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Industrial hydrogen system selection

Industrial Hydrogen Gas Generators

On-site H2 systems for factory process use: refining, ammonia, methanol, steel DRI, heat treatment, glass, chemical hydrogenation, data center backup power, H2 refuelling, semiconductors, labs, and high-purity applications. Gastek engineers, packages, commissions, and supports hydrogen generation systems around the actual use point.

Discuss H2 Requirement View Industrial Applications

Sizing Snapshot

Industrial H2 System

Purity

Based on technology, drying, and polishing package

Up to 99.999%

Pressure

Higher use-point pressure can be reviewed with compression

Up to 30 bar

Operation

PLC-controlled systems for process-critical H2 demand

Automatic

Common uses: Heat treatment·Hydrogenation·Generator cooling

1

Factory process hydrogen, not green-hydrogen hype

2

PEM or alkaline route selected from duty

3

Sizing around flow, purity, pressure, and safety

4

Engineered, packaged, commissioned, and supported

Selected Gastek industrial clients across gas generation applications

Trusted by serious steel, energy, chemical and pharma operators

Supplier experience across demanding factory and process environments in India and export markets.

Tata Steel - industrial client of Gastek Engineering

Steel

GAIL - industrial client of Gastek Engineering

Natural gas

Divi's Laboratories - industrial client of Gastek Engineering

Pharma

AM/NS India - industrial client of Gastek Engineering

Steel

Reliance Industries - industrial client of Gastek Engineering

Energy

Indorama Ventures - industrial client of Gastek Engineering

Polymers

JSW Group - industrial client of Gastek Engineering

Steel and energy

Farabi Petrochemicals - industrial client of Gastek Engineering

Petrochemicals

Why Gastek in hydrogen

The advantage is 30+ years of industrial gas generation, not startup hydrogen language.

Industrial hydrogen buyers need controls, utilities, safety, commissioning, and service discipline. That is where Gastek's nitrogen, HNX, ammonia cracking, and process-gas background becomes relevant.

Gas generation since 1993

Gastek's strength is industrial gas generation: utilities, controls, commissioning, service, and long-term plant support.

Industrial customer base

Hydrogen interest is coming from process plants that already understand the value of on-site gas generation.

Adjacent hydrogen experience

HNX protective gas, ammonia cracking, and hydrogen purification knowledge support a more mature H2 discussion.

System-level responsibility

The buying decision is not just the electrolyser stack. It is package engineering, safety, utilities, startup, and support.

PEM vs alkaline and technical specification

Choose the hydrogen generator route, then scope the complete plant package.

PEM and alkaline water electrolysis both produce hydrogen from water and electricity. The right industrial H2 generator depends on flow, purity, pressure, footprint, utilities, storage philosophy, controls, safety systems, commissioning, and the process use point.

Flow: Nm3/h, kg/day, peak uptake, operating hours

Quality: Hydrogen purity, dew point, pressure, contaminants

Delivery: Direct supply, buffer, compression, controls, safety

Compact high-purity route

PEM Hydrogen Generator

PEM electrolysis uses a solid polymer membrane and deionized water to generate high-purity hydrogen with fast response and compact plant layout.

Strong fit
Laboratories and analytical instruments, Fuel cell testing, Generator cooling, Dynamic or intermittent H2 demand
Selection logic
Best when gas quality, space, response time, and clean operation matter more than lowest cost at very large continuous load.
Strengths
No liquid caustic electrolyte | Fast startup and turndown | High-purity hydrogen output | Compact installation footprint

Industrial continuous-duty route

Alkaline Hydrogen Generator

Alkaline water electrolysis is a proven industrial route for steady hydrogen production where demand is continuous and plant economics matter.

Strong fit
Heat treatment and metallurgy, Glass manufacturing, Edible oil hydrogenation, Chemical and pharma hydrogenation
Selection logic
Best when the process has a stable hydrogen load and the plant can be engineered around industrial utilities and operating discipline.
Strengths
Proven industrial technology | Suitable for steady duty | Project-sized plant configuration | Working pressures up to 30 bar

Selection matrix

Match PEM or alkaline to the operating duty before quoting capacity.

Use this as a screening guide before final engineering, storage, and safety review.

Decision basis
PEM route
Alkaline route
Question to answer

Decision basis

Demand pattern

PEM

Fast response for variable or intermittent H2 demand

Alkaline

Steady production for continuous industrial loads

Ask first

Is your process batch-based, intermittent, or 24/7 continuous?

