Hydrogen Generators for Oil & Gas Refining
High-purity on-site hydrogen generation for hydrocracking, desulfurization, hydrotreating, and reforming processes in petroleum refining operations.
Why Hydrogen in Oil & Gas Refining?
Hydrogen is essential for modern refining operations, enabling the production of cleaner fuels, removing sulfur and other contaminants, and upgrading heavy crude into valuable products.
Critical for Desulfurization
Hydrogen removes sulfur from crude oil and petroleum products through hydrodesulfurization (HDS), meeting stringent environmental regulations for ultra-low sulfur fuels.
Enables Heavy Crude Processing
Hydrocracking breaks down heavy crude oil molecules into lighter, more valuable products like diesel and gasoline, maximizing refinery profitability.
Lower Operating Costs
On-site hydrogen generation reduces costs by 30-50% compared to merchant hydrogen supply, delivered hydrogen, or steam methane reforming with carbon capture.
Supply Reliability
Eliminate dependency on external hydrogen suppliers and pipeline infrastructure. Generate hydrogen on-demand to match refinery processing requirements 24/7.
Improves Product Quality
Hydrotreating with high-purity hydrogen improves fuel stability, reduces emissions, enhances cetane and octane ratings, and extends product shelf life.
Scalable Capacity
Modular systems scale from small refineries (100 Nm³/hr) to mega-refineries (10,000+ Nm³/hr) to match your hydrogen consumption and future expansion plans.
Refining Applications
Our hydrogen generators serve critical applications across petroleum refining operations.
Hydrodesulfurization (HDS)
Remove sulfur compounds from crude oil fractions to produce ultra-low sulfur diesel (ULSD), gasoline, and other clean fuels meeting environmental regulations.
- Diesel desulfurization (ULSD production)
- Gasoline desulfurization
- Kerosene and jet fuel desulfurization
- Naphtha and light distillate treatment
Hydrocracking
Break down heavy crude oil molecules and vacuum gas oil into lighter, more valuable products like diesel, gasoline, and jet fuel through catalytic cracking with hydrogen.
- Vacuum gas oil (VGO) hydrocracking
- Residue hydrocracking (heavy crude upgrading)
- Mild hydrocracking for middle distillates
- Lube oil base stock production
Hydrotreating
Improve fuel quality by removing nitrogen, oxygen, and metals while saturating olefins and aromatics to enhance stability, cetane/octane ratings, and combustion properties.
- Naphtha hydrotreating for reformer feed
- Diesel and kerosene hydrotreating
- FCC feed hydrotreating
- Lube oil hydrotreating and dewaxing
Catalytic Reforming
Convert low-octane naphtha into high-octane gasoline blending components and aromatics (benzene, toluene, xylene) while producing hydrogen as a valuable by-product.
- Semi-regenerative reforming units
- Continuous catalyst regeneration (CCR)
- Aromatics production (BTX extraction)
- Hydrogen recovery and purification
Hydrogenation & Isomerization
Saturate unsaturated hydrocarbons and rearrange molecular structures to improve fuel properties, stability, and performance characteristics.
- Olefin saturation in gasoline and diesel
- Benzene hydrogenation to cyclohexane
- Isomerization of light naphtha
- Selective hydrogenation of pyrolysis gasoline
Specialty Refining Processes
Advanced hydrogen applications for specialty products, petrochemicals, and emerging refining technologies requiring high-purity hydrogen supply.
- Lube oil hydrofinishing and dewaxing
- Wax hydrocracking and isomerization
- Petrochemical feedstock purification
- Bio-refinery co-processing applications
Benefits for Refineries
Significant Cost Savings
Reduce hydrogen costs by 30-50% compared to merchant supply, pipeline delivery, or SMR with CCS
Supply Independence
Eliminate dependency on external hydrogen suppliers, pipelines, and market price volatility
24/7 Reliability
Continuous hydrogen production matches refinery operations without supply interruptions
Scalable Capacity
Modular systems grow with your refinery from 100 to 10,000+ Nm³/hr hydrogen production
High Purity Standards
99.9-99.999% hydrogen purity suitable for all refining catalysts and processes
Lower Carbon Footprint
Green hydrogen option using renewable electricity reduces refinery CO₂ emissions by up to 90%
Enhanced Safety
Eliminate high-pressure tube trailer deliveries and large-scale hydrogen storage risks
Rapid ROI
Typical payback period of 3-5 years through hydrogen cost savings and operational efficiency
Future-Proof Technology
Modular design allows easy expansion and integration with renewable energy sources
Technical Specifications
| Hydrogen Purity | 99.9% to 99.999% (refinery-grade) |
| Flow Rate | 100 to 10,000+ Nm³/hr (scalable for any refinery size) |
| Operating Pressure | Up to 30 bar(g) standard, higher pressures available |
| Outlet Pressure | Adjustable to match refinery hydrogen network |
| Dew Point | -60°C to -70°C (with integrated dryer) |
| Technology | Alkaline Water Electrolysis or PEM Electrolysis |
| Energy Consumption | 4.5-5.5 kWh per Nm³ of hydrogen produced |
| Startup Time | 15-30 minutes from cold start |
| Control System | Industrial PLC with DCS/SCADA integration capability |
| Monitoring | Real-time purity, pressure, flow, and temperature monitoring |
| Power Supply | 380-415V, 3-phase, 50/60 Hz (customizable) |
| Water Requirement | Deionized water, ~0.9 liters per Nm³ of H₂ produced |
| Installation | Containerized or skid-mounted for easy refinery integration |
| Availability | > 95% uptime with proper maintenance |
Refinery Hydrogen Consumption Guide
Typical hydrogen requirements for various refinery capacities:
- Small refinery (10,000 BPD): 500-1,000 Nm³/hr hydrogen
- Medium refinery (50,000 BPD): 2,500-5,000 Nm³/hr hydrogen
- Large refinery (200,000 BPD): 10,000-20,000 Nm³/hr hydrogen
- Mega refinery (500,000+ BPD): Custom multi-unit systems available
Safety & Compliance Features
Industrial-grade safety systems for refinery environments:
- ATEX/IECEx certified for hazardous areas
- Multi-point hydrogen leak detection
- Emergency shutdown and isolation systems
- Pressure relief and safety valves
- Continuous gas quality monitoring
- Automated purge and vent systems
- DCS/SCADA integration for refinery control
- API and ASME code compliance
Ready to Optimize Your Refinery Operations?
Contact our refining industry specialists to discuss your hydrogen requirements and receive a customized solution for your petroleum refining facility.