Hydrogen as a Strategic Imperative for a Sustainable Energy Future
As the world accelerates its transition toward low-carbon energy systems, hydrogen has emerged as a critical enabler of deep decarbonisation across industry, mobility, and energy storage. For India—balancing rapid economic growth with ambitious climate commitments—hydrogen offers a strategic pathway to reduce emissions while strengthening energy security. At the forefront of this transformation is Indian Oil Corporation Ltd. (IndianOil), India’s largest integrated energy company, driving innovation across the hydrogen value chain through a combination of large-scale deployment, indigenous technology development, and ecosystem partnerships.
Hydrogen has long been integral to IndianOil’s refining operations, primarily for hydrocracking and desulphurisation. Traditionally produced from fossil feedstocks, this “grey” hydrogen has contributed to industrial emissions. The current transition marks a fundamental shift toward low-carbon and green hydrogen pathways, driven by three strategic imperatives:
I.Deep decarbonisation of refining and petrochemicals, which account for a significant share of industrial emissions.
II.Creation of new clean energy markets, including hydrogen mobility and merchant hydrogen supply.
III.Energy security and Atmanirbhar Bharat, through reduced dependence on imported fossil fuels and electrolyser technologies.
IndianOil’s engagement with hydrogen dates back to 2005, when it commissioned India’s first Hydrogen–CNG (HCNG) station at its R&D Centre in Faridabad. This was followed by the establishment of an HCNG demonstration plant at Delhi’s Rajghat Bus Depot in 2021 using indigenous patented technology, enabling large-scale trials in 50 city buses. These early initiatives demonstrated hydrogen’s potential as a clean transport fuel and laid the foundation for future hydrogen-based mobility solutions.
A decade later, IndianOil set up India’s first electrolyser-based hydrogen refuelling station at its R&D Centre, Faridabad in 2015. Powered by solar electrolysis, this facility became the country’s first dedicated green hydrogen station, equipped with advanced high-pressure storage and dispensing systems for hydrogen vehicle trials. These efforts closely align with the objectives of the National Green Hydrogen Mission (NGHM), which seeks to position India as a global hub for green hydrogen production, utilisation, and export.
Green Hydrogen Production: Scaling from Pilots to Industry
A major milestone in IndianOil’s hydrogen journey is the development of India’s largest green hydrogen project at the Panipat Refinery & Petrochemical Complex in Haryana. With a proposed capacity of around 10,000 tonnes per annum, the project represents one of the earliest commercial-scale green hydrogen deployments within the Indian refining sector.
The facility integrates renewable electricity with electrolysis to replace fossil-derived hydrogen currently used in refinery operations. IndianOil has undertaken comprehensive techno-economic evaluations, including levelised cost of hydrogen (LCoH) assessments, to ensure long-term commercial viability. Beyond emissions reduction, the Panipat project serves as a replicable template for deployment across other refineries and industrial clusters.
This initiative marks IndianOil’s transition from pilot-scale demonstrations to industrial-scale implementation—an essential step for mainstreaming hydrogen within India’s energy and industrial ecosystem.
R&D Leadership and Indigenous Technology Development
Cost reduction, efficiency improvement, and operational reliability remain central challenges for hydrogen adoption. Recognising this, IndianOil has placed strong emphasis on research, development, and indigenous innovation through its R&D Centre in Faridabad.
I.Hydrogen Generation and Refuelling Infrastructure
IndianOil has established a reformer-based hydrogen generation and refuelling station to support hydrogen fuel cell buses. The facility produces fuel-cell-grade hydrogen using natural gas via a steam methane reformer (SMR) with a capacity of 20 kg/hour, supported by 200 kg of hydrogen storage at 500 bar and a dispenser capable of 2 kg/min refuelling rates. Importantly, the system is designed to accept compressed biogas (CBG) as feedstock, enabling low-carbon hydrogen production from locally available organic waste and agricultural residues. This approach offers a scalable pathway for decarbonising both mobility and refinery hydrogen demand using existing SMR infrastructure.
In parallel, IndianOil is setting up a solar PV-powered electrolyser-based green hydrogen production and refuelling station at its R&D-II campus in Sector-67, Faridabad. A 1 MWp solar PV plant will power multiple electrolyser technologies, including alkaline (45 Nm³/hr), PEM (45 Nm³/hr), and solid oxide (5 Nm³/hr) electrolysers. Configured as test benches, these systems will enable comparative performance assessment under Indian climatic conditions, supporting informed technology selection and scale-up.
