Webinar category: Hydrogen

Innovation in Hydrogen Storage and Biofuels & Technology Mix

• emphasized innovations in hydrogen storage, particularly the use of Type-4 carbon fiber cylinders, which are up to 70% lighter than traditional Type-1 steel cylinders and can significantly reduce transportation and vehicle weight costs.
• highlighted biofuels as a game-changer, noting that India aims to achieve 20% ethanol blending by 2025, and biofuels could play a crucial role in decarbonizing hard-to-abate transport segments.
• also pointed out that hydrogen refueling infrastructure remains one of the key challenges today. Unlike CNG and LNG, which already have relatively established refueling networks, hydrogen requires dedicated infrastructure investments, which directly affects adoption.
• from a customer perspective, Total Cost of Ownership (TCO) remains a decisive factor—and technologies must be competitive not just in emissions but in lifecycle cost and operational reliability.

Technology Mix for Net-Zero Mobility

Hybrid approach, combining biofuels and batteries, citing that blended approaches could reduce lifecycle emissions by up to 60–70%, depending on fuel type and application.

• emphasized that any net-zero compatible fuel paired with battery support (e.g., H2ICE + battery or biofuels + battery) could offer flexibility, cost-efficiency, and scalability—especially for medium-duty and rural mobility segments.

H2ICE as a Transitional Technology

• H2ICE as a Transitional Technology
  Hydrogen Internal Combustion Engines (H2ICE) can leverage the existing ICE manufacturing and maintenance ecosystem, offering a 30–40% cost advantage over early-stage hydrogen fuel cell vehicles (FCEVs).
• While hydrogen-powered vehicles have lower energy efficiency (25–30%) compared to Battery Electric Trucks (BETs) with 70–90% efficiency, H2-based trucks are approaching cost parity with BETs for certain heavy-duty, long- haul applications, especially where quick refueling and payload optimization are critical.
• strongly emphasized that the source of hydrogen production is crucial— using fossil-based hydrogen in transport merely shifts emissions, rather than reducing them. For true decarbonization, only green hydrogen (produced via renewable energy) should be deployed in the transport sector.

Policy and Infrastructure requirements with Self-Sustaining and Indigenous Solutions

All speakers agreed on the urgency of strong policy interventions, including: Hydrogen fuel availability, with projections indicating India will require 5 million tones of green hydrogen annually by 2030 to meet decarbonization targets.

Refueling infrastructure—a key bottleneck—with suggestions for stations every 5 km on freight corridors, similar to EV charging infrastructure planning under FAME II. Meanwhile the challenges such as life of FCEV which is only 40,000 hour’s needs to be addressed through various R&D efforts in suggestions with various OEM manufactures.

Support for dual-use technologies like bidirectional fuel cells, which can act as both power sources and storage

Focus on Self-Sustaining and Indigenous Solutions

A strong emphasis was placed on self-reliant, decentralized energy solutions like Solid Oxide Fuel Cells (SOFCs).

SOFCs can run on biodiesel and syngas, making them suitable for off-grid and rural applications. India’s bioenergy potential is estimated at over 25 GW, underscoring the importance of tapping into this domestic resource base.

Hydrogen: The Fuel of the Future

Hydrogen is a key enabler for decarbonizing transport, offering long-range, fast-refueling solutions, particularly for heavy-duty trucks, buses, and trains. The global hydrogen vehicle market is projected to grow at a CAGR of over 40%, reaching USD 68.51 billion by 2030. As of 2023, over 60,000 hydrogen fuel cell electric vehicles (FCEVs) are on the road, with commercial models like Toyota Mirai and Hyundai NEXO leading the way. While passenger cars dominate, hydrogen’s high energy density makes it ideal for commercial vehicles, with heavy-duty hydrogen trucks expected to reach 15,000 units globally by 2030.

The hydrogen light mobility (HLM) market, encompassing two-wheelers, small vans, and passenger cars, is rapidly growing. Hydrogen-powered vehicles offer zero emissions, quick refueling, and competitive ranges due to advancements in fuel cell technology. Countries like Japan and South Korea are driving adoption with government support and expanding hydrogen infrastructure.