Decision basis

Purity requirement

PEM

Strong fit for compact high-purity applications

Alkaline

Can support industrial purity targets with gas conditioning

Ask first

What purity, dew point, and impurity limits are required at the use point?

Decision basis

Pressure and storage

PEM

Often paired with compact buffer and high-purity make-up use

Alkaline

Reviewed with receiver, compression, and process supply philosophy

Ask first

Do you need direct supply, buffer storage, or higher-pressure delivery?

Decision basis

Plant integration

PEM

Useful where footprint and clean operation are priorities

Alkaline

Useful where economics, duty cycle, and plant utilities drive selection

Ask first

What power, DI water, ventilation, and installation area are available?

Decision basis

Safety philosophy

PEM

Leak detection, purge logic, ventilation, and ESD still need design

Alkaline

Same safety discussion, often with larger system and storage decisions

Ask first

How will H2 detection, venting, ESD, and operator training be handled?

Technical scope and specification

Specify the complete H2 generator package.

Industrial hydrogen generation is specified around the total duty: electrolysis stack, power supply, water quality, drying, purification, compression, controls, safety, and commissioning.

Technology
PEM and alkaline water electrolysis systems
Hydrogen purity
Up to 99.999%, depending on technology and gas conditioning
Outlet pressure
Up to 30 bar as a standard project basis
Feed utilities
Deionized water and electrical power
Automation
PLC-based automatic operation with alarms and interlocks
Gas conditioning
Dryer, purifier, filtration, and compressor options based on application
Plant format
Skid-mounted or packaged system, configured around site and process needs
Support
Engineering review, installation guidance, commissioning, and operator training

Package architecture

A hydrogen plant is a system, not just an electrolyser stack.

The proposal should be sized from use-point data, not from a generic catalogue. These modules are reviewed together for PEM hydrogen generator and alkaline hydrogen generator projects.

01

Water treatment

DI water quality and feed monitoring

02

Power package

Rectifier, stack load, and electrical protection

03

Hydrogen stack

PEM or alkaline generation route

04

Gas conditioning

Separation, drying, purification, and filtration

05

Compression and buffer

Outlet pressure, storage philosophy, and use-point supply

06

Controls and safety

PLC, alarms, ESD, purge logic, and interlocks

Electrolysis can support low-carbon hydrogen when powered by renewable electricity, but this page is focused first on reliable industrial hydrogen supply for factories and process plants.

Application Map

Match the hydrogen generator to the process, not just the industry.

Hydrogen requirements change by process. A heat treatment furnace, edible oil reactor, glass line, generator cooling system, and lab instrument all need different flow, purity, pressure, dew point, safety, and operating assumptions.

Reduce

Create reducing atmospheres for metal processing, annealing, brazing, and sintering.

React

Supply hydrogen for hydrogenation, API synthesis, edible oils, and chemical processes.

Protect

Maintain protective atmospheres for glass, metallurgy, electronics, and process equipment.

Stabilize

Improve supply control where cylinders, tube trailers, or merchant gas create risk.

Industrial process
Hydrogen role
Sizing basis
Next step

Refinery hydrogen networks

Refining and hydrotreating

Hydrogen for refinery make-up supply, hydrotreating, desulfurization, hydrocracking, biofuel co-processing, and hydrogen-rich stream purification.

Make-up H2 / HDS and hydrotreating / PSA purification review

Make-up H2
HDS and hydrotreating
PSA purification review

Sizing basis

Unit demand, H2 flow, purity, pressure, dew point, storage, compression, controls

View

Ammonia and green fertilizer

Ammonia production

Hydrogen for ammonia synthesis, green ammonia projects, fertilizer plant decarbonization, H2/N2 feed preparation, and pilot Haber-Bosch loops.

NH3 feed hydrogen / Green ammonia support / H2/N2 ratio control

NH3 feed hydrogen
Green ammonia support
H2/N2 ratio control

Sizing basis

Ammonia TPD, H2 flow, N2 source, pressure, purity, compression, storage, power profile

View

Methanol and e-methanol feedstock

Methanol production

Hydrogen for methanol synthesis, green methanol, e-methanol, CO2 hydrogenation, syngas ratio adjustment, and pilot methanol loops.

Feedstock H2 / CO2 hydrogenation / Synthesis-loop interface

Feedstock H2
CO2 hydrogenation
Synthesis-loop interface

Sizing basis

Methanol capacity, H2/COx ratio, CO2 source, pressure, compression, storage, power profile

View

Steel DRI and green steel

Steel DRI and green steel

Hydrogen for direct reduced iron, green steel pilots, HBI, sponge iron, shaft furnace trials, and iron ore reduction projects.

