Fast Sense Ltd
Fast-Sense - Industrial Hydrogen Sensors
FromFast Sense Ltd
Hydrogen is rapidly becoming a cornerstone of industrial decarbonization. Hard-to-abate sectors like steelmaking, cement production, refining, and chemicals account for nearly 30% of global CO₂ emissions. Transitioning these industries from fossil fuels to hydrogen requires robust safety and efficiency measures. Fast Sense develops hydrogen sensors, hydrogen analyzers, and H₂ sensing systems that allow heavy industry to safely adopt hydrogen at scale, protecting both workers and assets while meeting emissions targets.
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The Challenge in Industrial Hydrogen Adoption
- Steelmaking – Hydrogen replaces coal in direct reduction iron (DRI) processes, but requires precise H₂ analysis to ensure complete combustion and avoid process instability.
- Cement – High-temperature kilns face risks of hydrogen backflow, leaks, and incomplete combustion without accurate H₂ sensing.
- Refineries & Chemicals – Hydrogen is already widely used in hydrocracking and ammonia production, but scaling up requires improved leak detection and process monitoring.
- Worker Safety – Hydrogen leaks in enclosed spaces can become explosive at just 4% concentration in air.
Without continuous hydrogen sensing, these industries face safety incidents, costly downtime, and compliance challenges with new hydrogen regulations.
Fast Sense Solution: H₂ Sensors for Heavy Industry
Fast Sense hydrogen sensors and analyzers are engineered for the harshest industrial environments:
- Real-Time H₂ Sensing – Early detection of leaks and incomplete combustion.
- Cross-Sensitivity Free – Accurate even with dust, CO, methane, and VOC interference.
- Predictive Maintenance – Detects anomalies in fuel use, burner efficiency, and emissions before system failure.
- Durability: resistant to oil contamination, humidity, and pressure fluctuations.
Use Cases
- Steel Plants: Hydrogen sensors ensure stable fuel switching from natural gas to hydrogen in DRI.
- Cement Kilns: Real-time H₂ analyzers prevent explosions by monitoring combustion gases.
- Refineries: Leak detection in hydrocrackers, reformers, and H₂ pipelines.
- Chemical Plants: Monitoring hydrogen purity for ammonia, methanol, and syngas production.
Technical Deep Dive
Fast Sense hydrogen analyzers provide:
- Range: ppm–% hydrogen detection for leak and process monitoring.
- Response Time: Seconds for critical safety alerts.
- Certifications: ATEX, IECEx, SIL2 for use in explosive atmospheres.
- Form Factors: Probe-based, wall-mounted, or integrated in-line analyzers.
Industrial Benefits
- Process Efficiency – Optimize hydrogen use, reduce waste.
- Worker Protection – Continuous monitoring prevents exposure to hazardous levels.
- Regulatory Compliance – Supports EU Hydrogen Strategy and OSHA/ATEX safety rules.
- Lifecycle Extension – Prevents equipment fatigue caused by undetected leaks or unstable combustion.
Case Studies
- Steel Plant (Sweden): Integrated hydrogen sensors into DRI operations, reducing unplanned downtime by 22%.
- Refinery (Middle East): Detected hydrogen leaks at ppm levels, preventing a $10M incident.
- Chemical Facility (Germany): Improved hydrogen purity monitoring, boosting catalyst efficiency by 15%.
Industry Stats
- Global hydrogen demand in industry is projected to grow 6x by 2050 (IEA).
- Steelmaking alone contributes 7–9% of global CO₂ emissions.
- A single cement plant can emit 2–3 Mt CO₂ per year — hydrogen could cut this by 60–70%.
- Hydrogen leaks account for 20–30% of refinery incidents, making H₂ analyzers mission-critical.
Benefits of Fast Sense H₂ Analysis in Industry
- Safety & Compliance – ATEX/IECEx-certified leak detection.
- Efficiency Gains – Optimize hydrogen fuel use in energy-intensive processes.
- Emission Reductions – Enable deep decarbonization in hard-to-abate sectors.
- Cost Savings – Prevents outages, improves equipment longevity.
Internal Links
- Related: Hydrogen Production Pathways for industrial hydrogen supply.
- Connected: Industrial Safety & Process Control for broader factory-wide hydrogen detection.
- Explore: Hydrogen Turbines for H₂ adoption in power generation.