Hydrogen Plant Archives | Hydrogengentech

In a world racing toward decarbonization, hydrogen has taken center stage as the fuel of the future. Yet, the logistics of hydrogen supply chains often pose barriers to adoption. This is where on-site hydrogen generation becomes a game-changing solution—offering industries autonomy, cost-efficiency, and alignment with sustainability mandates. From EPC contractors and industrial plant owners to renewable project developers, on-site generation presents both operational and strategic value.

What Is On-Site Hydrogen Generation?

On-site hydrogen generation refers to the process of producing hydrogen gas directly at the point of consumption, rather than transporting it from central production facilities. Most commonly, this is achieved using water electrolysis powered by renewable energy sources such as solar or wind. Other methods include natural gas reforming or methanol reforming, though green hydrogen via electrolysis is preferred for sustainability.

The core equipment for this setup includes an electrolyzer, balance of plant (BoP) systems like gas-lye separators and purification units, and a skid-mounted or modular containerized setup for easy integration. These systems are designed to scale with demand and can be fully automated with remote monitoring features.

Why Industries Are Shifting to On-Site Generation

Heavy industries often depend on hydrogen for refining, metal processing, glass production, semiconductor manufacturing, and ammonia synthesis. Traditionally, this hydrogen is supplied via gas cylinders or tanker trucks. However, these supply chains introduce risks—ranging from delays and storage hazards to cost fluctuations.

On-site generation addresses these concerns by providing a decentralized, reliable, and cleaner hydrogen source. It enables uninterrupted operations, minimizes dependence on third-party logistics, and reduces carbon emissions associated with hydrogen transportation.

Key Industrial Sectors Benefiting from On-Site Hydrogen

Steel and Metallurgy

Steelmakers are adopting hydrogen to replace coking coal in Direct Reduced Iron (DRI) processes. On-site hydrogen plants can be co-located with steel mills to ensure a continuous, high-purity supply. This also reduces the emissions footprint significantly, helping plants meet EU’s Carbon Border Adjustment Mechanism (CBAM) requirements.

Refineries and Petrochemical Plants

Refineries use large volumes of hydrogen for hydrocracking and hydrotreating. Generating hydrogen on-site using green energy helps reduce Scope 1 and 2 emissions. Skid-mounted hydrogen generation systems can be retrofitted into existing refining infrastructure with minimal disruption.

Electronics and Semiconductor Manufacturing

Ultra-high purity hydrogen is essential for chip fabrication and other semiconductor processes. On-site production reduces the risk of contamination during transit and enables 24/7 availability with real-time monitoring.

Glass and Ceramics

These industries require consistent high-temperature heat. Hydrogen combustion offers a low-emission alternative to natural gas or diesel-based heating. With on-site generation, companies can maintain tight control over fuel input quality and flow.

Fertilizer and Ammonia Plants

Traditionally, hydrogen for ammonia production comes from natural gas (via SMR). On-site green hydrogen systems allow producers to make low-carbon ammonia, which is increasingly in demand as both a fertilizer and hydrogen carrier.

Technological Components That Power On-Site Hydrogen Generation

Electrolyzers

Electrolyzers split water into hydrogen and oxygen using electricity. PEM and alkaline electrolyzers are most common. HGPL’s systems support both technologies with proven European designs for efficiency and scalability.

Balance of Plant (BoP) Systems

These include hydrogen purification units, gas-lye separators, heat exchangers, compressors, and safety instrumentation. HGPL manufactures fully integrated BoP skids that adhere to ISO 9001:2015 and can be customized for flow rates and purity.

PLC-Based Control Panels

Advanced automation through PLC and SCADA ensures optimal performance, real-time diagnostics, and operational safety. These systems can be remotely monitored for predictive maintenance.

Business Advantages of On-Site Hydrogen Generation

Implementing an on-site hydrogen system is more than a sustainability play—it’s a strategic move that offers long-term operational and financial advantages.

