computer program product, which includes all the features enabling the implementation of the operations described herein and which, when loaded in a computer system (1100), can carry out these operations. Computer program as used herein refers to an expression, in a machine -executable language, code or notation, of a set of machine-executable instructions intended to cause a device to perform a particular function, either directly or after one or more of a) conversion of a first language, code, or notation to another language, code, or notation; and b) reproduction of a first language, code, or notation. Such a computer program may be stored as instructions in a non-transitory computer-readable medium, for example.

[0137]

[0138] The above detailed description sets forth various features and operations of the disclosed systems, apparatus, devices, and / or methods with reference to the accompanying figures. The example embodiments described herein and in the figures are not meant to be limiting, with the true scope being indicated by the following claims. Many modifications and variations can be made without departing from its scope, as will be apparent to those skilled in the art. Functionally equivalent systems, apparatus, devices, and / or methods within the scope of the disclosure, in addition to those described herein, will be apparent to those skilled in the art from the foregoing descriptions. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations. Such modifications and variations are intended to fall within the scope of the appended claims. Finally, all publications, patents, and patent applications cited herein are hereby incorporated herein by reference for all purposes.

Claims

CLAIMS1. An electric reactor cell system comprising: a reactant input transported by an input feed; a plurality of electric reactor cells configured to transform the reactant input into a product output, wherein the plurality of electric reactor cells are secured to at least a first open skid; a plurality of system sensors configured to measure a reactor system setting and generate an input signal; and a programmable logic controller (PLC), configured to operatively communicate with the plurality of system sensors to receive the input signal and to automatically adjust at least one of a production setting, based at least in part, on the input signal.

2. The system of claim 1, wherein the reactor system setting comprises a temperature, a pressure, a flow rate, an electrical power, a feed flow or a measured product output.

3. The system of claim 1, wherein the production setting comprises a temperature, a pressure, a flow rate, a production capacity, an electrical power, and a movement of valves.

4. The system of claim 1 , wherein each of the plurality of electric reactor cells have a light housing in operative communication with the PLC, and wherein the reactor system setting comprises a temperature of an electrical component of the light housing.

5. The system of claim 1, further comprising a second plurality of electric reactor cells secured to a second open skid, wherein the second open skid is stacked on top of the first open skid.

6. The system of claim 1, further comprising: a reactant manifold, configured to partition the reactant input into each one of the plurality of electric reactor cells in a parallel formation along at least one of a reactor channel, wherein the plurality of electric reactor cells are configured to transform the reactant input into a plurality of channel product outputs along each reactor channel, and a product manifold configured to combine the plurality of channel product outputs to an exit feed; wherein the combined plurality of channel product outputs comprises the product output.

7. The system of claim 6, wherein the PLC is programmed with a flow balancing algorithm and wherein adjusting the production setting comprises balancing the reactant input flow between each reactor channel using the flow balancing algorithm.

8. The system of claim 6, wherein the PLC is programmed with a hot swap algorithm and wherein adjusting the production setting comprises performing a hot swap, using at least the hot swap algorithm.

9. The system of claim 1, wherein the plurality of electric reactor cells are configured to receive a start-up fluid in a series formation and wherein the reactant input is configured to enter the plurality of reactor cells in a parallel formation to produce the product output.

10. The system of claim 9, wherein adjusting the production setting using the PLC, comprises controlling the flow of the start-up fluid and the flow of the reactant input.

11. The system of claim 9, wherein the plurality of electric reactor cells are configured to receive the start-up fluid until at least one of a first predetermined start-up condition is met, prior to receiving the reactant input.

12. The system of claim 11, wherein the first predetermined start-up condition is a purging indicator.

13. The system of claim 12, wherein the purging indicator comprises an oxygen purging indicator.

14. The system of claim 9, wherein the plurality of electric reactor cells are further configured to receive a second start-up fluid that enters the plurality of electric reactor cells in a second series formation until a second predetermined start-up condition is met, prior to receiving the reactant input, and wherein adjusting the production setting using the PLC further comprises controlling the flow of the second start-up fluid.

15. The system of claim 14, wherein the plurality of system sensors comprises at least one of a start-up condition sensor configured to identify at least one of the first predetermined start-up condition or the second predetermined start-up condition.

16. The system of claim 14, wherein the second start-up fluid comprises a catalyst activation fluid and wherein the second predetermined start-up condition comprises a catalyst activation indicator.

17. A method of adjusting at least one of a production setting for at least one of a plurality of electric reactor cells, comprising: operating , using a programmable logic controller (PLC), an electric reactor cell system comprising the plurality of electric reactor cells secured to at least a first open skid, wherein the plurality of electric reactor cells are configured to transform a reactant input into a product output; measuring, using at least one of a plurality of system sensors, a reactor system setting; generating an input signal, using the plurality of system sensors; and transmitting the input signal to the PLC, wherein the PLC is in operative communication with the plurality of system sensors; andautomatically adjusting the production setting, using the PLC, based at least in part, on the input signal.

