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Using skid-mounted natural gas to hydrogen generator in hydrogen refueling station can significantly reduce the cost of hydrogen. In 2021, China successfully built the first 250 Nm3/h on-site skid-mounted natural gas to hydrogen generator, which was successfully debug-ed in Foshan, providing hydrogen products with purity ≥99.999% for FCVs. This paper summarized the technological process and development, analyzed the risk and the safety design of skid-mounted natural gas to hydrogen generator. Several key factors affecting compactness are analyzed, including process and technical route, reforming reformer and catalyst, heat exchange network, heat exchanger and steam generation system, PSA unit and overall integrated design, etc. In addition, innovative strategies to optimize the compactness of the device are given from the aspects of process flow, reforming reformer and steam generation system.The suggestions are put forward for the development and application of on-site skid-mounted natural gas to hydrogen generator. • The first 250 Nm3/h on-site skid-mounted natural gas to hydrogen generator in China. • The technological process and development of skid-mounted natural gas to hydrogen generator. • The risk analysis and safety design of skid-mounted natural gas to hydrogen generator. • Several key influencing factors and strategies to optimize the compactness. • Cost estimation and competitiveness of skid-mounted natural gas to hydrogen generator. [ABSTRACT FROM AUTHOR]

On-site hydrogen production through steam-methane reforming (SMR) from city gas or natural gas is believed to be a cost-effective way for hydrogen-based infrastructure due to high cost of hydrogen transportation. In recent years, there have been a lot of on-site hydrogen fueling stations under design or construction in China. This study introduces current developments and technology prospects of skid-mounted SMR hydrogen generator. Also, technical solutions and economic analysis are discussed based on China's first on-site hydrogen fueling station project in Foshan. The cost of hydrogen product from skid-mounted SMR hydrogen generator is about 23 CNY/kg with 3.24 CNY/Nm3 natural gas. If hydrogen price is 60 CNY/kg, IRR of on-site hydrogen fueling station project reaches to 10.8%. While natural gas price fall to 2.3 CNY/Nm3, the hydrogen cost can be reduced to 18 CNY/kg, and IRR can be raised to 13.1%. The conclusion is that skid-mounted SMR technology has matured and is developing towards more compact and intelligent design, and will be a promising way for hydrogen fueling infrastructures in near future. • Development status and future expectation of hydrogen refueling stations and fuel cell vehicles in China. • On-site hydrogen generator can significantly reduce the cost of hydrogen. • Technical composition and global development status of On-site hydrogen generator form natural gas. • China's first on-site natural gas to hydrogen refueling station in Foshan. [ABSTRACT FROM AUTHOR]