- Electrolyser Manufacturing and Innovation
To address supply-chain dependence and cost barriers, IndianOil is actively promoting domestic electrolyser manufacturing. The R&D Centre has developed an indigenous 1 kW Anion Exchange Membrane (AEM) electrolyser stack using non-noble metal catalysts, scheduled for demonstration at IEW 2026. Development of a 5 kW AEM stack and associated balance of plant is underway, while a joint proposal with Nanosol Inc. for a 20 kW AEM electrolyser system has been submitted under the MNRE R&D scheme.
- Alternative Hydrogen Production Pathways
IndianOil is also pursuing hydrogen production from biomass and waste-derived feedstocks. In collaboration with IISc, an oxy-steam biomass gasification process has been developed and demonstrated at 5 kg/hr using agro-residues and woody biomass. Plans are in place to establish a 100 kg/hr green hydrogen unit at an IndianOil refinery, reinforcing the role of indigenous, resource-diverse pathways in sustainable hydrogen production.
- Hydrogen Storage Innovation
Hydrogen’s low volumetric density poses storage challenges. Addressing this, IndianOil R&D, in collaboration with IIT Kharagpur, has indigenously developed a 57-litre Type-III composite hydrogen cylinder for 350-bar storage in light-duty vehicles. The cylinder has successfully passed all ISO 15869 tests at certified facilities in the United States, marking a significant step toward domestic manufacturing of advanced hydrogen storage solutions.
- Hydrogen Mobility and Fuel Cell Applications
Fuel cell electric vehicles (FCEVs) are gaining traction globally in heavy-duty transport due to their zero tailpipe emissions, long driving range (500–700 km), fast refuelling, and high efficiency. Recognising their suitability for Indian conditions, IndianOil is actively demonstrating hydrogen mobility solutions.
IndianOil has deployed 15 ARAI-approved hydrogen fuel cell buses across Delhi-NCR and Gujarat. These buses have already covered ~80,000 km under real-world operating conditions, with additional deployments with the Indian Army and Navy. The programme targets 3 lakh km of cumulative operation to generate robust performance and reliability data for future scale-up.
Under the NGHM, the Ministry of New & Renewable Energy (MNRE) has awarded four Hydrogen Demonstration Mobility projects to IndianOil in consortium with Tata Motors Ltd., with a total sanctioned outlay of Rs. 70.05 crore. IndianOil is establishing new hydrogen refuelling stations on the Jamshedpur–Kalinganagar and Mumbai–Pune corridors, while leveraging existing stations in Faridabad and Vadodara to support a fleet of 16 hydrogen vehicles.
Beyond road transport, IndianOil R&D has developed a 1 kW hydrogen fuel cell system for drone applications in collaboration with Urjahub Pvt. Ltd., with testing underway. A 2.4 kW air-cooled fuel cell system for mobility applications is also under development with High Energy Batteries (India) Pvt. Ltd.
Under the NGHM R&D scheme, IndianOil has been awarded three of the 23 sanctioned national projects, covering hydrogen fuel cell drones, hydrogen retrofitment kits, and hydrogen direct-injection engines, with a combined outlay exceeding ₹50 crore.
Infrastructure, Ecosystem Partnerships, and Policy Alignment
A sustainable hydrogen economy requires robust infrastructure for storage, transportation, and dispensing. Leveraging its extensive fuel logistics expertise, IndianOil is developing hydrogen-ready infrastructure, including refuelling stations, integration with existing energy systems, and comprehensive safety and materials-compatibility standards.
IndianOil’s hydrogen strategy is inherently collaborative, involving partnerships with engineering firms, academic institutions, automotive OEMs, and start-ups. These collaborations extend beyond technology deployment to encompass standardisation, skill development, and knowledge sharing.
As a public sector enterprise, IndianOil plays a pivotal role in translating national policy into implementation. Its hydrogen initiatives directly support the objectives of the National Green Hydrogen Mission by reducing industrial emissions, strengthening domestic manufacturing capabilities, and creating green jobs across emerging hydrogen clusters.
Conclusion: Advancing India’s Hydrogen Future
IndianOil’s hydrogen value chain innovations demonstrate how a traditional energy company can lead the transition to a low-carbon future. By combining large-scale green hydrogen production, indigenous technology development, infrastructure creation, and ecosystem collaboration, IndianOil is enabling hydrogen adoption across refining, industry, and mobility.
As India moves toward 2030 and beyond, IndianOil’s integrated and pragmatic approach positions it as a catalyst for the country’s emergence as a global hydrogen leader—aligning energy security, industrial competitiveness, and environmental stewardship in the pursuit of a cleaner, more resilient energy future.