India’s Hydrogen Potential

India is advancing hydrogen mobility under its National Hydrogen Mission, targeting 5 MMT of green hydrogen production by 2030, with 20% for transport. Companies like Tata Motors and Mahindra are piloting hydrogen-powered buses, trucks, and two-wheelers. Hydrogen adoption could significantly decarbonize India’s 200 million two-wheelers, with startups like Log9 Materials and HyZero leading innovation.

Challenges and Opportunities

Hydrogen faces barriers like high production costs, expensive infrastructure, limited distribution networks, and competition from EVs. However, its long-range, fast refueling, and zero-emission advantages make it ideal for fleets and urban mobility. With affordable fuel cells, compact storage, and supportive policies, hydrogen could revolutionize sustainable transport.

This webinar is exploring key aspects of hydrogen-powered light mobility, including:

• Unveiling its potential: Assessing the opportunities and applications in light mobility
• Techno-economic insights: Analyzing the technical feasibility and economic viability of hydrogen-powered solutions
• Policy imperatives: Identifying the necessary measures to drive growth and adoption in the sector

Hydrogen is an increasingly important piece of the net zero emissions by 2050 puzzle by meeting (22%) 1 of its energy demand which is reflected in its increasing share in cumulative emission reductions. The world’s H2 demand stands at 90 million metric tons per annum (MTPA), with projections soaring to a staggering 660 MTPA by 2050. The global hydrogen supply will need to increase sixfold, compared to 2020 levels, to meet the forecasted demand for hydrogen.

According to the International Energy Agency (IEA), the projected utilization of H2 by 2050 is primarily centered around key sectors: Transport (40% to 45%) industry applications (15%), power generation (12%), and buildings/refineries (28%). The anticipated Mobility demand projections (freight) for 2050 in the mobility sector indicate that the road sector is expected to contribute 25%, followed by the rail sector at 7%, the aviation sector at 3%, with the remainder attributed to the marine sector.

Strong hydrogen demand growth and the adoption of cleaner technologies enable hydrogen and hydrogen-based fuels to play a significant contribution to decarbonizing sectors such as long-distance transport where roughly one-third of greenhouse gas emissions from road transport stem. Long-distance transport efficiency varies significantly among battery electric vehicles (BEVs), internal combustion engines (ICE), fuel cell vehicles (FCEVs), and Hydrogen internal combustion engine (H2ICE) trucks.

In assessing the ideal option for future long-haul transport trucks, a comprehensive analysis of critical parameters: fuel efficiency, vehicle cost, fuel cost, climate impact, infrastructure investment requirements, technology selection, OEM readiness, and application suitability. This evaluation aims to provide a clear understanding of the most suitable choices for the evolving landscape of long-haul transportation trucks.eg., BEVs showcase exceptional efficiency, boasting a well-to-wheel efficiency of approximately (75%), significantly higher than FCEVs (30%) & ICEVs at (55%). For shorter distances, this weight disparity diminishes, making BEVs more feasible, especially for lighter cargo. On the other hand, FCEVs exhibit impressive range capabilities, reaching up to 1,000 km with liquid hydrogen storage or 800 km with 700 bar storage, catering effectively to long-haul transportation needs.

According to the Global Hydrogen Council and FMI, the market for H2 Trucks US$ 3.84 Billion (2023) was estimated to be about US$119.18 Billion4 with a CAGR of 41% for (2033). Hence it is crucial to determine the best option for future long-haul transport trucks amid this rapidly expanding market.

Key takeaways-

• Hydrogen application in the transport sector is dynamic and is influenced by evolving technologies and contextual factors. It is not one solution that will fit all requirements; rather, it’s a mixed bag of solutions.
• It is advisable to consider the immediate availability of blue and grey hydrogen rather than postponing and aspiring solely for the use of green hydrogen at the present moment.
• Affordability is crucial for market acceptance, and cost considerations play a significant role in the adoption of hydrogen solutions.
• In the adoption of any technology, safety often takes a backseat, with economics taking precedence. In the context of hydrogen (H2) applications in transportation, ensuring safety is most important. This is particularly considering hydrogen’s flammability, propensity for leakage, and its potential to cause embrittlement in steel.
• No one-size-fits-all solution exists for these problems. It’s important to take a practical approach, exploring different options, including hybrid approaches like blended fuels (e.g., CNG + H2), strategically planned for viability and market acceptance.
• In incorporating H2 into transportation, it becomes important to foster effective collaboration between vehicle manufacturers and fuel suppliers. This partnership will help tackle technical challenges and streamline the adoption of hydrogen.

