Draft HYDROGEN ENERGY AND FUEL CELLS IN INDIA – A WAY FORWARD Report prepared by Steering Committee on Hydrogen Energy and Fuel Cells, Ministry of New and Renewable Energy, Government of India, New Delhi June, 2016 0 CONTENTS S. No. Subject Page No. Preface 3 Abbreviations 6 Composition of Steering Committee on Hydrogen Energy and Fuel Cells along with Terms of Reference 11 1 Introduction 13 2 Hydrogen Production 18 3 Hydrogen Storage & Applications other than Transportation 24 4 Fuel Cell Development 33 5 Transportation through Hydrogen Fuelled Vehicles 42 6 Intellectual Property Right, Public Private Partnership, Safety, Standards, Awareness and Human Resource Development for Hydrogen related Activities 50 7 Recommendations 58 Annexures I Compositions of Sub-Committees on various aspects of Hydrogen Energy and Fuel Cells and Team of Experts along with their Terms of Reference Details of Meetings of Steering Committee on Hydrogen Energy and Fuel Cells and its Sub-Committees 66 III Carbon dioxide emissions from various countries 77 IV Draft Report on Hydrogen Production V Draft Report on Hydrogen Storage and Application Annexed other than Transportation II 1 75 Annexed VI Draft Report on Fuel Cell Development VII Draft Report on Transportation through hydrogen Annexed fueled vehicles VIII Draft Report on Intellectual Property Rights, Public Annexed Private Partnership, Safety, Standards, Awareness and Human Resource Development 2 Annexed PREFACE Use of fossil fuels has become a part of daily energy needs and their requirement is increasing with the passage of time. Consumption of fossil fuels gives rise to the greenhouse gas emissions in the environment and causes ambient air pollution, which have now become global concerns. This coupled with the limited reserves of fossil fuels have encouraged and promoted the development and use of new and renewable energy sources, including hydrogen energy as an energy carrier. The technologies for production of hydrogen from new and renewable sources of energy are in the process of development and demonstration. In order to meet the future energy demands in sustainable and environment friendly manner, technologies are required to be developed for the production, storage and applications of hydrogen in transportation sector as well as for portable & stationary power generation. With a view to accelerate development of hydrogen energy sector in India, a National Hydrogen Energy Road Map (NHERM) was prepared and adopted by the National Hydrogen Energy Board in January, 2006 for implementation. The main objective of NHERM was to identify the pathways, which will lead to gradual introduction of hydrogen energy, accelerate commercialization efforts and facilitate the creation of hydrogen energy infrastructure in the country. NHERM covered all aspects of hydrogen energy development in India including its production, storage, transport, delivery, application, codes & standards, public awareness and capacity building. NHERM formed the basis for implementation of Hydrogen Energy Progamme in the country from 2006-07 onwards. NHERM suggested modifying and upgrading it later based on field experience in the country and new developments worldwide. Accordingly, a Steering Committee on Hydrogen Energy and Fuel Cells was constituted by the Ministry of New and Renewable Energy (MNRE), Government of India to advise the Ministry and steer the overall activities of Hydrogen Energy & Fuel Cells under the Chairmanship of Dr. K. Kasturirangan, the then Member (Science), Planning Commission (now known as NITI Aayog), Government of India on 31.05.2012 for a period of three years. The duration of this Committee was later extended upto June, 2016. As per recommendation of Steering Committee on Hydrogen Energy and Fuel Cells in its 1stmeeting, five Sub-Committees were constituted by the Ministry on the following aspects of hydrogen energy and fuel cells for in-depth discussions, re-visiting NHERM and to suggest further course of action: 3 (i) Research, Development & Demonstration (ii) Fuel Cell Development (iii) Transportation (subsequently changed to Transportation through Hydrogen Fuelled Vehicles) (iv) Other Applications including Storage (subsequently changed to Hydrogen Storage and Applications other than Transportation) (v) IPR, Public-Private Partnership, Safety, Standards, Awareness and HRD Later, it was realised that Research, Development & Demonstration aspects in each area were covered by the respective Sub-Committees and therefore, it was decided that the Sub-Committee on Research, Development & Demonstration may focus only on hydrogen production aspects. The members of the Sub-Committees deliberated on different aspect of Hydrogen Energy and Fuel Cells during a series of meetings and spent considerable time discussing research, development, demonstration and commercialisation issues of different technological areas including deliverable outcome of each activity and its utility. The Sub-Committees also consulted subject experts in different areas. These Sub-Committees prepared reports on their respective subject areas. On the recommendation of the Steering Committee on Hydrogen Energy and Fuel Cells, the Ministry further constituted a Team of Experts, which