18. The method of claim 17, wherein the reactor system setting comprises a temperature, a pressure, a flow rate, an electrical power, a feed flow or a measured product output.

19. The method of claim 17, wherein the production setting comprises a temperature, a pressure, a flow rate, an electrical power, and a movement of valves.

20. The method of claim 17, further comprising a second plurality of electric reactor cells secured to a second open skid, wherein the second open skid is stacked on top of the first open skid.

21. The method of claim 17, wherein the electric reactor cell system further comprises: an input feed configured to transport the reactant input; a reactant manifold configured to partition the reactant input into each one of the plurality of electric reactor cells along at least one of a reactor channel, wherein the electric reactor cells are in a parallel formation and wherein the plurality of system sensors are disposed on each reactor channel; and a product manifold configured to combine a plurality of channel product outputs to an exit feed, wherein the combined plurality of channel product outputs comprises the product output.

22. The method of claim 21, wherein the PLC is programmed with a hot swap algorithm and wherein adjusting the production setting comprises performing a hot swap, using at least the hot swap algorithm.

23. The method of claim 22, wherein performing the hot swap comprises:operating, using the PLC, the electric reactor system at a first production capacity to obtain a cell stack benchmark production, wherein the first production capacity is less than a maximum production capacity; detecting, using the PLC, at least one of a target electric reactor cell from the plurality of electric reactor cells; disabling, using the PLC, the target electric reactor cell, while continuing to operate a remainder of electric reactor cells; increasing, using the PLC, the first production capacity of each of the remainder of electric reactor cells by a maintenance capacity factor to return the electric reactor cell system to the cell stack benchmark production; and activating a replacement electric reactor cell in the electric reactor cell system.

24. The method of claim 23, wherein performing the hot swap further comprises: operating the replacement electric reactor cell at the first production capacity; and decreasing a restored production capacity for each of the remainder of electric reactor cells by the maintenance capacity factor to return the electric reactor system to the cell benchmark production.

25. The method of claim 23, wherein calculating the maintenance capacity factor comprises: determining a cell maintenance production; subtracting the cell benchmark production by the cell maintenance production, to obtain a difference of production, and dividing the difference of production by the number of the remaining electric reactor cells to obtain the maintenance capacity factor.

26. The method of claim 23, wherein detecting the target electric reactor cell further comprises: receiving the input signal from at least one of the plurality of system sensors, and evaluating the input signal against an operational range metric.

27. The method of claim 21, wherein the cell stack benchmark production comprises the sum value of a measured product output from each of the plurality of electric reactor cells.

28. The method of claim 21, wherein the PLC is programmed with a flow balancing algorithm and wherein adjusting the production setting comprises performing a flow balancing, using at least the flow balancing algorithm.

29. The method of claim 27, wherein the flow balancing algorithm comprises the steps of: receiving the input signal from at least one of the plurality of system sensors; filtering a noise signal from the input signal to determine a true signal for each reactor channel; calculating an average system signal, based, at least in part, on the true system signal for each reactor channel; calculating a deviation between the average system signal and the true system signal for each reactor channel; evaluating each deviation against a predetermined condition, and for the deviation that does not satisfy the predetermined condition: sorting the deviation by its absolute value; selecting a proportional coefficient, based at least in part, on the sorted deviation value, and applying the proportional coefficient to the production setting.

30. The method of claim 17, wherein the plurality of reactor cells are configured to receive a startup fluid in a series formation and the reactant input in a parallel formation.

31. The method of claim 30, wherein adjusting the production setting using the PLC, comprises controlling the flow of the start-up fluid and the flow of the reactant input.

32. The method of claim 30, wherein the plurality of reactor cells are configured to receive the start-up fluid until at least one of a first predetermined start-up condition is met, prior to receiving the reactant input.

33. The method of claim 32, wherein the plurality of electric reactor cells are further configured to receive a second start-up fluid that enters the plurality of electric reactor cells in a second series formation until a second predetermined start-up condition is met, prior to receiving the reactant input, and wherein adjusting the production setting using the PLC further comprises controlling the flow of the second start-up fluid34. The method of claim 32 or 33, wherein the plurality of system sensors comprises at least one of a start-up condition sensor configured to identify at least one of the first predetermined start-up condition or the second predetermined start-up condition.

35. The method of claim 32, wherein the first predetermined start-up condition is a purging indicator.

36. The method of claim 33, wherein the second start-up fluid comprises a catalyst activation fluid and wherein the second predetermined start-up condition comprises a catalyst activation indicator.

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