On-site hydrogen generation for bus depots, truck fleets, forklift fleets, H2 refuelling stations, port logistics and fuel-cell mobility trials. Gastek reviews the generator, compression, storage, dispensing interface, fuel quality, controls and safety scope as one station package.
Sizing Snapshot
Fleet H2 Station
Common users
Buses, trucks, forklifts, port equipment, captive fleets and demonstration projects
Fleet depots
Fuel quality
Fuel-cell purity, drying and contaminant limits should be confirmed with vehicle requirements
OEM-led
Station scope
Generation, storage, compression, dispensing interface, controls and safety review
H2 + compression
Bus depots
Truck fleets
Forklifts
Daily kg demand, refuelling windows, vehicle count and back-to-back filling behavior are more important than a generic electrolyser size.
A refuelling project needs generation, drying, storage, compression and dispensing pressure to be reviewed together.
Bus depots, forklifts, logistics yards and port equipment create controlled demand that is easier to engineer than scattered public refuelling.
Captive refuelling starts with depots that have known vehicle count, known refuelling windows, predictable kg/day demand and enough site control to engineer storage, compression, ventilation and safety.
Daily depot refuelling
Heavy-duty trial corridors
Warehouse and material handling
Captive or public refuelling
Pilot and demonstration supply
Detection, venting, zoning
Mobility Applications
Hydrogen mobility enquiries become actionable when they define vehicle count, kg/day, fill pressure, fill time, refuelling window, storage philosophy and safety boundaries.
Transit and captive fleets
Support city bus depots, airport buses and captive passenger fleets where vehicles return to a controlled refuelling site each day.
Logistics and corridor pilots
Review on-site hydrogen for truck fleet pilots, industrial logistics yards and heavy-duty routes where high utilisation needs predictable fuel supply.
Warehouses and plants
Use compact on-site hydrogen supply for forklifts and material-handling equipment where fast refuelling and controlled indoor operations matter.
Station package review
Scope on-site generation as part of a wider H2 station package with drying, compression, cascade storage, dispensing interface and safety systems.
Captive mobility hubs
Support heavy equipment, shuttles, yard trucks and captive vehicles at ports, factories and logistics parks with a single engineered supply point.
Early fleet validation
Configure smaller hydrogen generation packages for fuel-cell trials where the buyer needs real operating data before full station investment.
Station Selection
A fleet H2 station is not specified from generator capacity alone. The refuelling event, compressor, storage bank and controls decide whether vehicles can be filled on time.
| Application | Hydrogen Role | Specification Focus |
|---|---|---|
| Bus depot | Daily fleet fuel production | Vehicle count, kg per bus, refuelling window, storage reserve and depot operating schedule |
| Truck fleet | Heavy-duty hydrogen fuel | Daily distance, kg/day, peak fills, compression duty and pilot-to-scale expansion |
| Forklift fleet | Shift-based material-handling fuel | Forklift count, shift pattern, indoor safety, fill location and cylinder replacement target |
| H2 refuelling station | Generation feed to station package | Fuel quality, drying, compression, cascade storage, dispenser pressure and controls |
| Fleet trial | Demonstration hydrogen supply | Test duration, fuel-cell supplier requirement, metering, data logging and modular expansion |
Engineering Scope
The H2 generator is only one part of a mobility project. A complete discussion includes fuel quality, drying, compressor duty, storage, dispenser interface, leak detection, venting, site layout and operating procedure.
Vehicle count, kg per vehicle, daily route, refuelling time, peak fills and future expansion set the station basis.
Fuel quality, dryness, pressure and contaminant limits should be agreed from vehicle, fuel cell and dispenser requirements.
The compressor and storage bank must support the actual fill sequence, not only average daily production.
Ventilation, access, safety distances, electrical area, weather exposure, operator workflow and maintenance access affect the package.
Define metering, alarms, ESD, purge logic, sequencing, operator training and interface with station controls.
Two depots with the same daily demand can need different packages if the refuelling window and peak fill rate differ.
Vehicle and fuel-cell supplier requirements should drive gas drying, purification, filtration and commissioning checks.
Dispenser pressure, fill sequence and storage bank design determine whether the fleet can refuel within the available window.
PEM and alkaline generation should be reviewed against station duty, response, purity, footprint and lifecycle cost.
View hydrogen generatorsThe useful starting point is a fleet operating profile. From there, the generation, storage, compression and controls can be sized with fewer assumptions.
Fleet type: bus, truck, forklift, port vehicle, campus vehicle or public station
Vehicle count, kg per vehicle, daily kg demand and expected growth
Fill pressure, fill time, refuelling window and peak fills per hour
Fuel quality requirement from vehicle or fuel-cell supplier
Storage philosophy, backup requirement and compressor expectations
Site layout, ventilation, safety distances and installation location
Power, water, weather exposure, operator access and maintenance access
Controls, metering, alarms, ESD, purge logic and dispenser interface
Yes, but the station scope also needs drying, compression, storage, dispensing interface, controls and safety systems. The generator should be sized from kg/day and the fill profile.
Captive fleets are often practical because vehicle count, refuelling windows and kg/day demand are known. Bus depots, truck fleets, forklift fleets, logistics yards and port equipment can be reviewed around a controlled site and repeatable fuel demand.
Usually no. Generation pressure, drying, compression, cascade storage and dispensing pressure must be reviewed as a station package. The compressor and storage design handle the final refuelling profile.
Share vehicle count, kg/day, kg per fill, fill pressure, refuelling window, peak fills per hour, fuel quality, site layout, power, water, storage and safety requirements.
Mobility hydrogen is usually a fuel-supply and refuelling-station duty with compression, storage, dispensing, metering and safety systems. Fuel-cell test hydrogen is usually a smaller lab or test-bench supply with different flow and operating requirements.
Start with vehicle count, kilograms per vehicle, daily mileage or duty cycle, fill window and peak fills per hour. Average kg/day is not enough because compression, storage and dispenser sizing depend on the refuelling pattern.
A practical station review includes hydrogen drying, compression, cascade or buffer storage, cooling where required, dispenser interface, controls, metering, leak detection, ventilation, ESD and site safety layout.
Share vehicle count, daily kg demand, fill pressure, refuelling window, fuel quality, storage philosophy and site constraints. Gastek can review the H2 generator as part of the full station package.
