Hydrogen
Hydrogen, the most abundant element, is an efficient energy carrier and a preferred zero-emission alternative fuel source. Traditionally, hydrogen is extracted from natural gas (CH₄) through a steam reforming process involving high-temperature steam and a catalytic reactor. This method, however, produces by-products such as carbon dioxide (CO₂) — approximately 9 kilograms per kilogram of hydrogen — and nitrous oxide, both potent greenhouse gases contributing to climate change. Mitigating these effects through CO₂ sequestration and utilization can significantly reduce the environmental impact of this process, which currently accounts for most hydrogen production worldwide.
To accelerate the transition to zero-emission hydrogen, the industry has developed technologies for hydrogen production via water electrolysis. When powered by renewable energy sources such as wind, solar, hydro, or geothermal, this method produces hydrogen with no harmful emissions, enabling a fully sustainable energy solution.
Regardless of how hydrogen is produced, a critical component of the supply chain is its transportation from source to end users, which can range from 1 ton per day to 5–20 tons per week, depending on demand. The transportation sector offers a unique opportunity for the rapid adoption of hydrogen, particularly in India. The country is well-positioned to reduce reliance on internal combustion engine (ICE) vehicles powered by petrol and diesel. Moreover, India’s rapid development of modern highway infrastructure creates an ideal setting for establishing a sustainable hydrogen supply chain to support the expanding hydrogen fuel cell electric vehicle (FCEV) market.
For large-scale hydrogen transportation, cryogenic transport trucks or ISO containers are essential. Smaller quantities can be delivered using high-pressure compressed gas cylinders, as hydrogen’s low volumetric density requires storage at pressures ranging from 500 to 1000 Bar. In practice, large-volume steel cylinders are often bundled, stacked, and securely mounted on trailers (tube trailers). However, due to regulatory limitations and the susceptibility of materials to fracture and fatigue, these cylinders are typically pressurized to below 300 Bar.
Vinjamuri Innovations Pvt Ltd, (VIPL) a startup enterprise located in Chennai, Tamil Nadu, developed subject matter expertise (SME) design, prototype fabrication, testing, approval process and business knowledge to develop carbon-epoxy filament wound composite aluminum cylinders which are suitable for ultra-high pressures up to 1000 Bar.
VIPL has committed to a particular design type cylinder which has a proven safety record for over 75 years, and improved manufacturing process (patented), innovative business model suitable for many applications including, but limited to HFCEV on-board fuel tanks, stationary and reusable onsite storage for dispensing. VIPL is in the process to set up an RDD&D facility for improved gravimetric density composite cylinders capable of storage at ultra-low temperatures for long duration transportation and storage at the end user facility. This will enable efficient bulk transportation and a smaller number of trips to and from end users.
Hydrogen Fuel Cell energy systems particularly for the transportation sector provide the necessary impetus and rationale for the policy makers to compartmentalize innovative RDD&D projects, small business enterprises with public and private investments for a fast-track path to zero-emission transportation in India by 2050, and be a primary business hub in the sector worldwide.
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Creating a complete hydrogen ecosystem, from production to storage and transportation, is critical for the success of hydrogen as a mainstream energy source. It’s great to see this perspective that addresses these challenges with innovative solutions.