Producing hydrogen and oxygen on-site for industrial brazing means bringing the gas source into the plant and configuring it around the needs of the production line. The decision involves more than the generator: it also covers the workstations to be supplied, gas consumption and the distribution system.
When assessing this solution, the question is therefore not just “how much gas is needed?”, but also “how is it used during production?”. This is the starting point for comparing external supply with in-house generation.
How hydrogen and oxygen are produced on-site
ILT technology uses demineralised water and electricity to produce hydrogen and oxygen through electrolysis. The two gases are produced separately in the electrolytic cell and made available at the points of use through the system designed for the installation. Production is therefore integrated into the plant according to process requirements. To explore the dedicated range, see the Elite Series hydrogen and oxygen generators.
From a single workstation to centralised production
A brazing line may include manual, semi-automatic or automatic workstations. In the manufacture of chillers, heat pumps, condensers, evaporators and heat exchangers, operations may be repetitive and spread across several points of use.
The ILT range allows production to be configured for one or more workstations. Where the process requires it, centralised production with distribution to the points of use can be considered.
However, the number of installed workstations does not necessarily match the number operating at the same time. Sizing the gas source also requires an understanding of simultaneous use.
For more application context, we have explored the role of hydrogen and oxygen in refrigeration, where they are used to braze pipes and components.
On-site hydrogen and oxygen: the data to collect
Before selecting a model, it is useful to establish the requirements of the production line. The starting data are:
- Gas consumption and flow rates required at the points of use
- Number of workstations and their simultaneous use
- Pressure, purity and operating conditions required by the process
- Operating hours and how production activities are organised
This information makes it possible to assess the system configuration and build an economic analysis specific to the plant, rather than relying on generic consumption figures.
Compare the total cost, not just the price of the gas
The price of a cylinder is only one part of the supply cost. The comparison also includes transport, delivery, stock management, internal handling, storage and cylinder changes.
For on-site production, the factors to consider are investment in the generator, electricity, demineralised water and maintenance. The two configurations must be compared against the same production requirements.
There is no standard saving that applies to every company: geographical location, supplier terms, consumption, number of workstations, operating hours and logistics can all affect the result. This is why ILT starts with actual consumption and simultaneous use when assessing the solution.
Less stored gas, with a system designed for safety
On-site production reduces the need to keep substantial stocks of combustible gas in cylinders and limits the activities involved in handling and replacing them. In plants with numerous workstations, this can contribute to the prevention and management of fire and explosion risks.
Reducing storage does not mean eliminating every risk. H₂/O₂ production and use still require design, installation, distribution and operation that comply with the applicable safety requirements.
The role of electricity
Electricity is one of the factors to consider when assessing the system, alongside demineralised water consumption and maintenance.
From an environmental perspective, integration with renewable electricity can support objectives to reduce the impact of gas production. This should be assessed alongside costs, workstation organisation and process requirements.
Questions about on-site hydrogen and oxygen production
Can one generator supply several workstations?
Yes. The configuration is defined according to the required flow rate and the number of points of use operating simultaneously. Production and distribution must be assessed together.
How much can be saved compared with external supply?
The figure depends on the individual plant. The total cost of the current supply must be compared with the investment, electricity, water and maintenance costs of the on-site solution.
Are hydrogen and oxygen produced separately?
Yes. In the ILT technology described here, the two gases are produced separately in the electrolytic cell and made available at the points of use through the system designed for the installation.
Let’s start with your brazing line
The starting point is not a catalogue model, but how gas is used in production. Consumption, workstations and operating conditions help identify a configuration and assess its economic viability for the specific case.
ILT Energia brings this approach to brazing lines, drawing on ILT’s experience in the sector since 1980 and more than 3,000 electrolysers installed worldwide.
Are you considering on-site hydrogen and oxygen for your production? Contact the ILT Energia team with details of your application, consumption and number of workstations: these are the starting points for an initial technical assessment.