Cost Control: Avoids recurring transportation and cylinder refilling costs.
Reliability: Reduces downtime caused by delivery delays or shortages.
Scalability: Modular systems grow with your production needs.
Safety: Minimizes high-pressure gas handling and storage risks.
Brand Positioning: Strengthens ESG profile and investor appeal.

Incentives for Indian Businesses

Under India’s National Green Hydrogen Mission, several subsidies and incentives are being offered for green hydrogen adoption, including:

Capital subsidies for electrolyzer installation
Viability gap funding for green hydrogen projects
Policy push for public procurement of green hydrogen in steel, fertilizer, and transport sectors

HGPL supports clients in navigating these incentives through feasibility studies and DPR support.

As the world accelerates toward sustainability, on-site hydrogen generation offers a flexible, cost-effective, and future-ready solution. It enables industries to control their energy inputs, meet compliance standards, and reduce carbon emissions—all while staying competitive.

Hydrogen Gentech Private Limited (HGPL) provides turnkey on-site hydrogen generation solutions—including design, fabrication, commissioning, and maintenance—tailored to diverse industrial needs. As one of India’s leading hydrogen EPC firms, we empower businesses to lead in the green transition. Let’s build the hydrogen future, together.

FAQs

How much space is required for an on-site hydrogen generation unit?

Depending on the capacity and design, a typical containerized skid occupies between 100–300 square feet. Modular systems can be stacked or expanded based on site constraints.

Is the hydrogen generated on-site safe?

Yes. Modern systems are equipped with leak detection, pressure relief valves, and explosion-proof enclosures. Automated shutdowns and remote alerts enhance safety.

What is the purity of on-site produced hydrogen?

HGPL systems deliver up to 99.999% purity using advanced Deoxo dryers and purification skids, compliant with industrial-grade requirements.

Can I integrate solar or wind with the electrolyzer?

Absolutely. Our PLC-integrated systems support renewable energy inputs and optimize electrolyzer operation based on power availability.

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Hydrogen Gentech Private Limited (HGPL) is pleased to announce that it has been selected by Coastal Industrial Gas P Limited for a significant project in Andhra Pradesh, India. HGPL will be responsible for the Design Engineering, Manufacturing, Supply, Erection Supervision, and Commissioning of a 100 Nm3/Hr Hydrogen Generation and Purification Plant.

HGPL’s scope of work for this project encompasses several critical phases:

Design Engineering: HGPL’s experienced engineering team will design the hydrogen generation and purification plant to meet the client’s specific requirements and industry standards. This includes detailed planning and schematics to ensure efficient operation and safety.
Manufacturing: The manufacturing process will involve the production of high-quality components and systems needed for the plant. HGPL’s state-of-the-art manufacturing facilities are equipped to handle the complexities of hydrogen generation and purification equipment.
Supply Completed: All necessary equipment and materials will be supplied to the project site. HGPL will ensure that everything is delivered on time and meets the stringent quality standards expected by the client.
Erection Supervision: HGPL’s team of experts will supervise the erection of the plant, ensuring that all components are installed correctly and efficiently. This phase is crucial for the overall success of the project, as proper installation is key to operational reliability.
Commissioning: Once the plant is erected, HGPL will oversee the commissioning process, which includes rigorous testing and validation to ensure the plant operates as intended. This phase ensures that the plant is ready for full-scale hydrogen generation and purification.

About Coastal Industrial Gas P Limited
Coastal Industrial Gas P Limited is a leading industrial gas company based in Andhra Pradesh, India. The company is known for its commitment to innovation and excellence in the field of industrial gases. This new hydrogen generation and purification plant will enhance their capabilities and support their mission to provide high-quality gas solutions to their clients.

About HGPL
Hydrogen Gentech Private Limited (HGPL) is a renowned name in the hydrogen generation industry, known for its expertise in designing, manufacturing, and commissioning state-of-the-art hydrogen plants. HGPL’s commitment to innovation, quality, and customer satisfaction has positioned it as a preferred partner for leading industrial gas companies.