Reducing gas / DRI process support / Green steel pilots

Reducing gas
DRI process support
Green steel pilots

Sizing basis

Ore feed, H2 flow, pressure, temperature, gas recycle, storage, controls

View

Fleet fuel and refuelling

H2 refuelling and fleet depots

Hydrogen generation for bus depots, truck fleets, forklift fleets, port logistics, H2 refuelling stations, and fleet demonstration projects.

Fleet kg/day demand / Compression and storage / Station package review

Fleet kg/day demand
Compression and storage
Station package review

Sizing basis

Vehicle count, kg/day, fill pressure, refuelling window, storage, compression, safety

View

Reducing and protective atmospheres

Metallurgy and heat treatment

Hydrogen for annealing, brazing, sintering, bright heat treatment, metal powder processing, and controlled furnace atmospheres.

Reducing atmosphere / Bright annealing support / H2/N2 atmosphere control

Reducing atmosphere
Bright annealing support
H2/N2 atmosphere control

Sizing basis

Furnace volume, H2 flow, H2/N2 mix, dew point, pressure, operating hours

View

Food and process hydrogenation

Edible oil hydrogenation

On-site hydrogen for edible oil hydrogenation, vanaspati, margarine, shortening, bakery fats, oleochemicals, and batch reactor supply.

Batch hydrogenation / Receiver and pressure control / Reduced cylinder dependence

Batch hydrogenation
Receiver and pressure control
Reduced cylinder dependence

Sizing basis

Batch size, hydrogen consumption, pressure, purity, food-grade requirements

View

Hydrogenation and synthesis

Chemical hydrogenation

Hydrogen for chemical hydrogenation reactors, specialty chemicals, catalyst reduction, oleochemicals, resins, fine chemicals, and feedstock-scale project screening.

Reaction feed gas / Catalyst process support / Batch and peak-flow review

Reaction feed gas
Catalyst process support
Batch and peak-flow review

Sizing basis

Reaction load, peak flow, purity, pressure, duty cycle, safety philosophy

View

API synthesis and pharma production

Pharma and API hydrogenation

Hydrogen for API hydrogenation, pharmaceutical intermediates, batch reactors, kilo labs, pilot plants, catalyst reduction, and pharma cylinder replacement.

API hydrogenation / Batch reactor supply / Documentation support

API hydrogenation
Batch reactor supply
Documentation support

Sizing basis

Reactor duty, peak uptake, purity, pressure, campaign schedule, receiver storage, safety

View

Float glass and specialty glass

Glass manufacturing

Hydrogen for float glass tin bath protection, solar glass, specialty glass, low-E coatings, and controlled H2/N2 atmospheres.

Tin bath protection / H2/N2 atmosphere / Surface quality support

Tin bath protection
H2/N2 atmosphere
Surface quality support

Sizing basis

Line demand, H2/N2 composition, pressure, dew point, continuous duty

View

Critical power and uptime

Data centers and backup power

Hydrogen for data center fuel-cell backup power, critical power microgrids, storage reserve planning, and diesel replacement studies.

Fuel-cell backup / Storage reserve / Critical power support

Fuel-cell backup
Storage reserve
Critical power support

Sizing basis

Critical load, backup hours, H2 kg reserve, fuel-cell quality, safety, controls

View

Power plants and rotating equipment

Stationary power and generator cooling

High-purity hydrogen supply for stationary fuel cells, generator cooling make-up gas, microgrids, turbine trials, and industrial backup power.

Cooling gas / Fuel-cell H2 / Power asset interface

Cooling gas
Fuel-cell H2
Power asset interface

Sizing basis

Load, make-up rate, purity, pressure, storage reserve, safety and monitoring needs

View

Ultra-high purity manufacturing

Semiconductor and electronics

Hydrogen for semiconductor tools, CVD, epitaxy, wafer processing, forming gas, display manufacturing, and high-purity electronics production.

CVD and epitaxy / Forming gas support / Ultra-high purity gas

CVD and epitaxy
Forming gas support
Ultra-high purity gas

Sizing basis

Tool count, peak flow, purity, dew point, pressure, filtration, uptime

View

High-purity and test environments

Laboratory and fuel-cell R&D

Hydrogen for analytical instruments, PEMFC and SOFC testing, stack validation, pilot labs, and high-purity R&D facilities.

Carrier or fuel gas / Test bench supply / Fuel-cell testing

Carrier or fuel gas
Test bench supply
Fuel-cell testing

Sizing basis

Instrument count, peak flow, purity, pressure, ramp rate, uptime requirement

View

Hydrogen safety

Safety engineering has to be part of the hydrogen proposal.

