Hydrogen use is growing rapidly in fuel cell vehicles, H₂ refueling stations, research labs, and industrial manufacturing. Each setting demands dependable hydrogen leak sensors and continuous gas monitoring to protect workers and maintain safety certifications.

Hydrogen can be produced from methane in large volumes, by two different process methods:

• Steam methane reformation is the most common method for producing bulk hydrogen and accounts for most of the world’s production. This process uses a reformer, which reacts steam at a high temperature and pressure with methane and a nickel catalyst to form hydrogen and carbon monoxide.
• Auto thermal reforming uses oxygen and carbon dioxide or steam to react with methane to form hydrogen. The downside of these two methods is that they produce carbon as a by-product, so we need to explore carbon capture solutions to trap and store this carbon.

A greener alternative is to use electrolysis, which is currently available on a small scale but offers the most significant opportunity. This process uses electricity to split water into hydrogen and oxygen – the benefit is that it produces pure hydrogen with no harmful by-products. Because it uses electricity, it also offers the potential to divert any excess electricity – which is hard to store (like surplus power from wind turbines) – to electrolysis, using it to create hydrogen gas that you can store.

Monitoring Hydrogen chain

• Storage tanks
• Fuel Cells
• ICE
• Hydrogen Distribution
• Electrolizers

What is Off-Gassing?

Off-gassing is the release of gases—such as hydrogen, carbon monoxide, and volatile organic compounds—from lithium-ion batteries due to internal component degradation. It typically occurs as a result of battery damage, abuse, or misuse, including:

• Physical damage, such as puncturing or crushing.
• Overcharging or over-discharging beyond recommended limits.
• Overheating or internal short circuits.
• Manufacturing defects.

The Risks of Off-Gassing

• Thermal Runaway: While not always a guaranteed precursor, off-gassing often occurs early in a battery failure event. It can lead to thermal runaway, an uncontrolled chemical reaction causing rapid increases in temperature and pressure that result in battery fires.

• Pressure Buildup: In confined spaces, such as battery storage racks, accumulated gases can turn containers into pressure vessels, creating a high risk of ignition.

The Importance of Early Detection

Detecting off-gassing early is essential for proactive risk management. The benefits include:

• Safety: It enables early evacuation, the implementation of emergency protocols, and the reduction of risks to personnel and property.

• Risk Mitigation: Operators can take corrective actions, such as isolating malfunctioning batteries or adjusting charging parameters.

• Operational Efficiency: Early intervention allows for preventative maintenance, which helps avoid costly repairs, extends battery lifespan, and prevents unplanned downtime.

• Compliance: Monitoring off-gassing helps organizations adhere to regulatory standards and safety guidelines, such as FM standards for Battery Energy Storage Systems (BESS).

Detection Technology

MLD H2 provides an early warning system for battery degradation. The detector is designed to sense hydrogen, as well as electrolyte gases like DMC and EMC, simultaneously. This capability allows for the identification of issues at an earlier stage in the P-F (Potential-to-Functional) failure curve, providing higher reliability and safety without the need for field calibration.

Would you like more information regarding the specific environmental factors that influence off-gassing dynamics in different setups? Get in touch with us for more details!