65 t/h Hydrogen Steam Boiler Case Study for a Chlor-Alkali Plant

Project Overview — Hydrogen Steam Boiler

FangKuai Boiler partnered with a Chinese chlor-alkali chemical plant to design and install a 65 t/h hydrogen steam boiler solution. The facility produces isobutane and, as a process byproduct, generates hydrogen. Historically the plant struggled to store surplus hydrogen because of safety risks and the high cost of energy storage. FangKuai proposed using an on-site boiler to convert that hydrogen into usable process steam, turning a safety and cost problem into a decarbonization advantage.

Challenge — Hydrogen Steam Boiler in Chlor-Alkali Production

Chlor-alkali processes often produce streams of hydrogen that are hazardous to compress and store. The client's site faced limited space for storage and strict safety regulations that made conventional storage impractical. The engineering team also needed to avoid interruptions to steam supply during variable process loads. Integrating a hydrogen-fired system required careful combustion control, advanced safety interlocks, and seamless integration with the plant’s steam header.

Solution — FangKuai Hydrogen Steam Boiler Integration

FangKuai delivered a purpose-built 65 t/h unit engineered for safe hydrogen combustion and efficient heat transfer. The system was fitted with dedicated sensors, flame supervision, and redundant safety valves to meet industrial standards. FangKuai implemented a staged-firing control strategy, adaptive modulating burners, and an economizer to recover flue heat. The new boiler was also connected to the plant’s distributed control system for automated ramping and centralized monitoring.

Installation & Commissioning — Hydrogen Steam Boiler Timeline

Installation followed a tightly scheduled plan to minimize downtime. Structural works, piping, and electrical integration were completed in modular sections. During commissioning the unit underwent leak testing, burner tuning, and safety validation. Operators received hands-on training and standard operating procedures specific to the hydrogen application, including emergency shutdown and ventilation protocols.

Results — Hydrogen Steam Boiler Performance & Emissions

After commissioning, the boiler supplied 65 t/h of saturated steam at the required pressure with stable performance under varying loads. Using on-site hydrogen reduced the plant’s natural gas consumption significantly and cut CO₂ emissions by a measurable margin. The economizer enabled recovery of waste heat, further improving overall thermal efficiency and lowering fuel-equivalent consumption. Safety incidents related to hydrogen handling dropped because the plant consumed gas at source rather than moving, compressing, or storing it off-site. Operational data showed consistent steam pressure during peak and partial loads, confirming the system’s ability to follow demand.

Economic & Environmental Benefits — Hydrogen Steam Boiler Gains

Economically, the project reduced the need for external fuel purchase and eliminated capital expense for large storage systems. Operational costs dropped as the plant avoided compression and storage energy expenses. Environmentally, switching the steam source to on-site hydrogen helped the client meet immediate decarbonization goals and improved sustainability metrics. The installation provided a low-cost pathway for the plant to convert a waste stream into value while minimizing risk.

Operational Insights — Hydrogen Steam Boiler Maintenance

Routine maintenance emphasizes burner inspection, sensor calibration, and heat-exchanger cleaning. FangKuai set up a preventive maintenance schedule and remote monitoring dashboards to detect anomalies early. Operators appreciated the simplified logistics — no hydrogen cylinders or cryogenic tanks on site — making day-to-day work safer and more predictable.

Key Lessons — Hydrogen Steam Boiler for Chemical Plants

This project illustrated that an on-site hydrogen-fired boiler can turn a hazardous byproduct into a strategic fuel source. Early involvement of process safety teams, robust combustion controls, staged commissioning, and operator training are essential to success. The approach is most attractive where hydrogen is a consistent byproduct and where storage is impractical or cost-prohibitive.

FAQ — Hydrogen Steam Boiler

Q: What is a hydrogen steam boiler and why use it in a chlor-alkali plant?
A: It burns hydrogen to generate steam. In chlor-alkali settings where hydrogen is produced as a byproduct, the boiler safely consumes hydrogen on-site to supply process steam and reduce emissions.

Q: How does the hydrogen steam boiler improve safety?
A: The system eliminates the need to compress or store large hydrogen volumes, reducing storage-related risk. Active monitoring, flame detection, redundant safety systems, and ventilation add layers of protection.

Q: Will a hydrogen steam boiler affect steam quality?
A: Properly designed systems provide steam that meets industrial temperature and pressure requirements. Combustion control, drum level management, and water treatment ensure steam quality is maintained.

Q: What are the maintenance needs for a hydrogen steam boiler?
A: Maintenance is similar to other industrial boilers: burner checks, sensor calibration, heat-exchanger cleaning, and periodic safety valve testing, with procedures tailored for hydrogen-fired applications.

Q: Can the hydrogen steam boiler handle variable process loads?
A: Modern controls include modulating burners and advanced logic to follow load changes while maintaining stable steam pressure.

Conclusion — Hydrogen Steam Boiler as a Decarbonization Strategy

FangKuai Boiler’s 65 t/h project demonstrates a practical pathway for chlor-alkali plants to convert hazardous hydrogen byproducts into a reliable, low-carbon steam source. The solution delivered safety improvements, cost savings, and emissions reductions—offering a repeatable model for similar chemical plants seeking efficient decarbonization. The hydrogen steam boiler concept proved scalable and can be adapted to other process industries that generate hydrogen as a byproduct.

Contact us today to explore how FangKuai Boiler can help your plant turn hydrogen byproducts into clean, efficient steam power.