HYCAL™
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Why Choose HYCAL™
HYCAL™ goes beyond a simple one-time reading. It is a true process control tool that helps producers better understand metal behavior, adjust their operations more quickly, and improve the consistency of their results.
With its direct measurement principle, speed, accuracy, long-lasting universal probe, and digital integration capabilities, HYCAL™ offers a high-performance solution for operations looking to modernize the monitoring of dissolved hydrogen in liquid aluminum.
How It Works
The Hycal enables real-time measurement of dissolved hydrogen in liquid aluminum alloys, a critical parameter for controlling the quality of molten metal. The technology is based on a ceramic material capable of conducting hydrogen ions at high temperatures. When there is a difference in hydrogen concentration on either side of this ceramic, an electrical voltage is generated. This voltage is then used to accurately determine the hydrogen concentration.
The sensor incorporates a patented internal solid-state reference, which provides a stable and known hydrogen concentration. By comparing this reference to the gas present in the measurement chamber, the analyzer directly calculates the hydrogen content. During analysis, hydrogen dissolved in the bath passes through a porous diffusion barrier located at the tip of the probe and forms a gas measured by the cell.
To ensure a measurement representative of actual process conditions, the analyzer also accounts for the bath temperature and the alloy composition, since hydrogen solubility varies with these parameters. This approach provides a reliable, accurate, and directly actionable measurement for process monitoring and metallurgical quality control.
The Probe: The Heart of The Technology
The HYCAL™ probe is at the heart of the system’s performance. It is designed to provide reliable measurements, ease of use, and improved operational efficiency.
Superior Durability
A HYCAL™ probe typically allows for up to 100 measurements or approximately 20 hours of cumulative immersion. This extended service life significantly reduces replacements, operator intervention, and operating costs.
Universal design
HYCAL™ uses a universal probe compatible with all aluminum alloys, eliminating the need to manage multiple probe types depending on the application.
Integrated thermocouple
The probe includes an integrated thermocouple, eliminating the need for an external device to measure temperature and simplifying field use.
Integrated Traceability
Each probe is equipped with an EEPROM chip containing, among other things, the serial number, calibration data, immersion time, and usage history. This feature improves traceability, reduces the risk of operator error, and supports better quality control.
Available models
The HYCAL™ series has been designed to meet a variety of operational needs, ranging from mobile measurement requirements to fixed and automated installations. The models offered by STAS in the Americas are the HYCAL™ Mk4, the HYCAL™ 1000, the HYCAL™ 100, and the HYCAL™ 200.
HYCAL™ Mk4
The HYCAL™ Mk4 is the go-to model for environments where mobility, flexibility, and portability are key. It is the flagship portable model in the range, well-suited for operations that need to take measurements at different locations throughout the plant while maintaining a high level of accuracy and reliability.
HYCAL™ 1000
The HYCAL™ 1000 is designed for fixed installations and more automated environments. Panel-mounted, it is intended for operations that require deeper process integration, with PLC-controlled measurements and an architecture better suited to connectivity and automation needs.
HYCAL™ 100
The HYCAL™ 100 is a more economical and streamlined version of the HYCAL™ 1000. Also panel-mounted, it is particularly well-suited for multiplexed installations or for plants that wish to integrate HYCAL™ technology into an existing infrastructure, notably via their own PLC/HMI. It is the right choice when seeking the benefits of HYCAL™ with a simpler approach and reduced CapEx.
HYCAL™ 200
The HYCAL™ 200 stands out for its ability to measure simultaneously at two locations from a single station. This configuration is particularly useful when comparing two points in the process—for example, before and after a degasser—or when continuous readings at two positions provide better visibility into metal treatment performance.
“Distribution in North America
STAS is the exclusive distributor and support partner for HYCAL™ in the casthouse sector across North America, under license from EMC
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Key Features
Direct, real-time measurement
- Real-time measurement of dissolved hydrogen in molten aluminum alloys.
- Direct measurement technology based on a hydrogen concentration cell.
- Patented internal reference ensuring stable and accurate measurements.
Enhanced process control
- Enables better control of hydrogen content during production and casting operations.
- Takes molten aluminum temperature and alloy composition into account in the calculation.
- Can be used to control degassing or gassing operations based on a target hydrogen value, rather than a fixed processing time.
Simplified integration and use
- Includes PC software for data visualization, remote control, and secure data archiving.
- Easy integration into an existing SCADA system via the PROFINET / EtherNet/IP.
- Advanced user interface with access levels based on user profiles.
- Onboard diagnostics monitoring sensor status, flow rate, and internal pressure, with alert messages and recommendations.
Other compatible equipment – Metal treatment and casthouse technologies
Metal treatment and casthouse technologies