Industrial-grade hydrogen is a high-purity hydrogen gas produced specifically for large-scale industrial applications such as oil refining, chemical manufacturing, metallurgy, food processing, and energy systems. While not as ultra-pure as laboratory or semiconductor hydrogen, it maintains consistent quality suitable for continuous industrial operations.
Typical purity levels range from 99.5% to 99.99%, providing an optimal balance between performance, cost-efficiency, and scalability across diverse industrial sectors.
Key Characteristics
High and consistent purity (99.5%–99.99%)
Extremely high gravimetric energy density (120–142 MJ/kg)
Clean-burning fuel – water vapor as the only combustion product
Highly reactive reducing agent for chemical processing
Colorless, odorless, and non-toxic (asphyxiation risk in confined spaces)
Lightweight gas with rapid diffusion characteristics
Typical Production Methods
Steam Methane Reforming (SMR)
Most widely used global production route.
CH₄ + H₂O → CO + 3H₂
CO + H₂O → CO₂ + H₂
Autothermal Reforming (ATR)
Combines partial oxidation and steam reforming, well-suited for carbon capture integration.
Coal Gasification
Used in coal-rich regions; requires extensive purification and often CCUS.
Water Electrolysis
Alkaline or PEM electrolysis producing green, pink, or purple hydrogen.
By-Product Hydrogen Recovery
Recovered from chlor-alkali plants, ethylene crackers, and refinery off-gases.
Physical & Chemical Properties
| Property | Typical Value |
|---|---|
| Chemical Formula | H₂ |
| Purity (Industrial Grade) | 99.5% – 99.99% |
| Molecular Weight | 2.016 g/mol |
| Density (STP) | 0.0899 kg/m³ |
| Energy Content (LHV) | ~120 MJ/kg |
| Boiling Point | –252.9°C |
| Flammability Range | 4–75% in air |
| Auto-Ignition Temperature | ~585°C |
Typical Impurity Control Limits
| Impurity | Typical Limit |
|---|---|
| Oxygen (O₂) | < 10–100 ppm |
| Nitrogen (N₂) | < 100–1,000 ppm |
| Moisture (H₂O) | < 5–50 ppm |
| Carbon Monoxide (CO) | < 10–100 ppm |
| Carbon Dioxide (CO₂) | < 100 ppm |
| Sulfur Compounds | Trace |
Refining & Processing Role
Hydrocracking of heavy hydrocarbons into lighter fuels
Hydrotreating and desulfurization for ULSD and Euro-VI fuels
Fuel stability improvement via hydrogenation
Reduction of SOx and NOx precursors to meet emission norms
Available Supply Forms
Compressed hydrogen gas (150–700 bar cylinders or tube trailers)
Liquid hydrogen (−253°C cryogenic storage)
Pipeline hydrogen for continuous industrial supply
On-site hydrogen generation (SMR, ATR, electrolysis)
Industrial Applications
Oil & Gas Refineries: Hydrocracking, hydrotreating, isomerization
Chemicals: Ammonia, methanol, hydrogenation reactions
Metallurgy: Reduction, annealing, heat treatment
Glass & Electronics: Protective atmospheres, float glass
Food Industry: Vegetable oil hydrogenation
Energy: Hydrogen turbines, fuel cells, gas blending
Safety & Handling
Highly flammable gas with wide ignition range
Requires leak detection, ventilation, and explosion-proof systems
Hydrogen-compatible materials required to avoid embrittlement
Compliance with ISO 14687, CGA, NFPA 2, ATEX / IECEx standards
Industrial vs Other Hydrogen Grades
| Parameter | Industrial | Laboratory | Semiconductor |
|---|---|---|---|
| Purity | 99.5–99.99% | ≥99.999% | ≥99.9999% |
| Cost | Low–Medium | High | Very High |
| Volume | Very High | Low | Medium |
| Use Case | Bulk Industry | R&D | Microelectronics |
Strategic Importance
Industrial Grade Hydrogen is the backbone of global hydrogen consumption. It enables refinery modernization, cleaner fuel production, large-scale chemical manufacturing, and serves as a critical bridge between traditional fossil-based industries and the future green hydrogen economy.