DDH-HyCO Series On-Site Hydrocarbon Mixture Generator

This syngas generator produces high-purity syngas exclusively composed of hydrogen and carbon monoxide via advanced methanol reforming technology.

Fabricated as a compact integrated skid-mounted unit, the system integrates reforming, gas conditioning and optional purification modules to deliver stable, on-demand syngas. Replacing conventional decentralized gas supply approaches, it drastically reduces logistics costs and provides consistent, reliable syngas feedstock for industrial synthesis processes.

Features

  • Adjustable H₂/CO ratio – Output composition can be tuned to meet specific process requirements (e.g., 1:1, 2:1, or custom)

  • Up to 99.99% total purity – Combined H₂+CO purity with minimal impurities

  • Seamless integration – Skid‑mounted, explosion‑proof, pre‑piped for fast on‑site installation

  • 5‑year catalyst lifetime – Longer than industry standard (2‑3 years), reducing downtime and maintenance

  • IoT‑enabled remote intelligence – Full remote monitoring, telemetry & telecontrol for unattended operation

Applications

  • Chemical synthesis – Production of methanol, acetic acid, formaldehyde, and other C1 chemicals

  • Pharmaceuticals – Syngas as a feedstock for carbonylations and hydrogenations

  • Metal processing – Reducing atmosphere for direct reduced iron (DRI) or specialty alloys

  • Glass & ceramics – Protective or reactive atmosphere in high‑temperature processes

  • Power generation – Fuel for gas engines or gas turbines in combined heat and power (CHP) systems

On-Site Integrated Hydrocarbon Mixture Production

Our DDH-HyCO syngas generator is tailored to produce custom hydrocarbon mixture on-site via mature methanol reforming technology. System configuration is determined by hydrocarbon mixture output volume, adjustable internal molar ratio, overall gas purity, outlet delivery pressure, site space constraints, upfront investment and long-term operational costs.
We supply complete skid-mounted turnkey solutions widely deployed within hydrogen production plant, green hydrogen plant and Green Hydrogen Production Plant projects. Drawing on extensive methanol reformer application experience, our engineering team develops exclusive hydrocarbon mixture proportion schemes and site layouts for every project, supporting industrial decarbonization and the implementation of industrial green hydrogen solutions.

Methanol Cracking Technology for Hydrocarbon Mixture Generation

As a professional syngas generator manufacturer, we integrate methanol steam reforming, reforming methanol and steam reforming of methanol catalytic reactions into a single explosion-proof unit, equipped with gas conditioning modules and optional deep purification assemblies.
The unit steadily and continuously outputs qualified hydrocarbon mixture, removing the hassle of repeated bottled gas purchasing and complicated multi-gas pipeline layout. Only industrial power and methanol feedstock are required for round-the-clock uninterrupted operation. Serving as essential hydrogen equipment for renewable hydrogen projects, it fully satisfies upstream gas supply demands of hydrogen power plant.

Integrated Methanol Reforming & Hydrocarbon Mixture Conditioning Platform

Two standard modular models are available in this series: HGS-100 and HGS-250. Multiple skids can run in parallel to scale up total hydrocarbon mixture supply for large chemical industrial parks. All units share unified PLC control, feeding systems and waste heat recovery subsystems while maintaining stable internal gas ratios. The system can be seamlessly connected with Hydrogen Compressor and Reciprocating Hydrogen Compressor for subsequent gas pressurization and transportation.

Technical Parameters & Core Advantages: Syngas Generator for Hydrocarbon Mixture Production

Key performance strengths of our syngas generator dedicated to hydrocarbon mixture preparation:
  • Fully integrated explosion-proof skid construction; all pipelines, circuits and functional modules pre-assembled and calibrated prior to factory shipment
  • Fast on-site deployment; full mechanical assembly, electrical commissioning and hydrocarbon mixture composition acceptance completed within 5–7 working days
  • PLC+IoT intelligent automatic control system with remote monitoring, parameter tuning and fault early warning for unattended operation
  • Fully customizable internal gas ratios to meet diverse downstream production requirements
  • High-efficiency reforming structure lowers methanol consumption and cuts long-term operational expenses
  • Optional purification upgrades raise total hydrocarbon mixture purity up to 99.99 vol.%
  • Proprietary reforming catalyst with 5-year service life, far exceeding mainstream industry standards
  • Constant stable outlet pressure, compatible with reactors, heating furnaces and fuel gas pipelines across production lines

Working Principle: Methanol Steam Cracking to Generate Hydrocarbon Mixture

Methanol and demineralized water are blended at a fixed ratio and vaporized via waste heat exchangers to reduce auxiliary power usage. Heated vapor enters insulated catalytic reactors under precise temperature and pressure regulation. Methanol reforming cracking reactions take place inside reactors to generate crude hydrocarbon mixture.
Crude gas passes through multi-stage conditioning units to eliminate moisture, impurities and substances captured via CO₂ Capture. For ultra-high purity requirements, optional separation modules further refine the hydrocarbon mixture to maximum purity. Treated gas is stored in pressure stabilization tanks and delivered downstream at constant pressure, with output flow automatically adjusted according to real-time gas consumption.

