Hydrogen Industry
Gas Detection
Hydrogen is rapidly emerging as a cornerstone of the global energy transition, supporting decarbonisation across energy, transport and industrial sectors. When produced using renewable electricity, hydrogen offers a low‑carbon alternative to fossil fuels, helping organisations reduce emissions while maintaining energy security. However, hydrogen behaves very differently to conventional fuels. It is highly flammable, extremely prone to leakage and capable of igniting with very low energy, making effective hydrogen detection essential throughout the entire hydrogen process.
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Hydrogen Industry Gas Hazards
Hydrogen (H₂)
• Highly flammable between 4–75% VOL
• Extremely low ignition energy
• Lighter than air, requiring high‑level detection
Oxygen (O₂)
• Sole by‑product of water electrolysis
• Enrichment significantly increases fire and explosion risk
Methane (CH₄)
• Flammable feedstock in reforming processes
• Contributes to explosive atmospheres
Carbon Monoxide (CO)
• Highly toxic even at low concentrations
• Common by‑product of reforming processes
Carbon Dioxide (CO₂)
• Asphyxiant at elevated concentrations
• Heavier than air in enclosed spaces
Ammonia (NH₃)
• Toxic gas used for hydrogen storage and transport
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The Hydrogen Process
Hydrogen production environments represent some of the highest‑risk areas within the hydrogen economy. Hydrogen is generated within enclosed equipment, often under pressure, and frequently alongside other gases that can significantly increase the consequences of a leak.
Water Electrolysis
Water electrolysis plays a central role in the transition to greener hydrogen production. The process uses electrical energy to split water into hydrogen and oxygen. When powered by renewable electricity sources such as wind or solar, electrolysis enables the production of hydrogen with no carbon emissions at the point of generation.
A key advantage of water electrolysis is that the only direct by‑product of the process is oxygen. While this makes electrolysis an attractive low‑carbon production method, it also introduces a unique safety consideration. Oxygen enrichment within enclosed spaces significantly increases flammability and can dramatically accelerate combustion if hydrogen is present.
Within electrolyser installations, IGD typically deploys ATEX‑rated hydrogen detection using the TOC‑903‑X5. This allows hydrogen (%LEL) and oxygen (%VOL) sensors to be housed within a single transmitter, reducing installation complexity and cost while providing continuous monitoring of both gases. Where higher point density or remote sensing is required, TOC‑750X ATEX detectors are used alongside the TOC‑903‑X5.
Steam Methane Reforming
Steam methane reforming (SMR) remains a widely used hydrogen production method, particularly in established industrial environments. Unlike electrolysis, SMR relies on fossil fuel feedstocks and produces additional by‑product gases alongside hydrogen.
Hydrogen detection in SMR facilities must account for a broader range of flammable and toxic hazards. IGD deploys fixed hydrogen detection alongside multi‑gas monitoring and portable monitoring in these facilities.
Other Detection Technologies
Several other gas detection technologies exist; however, these are not recommended for hydrogen detection.
Infrared sensors are unable to detect hydrogen since diatomic molecules like hydrogen don’t absorb infrared radiation.
Thermal conductivity is another viable technology, though low sensitivity and selectivity render them poor for hydrogen detection applications.
Semiconductor gas detectors can be used to detect hydrogen; however, these sensors also typically respond to a wide range of other gases and vapours. The likelihood of false alarms means that semiconductor sensors are not advised for these applications.
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