Conclusion
HGPL is honoured to partner with Coastal Industrial Gas P Limited for this prestigious project. The successful completion of this hydrogen generation and purification plant will mark another milestone in HGPL’s journey of delivering cutting-edge hydrogen solutions. We look forward to contributing to Coastal Industrial Gas P Limited’s growth and success with our advanced technology and unparalleled expertise.

Stay tuned for more updates on the progress of this exciting project!

For more information about HGPL and its services, please visit our website or contact our sales team.

Hydrogen Gentech Private Limited (HGPL) has achieved a significant milestone by successfully commissioning a state-of-the-art Hydrogen Generation & Purification Plant based on Water Electrolysis technology at Divis Laboratories Limited, India. Divis Laboratories Limited, one of India’s leading pharmaceutical companies, boasts the world’s largest Active Pharmaceuticals Ingredients (API) manufacturing facility, equipped with advanced manufacturing and in-house analytical facilities. Notably, the company holds a substantial global market share, ranging from 60% to 85%, in generic naproxen, dextromethorphan, and gabapentin APIs, with a production process that is backward integrated.

HGPL’s contribution to this project involved a comprehensive scope of work, including design, engineering, manufacturing/supply, erection supervision, and commissioning. The Hydrogen plant facility consists of two independent streams, jointly capable of generating an impressive 3600 Nm3/day of high-purity Hydrogen. This high-purity hydrogen is a valuable resource utilized across diverse applications in the pharmaceutical, steel, glass, and chemical industries.

The heart of the facility is the Stack, which is essentially a series of cells where DC power is applied to initiate an electrolytic reaction at high pressure, effectively splitting water into hydrogen and oxygen. The process then involves the separation of raw hydrogen and oxygen from Lye and moisture, with oxygen being vented out while the hydrogen proceeds to the purification stage. Here, hydrogen is further purified using a deoxo reactor and subjected to a drying process, resulting in the production of high-purity dry hydrogen.

The facility’s operation is meticulously controlled by a PLC (Programmable Logic Controller) system, ensuring seamless and automatic operation while adhering to international safety standards. HGPL’s expertise in designing, engineering, manufacturing, supplying, and successfully commissioning water electrolysis technology-based Hydrogen plants is a testament to their technical capabilities.

Hydrogen Gentech Private Limited (HGPL) is a renowned international EPC (Engineering, Procurement, and Construction) company specializing in technology-based Hydrogen Generation plants. Operating out of India, HGPL is dedicated to Green Hydrogen Generation, Purification, Recovery, Storage solutions, and their applications across various industries, including renewable energy, fuel, and mobility sectors. With a strong commitment to advancing hydrogen technology, HGPL continues to make significant strides in the field of hydrogen generation and its diverse applications.

Hydrogen Gentech Private Limited (HGPL), an international technology based company specializing in hydrogen generation plants, has recently secured a noteworthy Engineering, Procurement, and Construction (EPC) contract from Hygenco India. The contract entails the development of a multi-megawatt scale green hydrogen facility in India, which will be owned and operated by Hygenco India. This ground-breaking project aims to significantly reduce carbon emissions by approximately 2,700 metric tons annually.

The selection of Hydrogen Gentech Private Limited (HGPL) for this project serves as a testament to the company’s exceptional EPC capabilities, enabling it to actively contribute to the establishment of top-tier, competitive, and cost-efficient green hydrogen facilities on behalf of its esteemed clientele. Company officials expressed their enthusiasm for this opportunity, emphasizing their commitment to delivering high-quality solutions.

Hydrogen Gentech Private Limited (HGPL)’s scope of work encompasses a comprehensive range of tasks, including detailed engineering, procurement, and the supply of the H2 purification unit, storage tanks, and various other equipment. Additionally, the company will be responsible for the erection and construction of the green hydrogen facility.

The significance of adopting green hydrogen, as highlighted in the National Hydrogen Mission document published by the Government of India, Green Hydrogen is deemed crucial for key industries such as steel, fertilizers, and refineries, particularly for a country like India that heavily relies on energy imports. By actively engaging in the development of green hydrogen facilities, Hydrogen Gentech Private Limited (HGPL) aligns itself with the national vision outlined in the government’s mission document.