Product Model Specifications

HYVODA DDH-HyCO Hydrocarbon Mixture Generator Series HGS-100 Standard Model HGS-250 Reference Model
Nominal Hydrocarbon Mixture Output 50 – 100 Nm³/h 150 – 250 Nm³/h
Internal Gas Volume Fraction 1 65 – 75 % 65 – 75 %
Internal Gas Volume Fraction 2 20 – 25 % 20 – 25 %
Tunable Internal Molar Ratio Customised (1:1 / 2:1 / bespoke stoichiometry) Customised (1:1 / 2:1 / bespoke stoichiometry)
Standard Total Purity of Hydrocarbon Mixture ≥ 99.5 vol.% ≥ 99.5 vol.%
Optional Ultra-High Purity Upgrade Up to 99.99 vol.% Up to 99.99 vol.%
Stabilised Outlet Delivery Pressure 0.5 – 1.2 MPaG 0.5 – 1.2 MPaG
Specific Methanol Feed Consumption ≤ 0.55 kg per Nm³ hydrocarbon mixture ≤ 0.55 kg per Nm³ hydrocarbon mixture
Reforming Catalyst Service Lifetime 5 years continuous rated operation 5 years continuous rated operation
Total Installed Electrical Power Load 35 kW 75 kW
Overall Unit Dimension (L×W×H) 4500×2600×3100 mm 6500×3000×3600 mm
Approximate Skid Gross Weight ~5.2 tons ~9.5 tons
Integrated Process Modules Methanol Vaporiser, Catalytic Reformer, Gas Conditioning, PLC Control Methanol Vaporiser, Catalytic Reformer, Gas Conditioning, PLC Control
Optional Add-On Module Deep Purification System Deep Purification System
Required Site Utilities Industrial Power, Methanol Feedstock Industrial Power, Methanol Feedstock

Core Functional Advantages of Hydrocarbon Mixture Generator

  1. Accurate Custom Ratio Regulation for Hydrocarbon Mixture

    Our syngas generator adopts optimized reforming technology to deliver full-range ratio adjustment for hydrocarbon mixture. Standard 1:1, 2:1 and fully bespoke molar ratios are supported, removing the need for extra gas blending equipment and avoiding unstable mixed gas supply.

  2. Single-Skid Integrated Continuous Hydrocarbon Mixture Production

    Methanol vaporization, catalytic reforming, impurity removal and pressure stabilization are all integrated into one compact skid unit. The syngas generator continuously produces hydrocarbon mixture, drastically reducing procurement costs, safety risks and labor costs arising from bottled gas storage and frequent cylinder replacement.

  3. Low Feedstock Consumption for Sustainable Cost Savings

    Optimized waste heat recovery systems and high-efficiency catalysts significantly lower methanol usage. It delivers lasting economic benefits to renewable hydrogen plant operators and accelerates the overall industrial decarbonization process.

  4. Long Service Life Reforming Catalyst

    Exclusive high-temperature resistant reforming catalyst operates steadily for 5 years under rated working conditions, greatly shortening equipment downtime, cutting spare parts expenditure and minimizing production losses.

  5. IoT Intelligent Unattended Operation System

    Cloud-linked PLC control enables 24/7 real-time data monitoring, remote parameter modification and automatic safety interlock protection. Centralized multi-device management is available, perfectly matching Energy Storage System and comprehensive clean energy projects.

  6. Explosion-Proof Plug-and-Play Rapid Installation

    ATEX-certified pre-assembled skids can be directly connected to existing production pipelines, shortening construction cycles for hydrogen production plant and green hydrogen plant projects undertaken by Renewable Energy EPC Contractor.

End-To-End Full Lifecycle Customer Service Package

1. Pre-Sales Process Engineering Consultancy

Feedstock consumption calculation, hydrocarbon mixture ratio simulation, purity grading matching, hazardous area layout design and full-cycle CAPEX & OPEX cost analysis to provide reliable project decision support.