Historically, nations have heavily relied on external sources for their energy needs. However, the present era offers a unique proposition – harnessing renewable resources such as solar, wind, and water to produce hydrogen, which can serve as a versatile replacement for traditional fossil fuels like petrol and diesel. This shift towards energy independence is paramount, and H2 plays a pivotal role in this transition. Currently, the world’s H2 demand stands at 90 million metric tons per annum (MTPA), with projections soaring to a staggering 660 MTPA by 2050. To realize the full potential of hydrogen, it is essential to address the economics of H2 production and, equally important, the cost-efficient transportation of hydrogen. Pipelines emerge as a frontrunner in this domain, leveraging the extensive global network of natural gas pipelines, which already span thousands of kilometers. The levelised cost of H2 production from natural gas is estimated at $1 to $2 per kilogram (kg). Of these costs, pipelines are used for longer distances (ranging from 1,500 to 3,000 km), with a cost ranging from $0.09 to $0.47 per kg.

In contrast, medium-distance H2 distribution may favor alternatives like liquefied H2 or ammonia transport by trucks, tube trailers, etc., which cost $0.75 to $1.51 per kg. Importantly, utilizing greenfield pipelines and repurposing natural gas pipelines for H2 transport could save costs by 20-50% and 50-70%, respectively. These statistics underscore the economic advantage of pipeline-based H2 transportation. In countries like India, with substantial natural gas consumption and pipeline infrastructure (15,583 km of gas pipeline network with a capacity of 206 MMSCMD2), it is observed that these pipelines are highly under-utilized and can play a critical role in H2 transportation by blending H2 in pipeline networks. Various studies by GAIL, PIL, and NTPC have found that pipelines can be repurposed for blending at levels of 10-15% with minor modifications. In different countries, such as Australia, the United States, and Canada, demonstration projects are being developed to allow H2 blending in various percentages, ranging from 1% to 20%, showcasing the potential for H2 integration in existing infrastructure. The advantages of transporting H2 through pipelines are evident, with the potential to reduce costs significantly compared to alternative modes of transportation such as trucks.

However, while H2 holds great promise, it presents unique challenges, including its propensity to permeate metal structures and induce cracking. As we delve into the nuances of H2 distribution through pipelines, we will explore these challenges and delve into global best practices, from green-field pipeline development to blending solutions. In conclusion, this webinar with a focus on H2 Distribution through Pipelines: Green-field vs. Retrofit and Blending, aims to pave the way for increased H2 production and economic consumption by addressing critical issues, exploring global best practices, and dissecting the country’s commitment to H2 distribution through pipelines.

The Webinar focuses on:

1. Economics of H2 Pipeline – New Vs Retrofit
2. Technical & Economic Considerations for Choosing Retrofitting over New Pipeline
3. Engineering & Design Consideration for H2 Pipeline
4. Investment Required & Viability for H2 Pipeline
5. Emerging Policies Landscape to Fuel Investments in H2 Infrastructure

Key takeaways

• We need to view it from both perspectives: as a commodity at a large scale and user/ customer perspective (bird’s ant’s view)
• 3A’s paramount for all developing economies – Affordability, Accessibility, and Availability.
• The pipeline requires the least transportation and fuel consumption, relieving road congestion. Aligns with the National objective of Net zero goals and the cheapest product reaches the consumer.
• In the context of vehicles: if the blending is more than 2%, unburnt H2 leads to cracking.
• Blending H2 with natural gas is a good option
• Pipelines will require a lot of funding, commercial structure, regulatory and policy support
• Indore Pilot: GAIL started injecting grey H2 in the CGD network to establish the techno-commercial feasibility of blending H2. To be supplied to Avantika Gas Limited.
• Higher percentages of blending will require the burners to be changed due to high flames.

India with the aim to achieve net zero by 2070 has set ambitious climate goals to tackle the growing issue of GHG and mitigate climate change. Hydrogen is emerging as a crucial element in achieving these goals due to its potential as a clean and sustainable energy carrier^[1].

