Hydroform C: Steam
Methane Reforming (SMR)

The majority of hydrogen is produced by steam methane reforming (SMR). Hydrogen is generated from hydrocarbons (e.g. natural gas) and steam in a chemical reaction. Typically, the hydrogen is purified by using a PSA unit.

Hydroform C is designed for hydrogen production capacities from 200 to 20,000 Nm³/h per unit.

Mahler AGS plants produce hydrogen with an ultra-high purity of up to 99.9999 vol.%. This quality is required worldwide in numerous industrial sectors where even the slightest impurities can disrupt processes or impair products. Examples include electronics manufacturing (e.g. semiconductors), the glass industry (preventing streaks and defects), the food and pharmaceutical industries (ensuring high product safety), as well as chemical synthesis processes where long catalyst life and high activity are essential.
Lower purity levels can also be supplied upon request to meet specific customer requirements.

For hydrogen of 5.0 quality (99,999%) and higher, a precisely coordinated interplay of feed preparation, material conversion, and post-treatment is essential. The critical factor, however, lies in product purification. The downstream Hydroswing plants from Mahler AGS are fully automated pressure swing units, whose efficiency is based on the targeted selection and combination of different filling materials – the basis for high-quality product gas. It is only through Mahler AGS’s decades of operating experience that the process parameters and operating conditions can be optimally adjusted to reliably produce hydrogen of the highest purity.

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No. All reforming plants from Mahler AGS are equipped with an integrated steam generator that covers the entire steam demand by utilising process waste heat. In many cases, it is even possible to produce steam quantities exceeding the plant’s own requirements

At Mahler-plants the ignition of the burners is done automatically from the control container/room, no manual ignition by an operator is necessary.

Hydroform C plants are fully automated and designed for remote operation. Consequently, no personnel is needed on site. They also feature automated start-up and shutdown processes, as well as the capability for load adjustment and remote monitoring.

The plant achieves high energy efficiency through optimized heat recovery. Hot process and flue gases are used to preheat feed streams and generate process steam. This integrated heat management system significantly reduces overall fuel consumption.

The fully automated plant is delivered in the form of prefabricated modules, allowing for rapid on-site assembly. Mahler AGS provides full commissioning support, including start-up assistance and remote guidance, to ensure the plant quickly reaches full operational readiness.

Our hydrogen plants use hydrocarbons such as natural gas, methanol or naphtha as feedstocks. During the steam reforming of such feedstocks, CO₂ is produced as a result of the process, which is normally emitted into the atmosphere. Recycling the tail gas from the hydrogen treatment plant can substantially decrease the amount of fuel gas needed to supply the required cracking energy during the reforming process. This also leads to a reduction in CO2 emissions. The exact amount of emissions depends mainly on the feedstock and the plant capacity.

Mahler AGS plants offer the option of integrating carbon capture technologies into different process streams of the hydrogen plant. By storing or reusage of CO2, greenhouse gas emissions can be significantly lowered and the carbon footprint of the plant reduced. Besides the direct sale of CO₂, further revenue opportunities may arise through certificate trading in regions with suitable legal frameworks.