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

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.
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.
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.
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.
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.
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’S

What adjustable molar ratios can this syngas generator configure for hydrocarbon mixture?

Custom molar ratios including standard 1:1 and 2:1 are available. The standard total purity of hydrocarbon mixture reaches 99.5 vol.%, upgradable to 99.99 vol.% via optional purification modules.

Does the syngas generator require full-time on-site operators?

Continuous manual supervision is unnecessary. The IoT-PLC automatic system runs round the clock with remote fault alerts and safety interlock triggers. Scheduled preventive maintenance can be completed by your in-house technical team following the official operation manual.

Can hydrocarbon mixture production capacity be expanded in the later stage?

The two standard models can be arranged in parallel layout to achieve unlimited capacity expansion, with stable hydrocarbon mixture ratios maintained under all operating loads.

What are the advantages of on-site methanol reforming production compared with bottled hydrocarbon mixture supply?

Our syngas generator avoids repeated gas procurement, high-pressure cylinder storage hazards and labor costs from frequent cylinder replacement. Output flow dynamically adapts to fluctuating production demands without supply interruption or purity deviation.

How long does on-site installation and commissioning take?

Installation and full commissioning of a single skid unit only take 5–7 working days, including equipment calibration and operator training services.

What noise level does the hydrocarbon mixture generation unit produce during steady rated operation?

Optimized blower and pump structures control noise below 75 dBA at a 1-meter measuring distance, fully complying with indoor noise standards for chemical plants.

Where can I obtain the complete maintenance schedule for catalysts and core components?

Detailed periodic inspection checklists, catalyst replacement timelines and overhaul standards are documented in the official operation manual. Monthly minor inspections are required, while core reforming catalyst only needs replacement every 5 years under continuous rated operation.