Recognizing this, Indiahas taken significant initiatives to enhance the use of hydrogen in the country. One such initiative is the launch of the National Green Hydrogen Mission (NGHM) with the aim to achieve 5 MMTPA^[2] of green hydrogen by 20303 and become a green hydrogen production and export hub. The initial financial outlay for the mission is INR 19,744 crore, out of which 89% is allocated for SIGHT4 Program, 7% for Pilot Project, 2% for R&D and 2% for other mission components.

Under the SIGHT^[3] program, MNRE^[4] announced two distinct financial incentive and implementation mechanisms. These are for i) Electrolyser Manufacturing and ii) Green Hydrogen Production, covering supply-side and demand creation incentives respectively.

Scheme 1, with a capital outlay of Rs 4,400 Crore over 5 years, incentivizes Electrolyser Manufacturing, emphasizing indigenization, technology, efficiency, and local sales. It promotes continuous improvement through performance-linked incentives, driving advancements in electrolyzer technology, while fostering competition and diversity with multiple OEMs.

Scheme 2, with a capital outlay of Rs 13,090 Crore over 5 years, incentivizes Green Hydrogen Production. It includes a separate tranche for biomass, promoting distributed production and diverse feedstock utilization. Wide eligibility criteria allow small to midsize companies to participate, fostering sectoral inclusivity. The scheme emphasizes monitoring transparency and accountability, building trust in the process.

In this Webinar, we shall focus on:

1) Technology Roadmap of Alkaline & PEM Electrolysers and Design & Performance Improvements

2) Cost Economics of Electrolyser Manufacturing and GH2 Production

3) Market Needs and Growth Opportunities for GH2 – National Consumption and Exports

4) Indigenization Potential and Roadmap for Electrolyser Manufacturing in India

5) Leveraging MNRE Announced Mechanisms and the Need for a Supporting Ecosystem and Measures

Join us as we uncover key insights and strategies to drive India’s hydrogen objectives and accelerate the transition towards a sustainable future. This webinar will specifically focus on the development of the India Green Hydrogen Market, providing valuable insights and serving as a precursor to the upcoming Conference on Green Hydrogen 2023, scheduled from 5th to 7th July’ 2023 in Delhi.

^[1]Harnessing Green Hydrogen, NITI Aayog, 2022

^[2] MMTPA: Million Metric Ton per Annum

^[3] SIGHT – Strategic Interventions for Green Hydrogen Transition

^[4] Ministry of New and Renewable Energy

Our Speakers-

Kiran Kumar Alla – Green H2 Market Development, Plug Power
Aravind Kumar Chandiran – Associate Professor, IIT-Madras
Viswanathan Mahadevan – MD at RENSOL POWER PRIVATE LIMITED

Key Takeaways-

• Achievable cost reduction targets for Alkaline electrolysers by 2030: 15-20%. PEM is still under maturing pathways with higher potential for cost reduction: 25-35%. Major targeted cost reductions can be achieved from the material and the DC side of engineering (current pathway).
• Green path – There are still unanswered questions regarding the seamless integration of renewable energy sources and user-side integration within the overall system. The holistic functioning of the entire system, leveraging these two schemes, remains to be seen.
• Changes in State policy around renewable energy (RE) and banking creates investor uncertainty.
• Rapid deployment of R&D and pilot funds is critical for techno-economic feasibility. This timely action is necessary to reach valuable conclusions, attract investments, and facilitate scaling up. The outcomes from this research will serve as a guide for implementing future R&D schemes over the two-year period.
• Implementing import concessions/exemptions and GST exemptions during the selling process can contribute to significant cost reductions.
• Appropriate tax exemptions during the initial years for critical raw materials such as membranes and electrode materials.
• Need for establishing labels and standards for green hydrogen. Validation of all pilots and use cases by reputable agencies to ensure the credibility and reliability of green hydrogen initiatives.
• Capacity building is essential for multiple and diverse players involved in manufacturing various parts of the electrolysis value chain.
• Indigenising and declocalising the manufacturing – will benefit and bring the cost of electrolysers.Note : Please be careful while uploading the images below. The rectangular to be used as a thumbnail and the other other one is a smaller size of the current image. (to be used inside.)