Hydrogen Gentech Private Limited, headquartered in India, has established itself as a reputed manufacturer and supplier in the field of hydrogen generation plants. The company’s unwavering focus on green hydrogen generation, purification, recovery, storage solutions, and their application in various sectors including, renewable energy, fuel, and mobility solidifies its position as an industry leader.

The Indian Army has taken a major step towards promoting sustainable energy by signing an MoU with National Thermal Power Corporation Renewable Energy Limited (NTPC REL) for the installation of a Green Hydrogen-based Micro Grid Power Plant project in the Northern borders. This initiative aligns with the National Green Hydrogen Mission, which seeks to promote the use of renewable energy and reduce dependence on fossil fuels.

Under the MoU, the Indian Army will provide land on lease for 25 years and commit to purchasing the generated power through a Power Purchase Agreement (PPA). The proposed project will be set up by NTPC on Build, Own, and Operate (BOO) Models at a mutually identified location in Eastern Ladakh. The project will involve the installation of a Solar Power Plant for the hydrolysis of water to produce Hydrogen. The Hydrogen produced will then be used to power fuel cells during non-solar hours, thus reducing dependence on fossil fuel-based generator sets and contributing towards the abatement of greenhouse gas emissions.

This project is a significant milestone for the Indian Army, as it is the first government organization to enter into an agreement with NTPC REL for such a project. It sets the stage for similar projects in the future, promoting sustainable energy and reducing the country’s dependence on fossil fuels. This initiative will not only benefit the environment but also help meet the energy requirements of the Indian Army in remote areas where there is no access to national/state grids.
Overall, the Indian Army’s decision to install a Green Hydrogen-based Micro Grid Power Plant project is a major step towards promoting sustainable energy in the country. The success of this project will pave the way for similar initiatives, encouraging other government organizations to adopt sustainable practices and contribute towards the goal of reducing greenhouse gas emissions.

Balaji Speciality Chemicals Limited (BSCL), a subsidiary of Balaji Amines Limited, has selected Hydrogen Gentech Private Limited (HGPL) to design, engineer, manufacture, supply, and commission its Hydrogen Purification Unit. The unit will generate high-purity hydrogen using the Methanol cracking process.

To produce high-purity hydrogen, the H2 Purification process technology involves a process study of the composition of mixed gas received at the outlet of the Methanol cracking reactor. This study determines the suitable adsorbents required to remove each impurity via adsorption-based removal and achieve the desired purity level of the hydrogen product.

The PSA-based hydrogen purification system will have five towers working cyclically in different phases of H2 generation and tower regeneration stages. Each of the five towers will cyclically work in high purity H2 generation mode while the other four towers operate in different stages of pressurization, depressurization, equalization, and regeneration modes. This design allows for the continuous generation of pure H2.

The adsorber tower for the PSA-based hydrogen purification system will consist of a customized multi-layered, molecular sieve-based adsorption bed system based on the type and quantum of impurities present in the mixed gas streams. The design will ensure that high-purity H2 is generated while minimizing the loss of any H2 during the adsorption process.

HGPL’s scope of work includes detailed engineering, procurement, manufacturing, supply, erection supervision and commissioning, Performance Guarantee Test Run (PGTR), and training. The PGTR will ensure that the unit performs as per the specified parameters and guarantees the performance of the system.

The Hydrogen Purification Unit will be fully automatic, with a control system that includes all safety measures. The PSA-based hydrogen purification technology is a popular route to establish small and medium capacity H2 generation plants, making HGPL a fast-emerging key technology player in India in the field of Hydrogen generation and Purification systems using the Methanol cracking process.

Hydrogen Gentech Private Limited (HGPL) is an international technology-based Hydrogen Generation Plant EPC Company, manufacturer, and supplier based in India. The company has a clear focus on Green Hydrogen Generation, Purification, Recovery & Storage solutions & their applications in Industry, Renewable Energy, Fuel, and Mobility sectors.