2. Factory Full Performance Validation

Every syngas generator undergoes continuous load cycle testing, hydrocarbon mixture composition calibration and air tightness inspection before delivery, greatly reducing on-site debugging workload.

3. On-Site Installation & Compliance Commissioning

Professional gas process engineers complete mechanical assembly, pipeline connection, electrical debugging and international safety standard acceptance on site.

4. Operation & Preventive Maintenance Training

Comprehensive hands-on training covering startup/shutdown sequences, ratio calibration, fault diagnosis and catalyst replacement during equipment handover.

5. Global Lifecycle After-Sales Support

24-hour remote technical hotline, expedited delivery of genuine spare parts and extendable equipment warranty services worldwide.

6. Customized Retrofit & Upgrade Engineering

Purification module retrofitting, control system upgrading, capacity expansion and waste heat recovery transformation services for existing installed syngas generator units.

Industrial & Energy Application Fields

Application Segment Process Description
C1 Chemical Synthesis Steady hydrocarbon mixture supply for mass production of acetic acid, formaldehyde, polycarbonate and various chemical intermediates
Pharmaceutical Carbonylation Manufacturing High-purity hydrocarbon mixture for API carbonylation and hydrogenation synthesis workflows
Specialty Metallurgical Processing Reducing protective atmosphere for alloy sintering, annealing and precision metal heat treatment
High-Temp Glass & Ceramic Manufacturing Balanced hydrocarbon mixture atmosphere for glass melting and advanced ceramic sintering kilns
Combined Heat & Power Generation Clean hydrocarbon mixture fuel for distributed gas turbine power plants, supporting hydrogen power plant construction and Clean Energy Storage Solutions

FAQ

How to adjust H₂/CO ratio of this syngas generator via methanol reforming process parameters?

This syngas generator relies on methanol reforming core process to regulate H₂/CO proportion. Operators adjust the mixing ratio of methanol and demineralized water, reforming reaction temperature and steam injection volume inside the reactor. More steam input promotes water-gas shift reaction to raise hydrogen proportion, reducing the H₂/CO ratio; lower steam dosage retains more carbon monoxide in hydrocarbon mixture. The PLC system precisely locks target molar ratios like 1:1 or 2:1 to meet different synthesis demands of the syngas generator without extra blending equipment.

What’s the core difference between HyCO equipment and DDH-H hydrocarbon mixture generation system?

Both adopt methanol reforming routes but target distinct working scenarios as Hydrocarbon Mixture Generation System. DDH-H hydrocarbon mixture generation system only produces low-dew reducing gas with simple composition dedicated to metallurgical annealing furnaces, without adjustable H₂/CO proportion. This HyCO syngas generator supports customizable H₂/CO molar ratios, equips optional deep purification modules to reach total gas purity up to 99.99%, specially designed for chemical carbonylation synthesis instead of thermal treatment combustion.

Can the output mixed gas directly feed carbon monoxide generator downstream synthesis lines?

Yes, the hydrocarbon mixture produced by this syngas generator can be directly delivered to carbon monoxide generator and downstream synthesis pipelines. The stable controllable H₂/index matches the raw gas standard of fine chemical synthesis; users can also add auxiliary separation modules to extract pure CO from methanol reforming mixed gas for pharmaceutical and polymer production processes.

Does the unit reserve interface for matched CO₂ Capture carbon recovery devices?

This syngas generator reserves standard pipeline interfaces matched with CO₂ Capture supporting equipment. Crude hydrocarbon mixture after methanol reforming contains concentrated carbon dioxide components, which can be shunted into CO₂ Capture units for separation and recycling, realizing complete carbon resource circulation and advancing factory industrial decarbonization.

What raw material consumption advantage compared with natural gas reforming syngas route?

Against natural gas reforming technology, this syngas generator based on methanol reforming adopts low-temperature catalytic reaction below 300°C, removing high-temperature transformation furnace equipment. Liquid methanol is easier to store and transport without natural gas pipeline construction investment, and the whole skid occupies smaller plant space. The system supports waste heat recovery to lower methanol consumption per cubic hydrocarbon mixture, bringing stable long-term operation cost advantages for medium-sized chemical hydrogen production plant.

Can multiple HyCO skids run parallel for large chemical plant continuous synthesis demand?

Modular parallel operation is fully supported for this syngas generator. Multiple HyCO units can operate synchronously to lift total output of hydrocarbon mixture generation system, maintaining fixed H₂/CO ratio under variable production loads. Stepwise capacity expansion avoids one-time huge equipment investment, perfectly matching large chemical plant long-term continuous synthesis and green hydrogen plant supporting gas supply demands.

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