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Hydrogen generation plant based on steam reforming

Mahler AGS hydrogen plants based on steam reforming of hydrocarbons cover hydrogen demands from 200 to 10.000 Nm³/h at purities up to 99,9999 vol.-% and typical product pressures from 10 bar to 30 bar(abs).


Steam reforming of natural gas, LPG or naphtha (feedstocks) with subsequent purification is the most economic and thus most common process for hydrogen generation and serves 95% of the world’s hydrogen demand.

Basic process steps:
The feedstock is desulphurized, mixed with steam and converted to synthesis gas in the top fired reformer furnace using nickel catalyst. The synthesis gas is cooled down in the heat recovery section and subsequently fed to the high temperature CO-conversion reactor followed by cooling and HYDROSWING PSA purification.

For a detailed process description and process flowsheet please click here.

The majority of Hydrogen is produced by steam methane reforming (SMR). Hydrogen is generated from a hydrocarbon (e.g. natural gas) and water at high temperatures in catalytic reformers. Typically, the Hydrogen is purified by using a PSA unit. About 95 % of the total global Hydrogen is used at the site where it is produced.

In most cases, the steam is generated inside the hydrogen plant by cooling down the hot process gas and the fluegas from the steam reformer.

At Mahler-plants the ignition of the burners is done automatically from the control container/room, no manual ignition by an operator is necessary. Mahler designs tailor-made and standard plants and has already built more than 4500 plants worldwide.

From a reasonable and economical point of view the operating pressure of the Hydrogen-PSA-unit, as part of a hydrogen generation plant as well as for a stand-alone plant, should be between 10 and 30 bar(abs).

Plant features of the HYDROFORM-C hydrogen generation plant

  • Design for long lifetime
  • High operational reliability
  • High quality and high safety standard
  • First class sub-suppliers for equipment and components
  • Fully automatic operation and remote control
  • Prefabrication in skids/modules
  • Easy maintenance and accessibility

Plant data

Natural gas, LPG, naphtha
Hydrogen capacity:
200 to 10.000 Nm³/h
Hydrogen product pressure:
10 – 30 bar(abs)
Hydrogen purity:
up to 99,9999 vol.-%

Typical consumption data for 1.000 Nm³/h hydrogen:

Natural gas:
430 Nm³/h
Demineralized water:
900 kg/h
Cooling water:
38 m³/h
Electric power:
38 kW

Additional/Optional features for hydrogen generation units:

Individual plant concepts with respect to desulphurization, export steam generation, product compression, turn-key delivery, water treatment, hydrogen product storage etc. can be offered.

Our plants are used worldwide. Especially for Russia, Belarus and Kazakhstan we are able to provide our plants with all necessary TR certificates and declarations for the import and operation in the Custom Union. Our HYDROFORM-C plants are equipped with a serial declaration according TR CU 010/2011 (MD), TR CU 004/2011 (LVD) and TR CU 020/2011 (EMC), valid until beginning of 2020. Certificates or declarations according TR CU 032/2013 for all pressure vessels as well as a TR CU 012/2011 certificate for the entire equipment placed inside areas with potentially explosive atmospheres are also part of our scope of supply.

HYDROFORM-C 6000 Nm³/h
HYDROFORM-C 6000 Nm³/h
Hydrogen plant
Hydrogen plant
Hydrogen plant
Hydrogen plant