Hydrogen is not handled like nitrogen. The design discussion must include leak detection, ventilation, interlocks, purge logic, safe venting, pressure relief, storage philosophy, and operator training.

Industrial gas generation background

Gastek has worked in on-site gas generation since 1993. That background matters when hydrogen must integrate with plant utilities, process equipment, controls, commissioning, and after-sales support.

Safety inputs

Hydrogen leak detection and alarm integration
Emergency shutdown logic and interlocks
Safe venting, pressure relief, and isolation philosophy
Purge, startup, and shutdown sequence review
Ventilation and installation-area review
Operator training and commissioning support

Quote inputs

Required H2 flow rate

Purity or impurity target

Outlet pressure

Application and industry

Operating hours or duty cycle

Current H2 supply method

Power and DI water availability

Storage or no-storage preference

Safety constraints and installation city

These inputs help the team recommend PEM or alkaline electrolysis with a clearer technical basis.

Industrial Hydrogen FAQ

Questions buyers ask before specifying an on-site H2 system

What is the difference between PEM and alkaline hydrogen generators?

PEM hydrogen generators are usually selected for compact, high-purity, responsive applications. Alkaline hydrogen generators are often reviewed for steady industrial demand where duty cycle, project economics, and plant integration matter. The right route depends on flow, purity, pressure, operating pattern, utilities, footprint, and safety philosophy.

Can an on-site hydrogen generator replace cylinders or tube trailers?

It can be a strong option when hydrogen demand is regular, logistics are difficult, purity needs are repeatable, or supply continuity is important. Final selection should compare flow, pressure, operating hours, storage needs, electricity and water availability, safety requirements, and delivered-gas cost.

What hydrogen purity is possible from an industrial H2 generator?

Hydrogen purity can reach up to 99.999% depending on the electrolysis route, drying, purification, gas conditioning, and application requirement. The practical target should be specified from the process use point rather than from a generic catalogue value.

What pressure can an industrial hydrogen generator supply?

Project basis can be reviewed up to 30 bar, with higher use-point pressure considered through compression and storage design where suitable. Pressure selection should include process demand, receiver sizing, safety, and downstream regulation.

Which industries use on-site industrial hydrogen generators?

Common industrial uses include refining and hydrotreating, ammonia production, methanol production, steel DRI and green steel, H2 refuelling and fleet depots, heat treatment and metallurgy, edible oil hydrogenation, chemical hydrogenation, pharma API hydrogenation, glass manufacturing, data center backup power, generator cooling, laboratories, semiconductors, electronics, fuel-cell testing, and other high-purity hydrogen applications.

What safety systems are required for hydrogen generation?

Typical safety discussions include H2 leak detection, ventilation, emergency shutdown logic, purge sequences, pressure relief, safe venting, electrical classification review where applicable, storage philosophy, commissioning checks, and operator training.

Is Gastek focused on green hydrogen or industrial hydrogen?

This page is focused on industrial hydrogen for factory and process use. Electrolysis can support low-carbon hydrogen when powered by suitable electricity, but the immediate buying decision here is reliable industrial H2 supply for process applications.

Continue Research

Adjacent Gastek hydrogen systems

PEM and alkaline electrolysis are the focus here. Some processes also need H2/N2 atmospheres, cracked-ammonia gas, or hydrogen-rich stream purification.

HNX protective gas systemsFor controlled nitrogen-hydrogen protective atmospheres.Ammonia cracking unitsFor H2/N2 gas where cracked ammonia is the right process route.PSA hydrogen purificationFor purification of hydrogen-rich gas streams where applicable.

Route the discussion

Direct hydrogen from water and power: review PEM or alkaline electrolysis.

Controlled H2/N2 atmosphere: review HNX or ammonia cracking route.

Hydrogen-rich stream cleanup: review PSA hydrogen purification.

Useful before enquiry

Application, H2 flow, purity, pressure, duty cycle, utilities, and installation location.

Discuss H2 Requirement

Next step

Share your hydrogen requirement and get a system route, not a generic equipment quote.

Tell us the application, flow, purity, pressure, operating hours, site utilities, and installation location. Gastek can review whether PEM or alkaline water electrolysis is the right starting point for your process.

Application-led sizing

Flow, purity, pressure, and duty are reviewed before plant selection.

Automatic control package

PLC controls, alarms, and interlocks are planned around project needs.

Commissioning support

Installation, operator training, and handover support can be coordinated.

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