identified seven mission mode projects based on the recommendations of the Sub-Committees on various aspects of Hydrogen Energy and Fuel Cells to be implemented on priority. The Team of Experts took suggestions from various stakeholders for developing the broad outlines of the projects and indicative project cost. We hope that the recommendations of this Committee would enable the Government to take appropriate decision to accelerate development of hydrogen energy and fuel cells sector in country. This would also help the Government to work in a focused and goal oriented manner to move forward in generating knowledge in the emerging area of hydrogen energy. I am grateful to the members of the Steering Committee and SubCommittees especially the Chairpersons of the five Sub-Committees for their contribution, Shri Upendra Tripathy, Secretary, MNRE and Ms. Varsha Joshi, Joint Secretary, MNRE. I am also thankful to Dr. M. R. Nouni, Scientist ‘G’, 4 MNRE and officials of the Project Management Unit – Hydrogen Energy and Fuel Cells at the Ministry, Dr. Jugal Kishor and Dr. S. K. Sharma in particular for their active role in organising the meetings, coordination amongst different SubCommittees and preparing different draft documents based on the inputs provided by the members/experts. I also extend my compliments to the Team of Experts for putting their efforts in identifying seven mission mode projects and developing their broad outlines. I am confident that implementation of the recommendations of this report will bring paradigm shift in the area of hydrogen energy and fuel cell technologies in the country. June, 2016 (Dr. K. Kasturirangan), Chairman, Steering Committee on Hydrogen Energy and Fuel Cells 5 ABBREVIATIONS AFC Alkaline Fuel Cells CEA Central Electricity Authority AFCC Automotive Fuel Cell Cooperation CECRI Central Electrochemical Research Institute ANSI American National Standards Institute CFCT Centre for Fuel Cell Technology ARAI Automotive Research Association of India CFR Code of Federal Regulations CGCRI ARCI International Advanced Centre for Powder Metallurgy & New Materials Central Glass and Ceramic Research Institute CHP Combined Heat And Power ASME American Society of Mechanical Engineers CIRT Central Institute of Road Transport ATR Auto-thermal reformer C-MET Centre for Materials for Electronics Technology BARC Bhabha Atomic Research Centre CMVR Central Motor Vehicles Rules BC Bottoming Cycle CNG Compressed Natural Gas BEV Battery Electric Vehicle CNT Carbon nanotube BFC Bio-fuel Cell CRDI Common Rail Direct Injection BHEL Bharat Heavy Electricals Limited CSA Canadian Standards Association BoS Balance of System CSIR Council of Scientific and Industrial Research BPCL Bharat Petroleum Corporation Limited CSMCRI Central Salt & Marine Chemicals Research Institute Boiler & Pressure Vessel Code CSP Concentrating Solar Power Cu-Cl Copper-Chlorine DAE Department of Atomic Energy DCFC Direct Carbon Fuel Cell DEFC Direct Ethanol Fuel Cell BPVC BRNS Board of Research in Nuclear Sciences BS Bharat Stage CDT Centre for Doctoral Training 6 DI Direct Injection FCX Fuel Cell eXperimental DMFC Direct Methanol Fuel Cells FICB Fast Internally Circulating Fluidized-bed DRDO Defence Research and Development Organisation GAIL Gas Authority of India Limited GDL Gas Diffusion Layers DSIR Department of Scientific and Industrial Research GDP Gross Domestic Product DST Department of Science & Technology GHG Greenhouse Gas ECU Engine Control Unit GTI Gas Technology Institute EDGAR Electronic Data Gathering, Analysis, and Retrieval GTR Global Technical Regulation GW Gigawatt EEC European Economic Community HAL Hindustan Aeronautics Limited EERE Energy Efficiency and Renewable Energy HCCI Homogeneous charge compression ignition EIGA European Industrial Gases Association H-CNG Hydrogen – Compressed Natural Gas EIHP European Integrated Hydrogen Project HCV Heavy Commercial Vehicle ENG Expanded Natural Graphite HGV Hydrogen Gas Powered Vehicles EPO European Patent Office HHC Higher Hydrocarbons EPSRC Engineering and Physical Sciences Research Council HPCL Hindustan Petroleum Corporation Limited ER Equivalence Ratio HRD ESS Energy Storage System Human Resource Development FC Fuel Cell HT-PEMFC FCC Face Centered Cubic High Temperature Polymer Electrolyte Membrane Fuel Cell FCEV Fuel Cell Electric Vehicle HTSE High Temperature Steam Electrolysis FCH Fuel Cell and Hydrogen hymet FCHV Fuel Cell Hybrid Vehicle Mixture of bio-hydrogen and bio-methane FCT Fuel Cell Technologies Hythane® Trade Name of Hydrogen + 7 HyTRIP Methane IS Indian Standard Hydrogen for Transportation through Research & Innovation driven Program I-S Iodine-Sulphur ISO International Standard Organization ISRO Indian Space Research Organization IC Internal Combustion ICC International Code Council ICE Internal Combustion Engine ITI Industrial Training Institute ICHET International Centre for Hydrogen Energy Technologies ITPO India Trade Promotion Organization KOH Potassium Hydroxide Institute of Chemical Technology LCVs Light Commercial Vehicles IEA International Energy Agency LDVs Light Duty Vehicles IEC International Electrotechnical Commission LHV Lower Heating Value LOH Liquid Organic Hydride LPG Liquefied petroleum gas LT-PEMFC Low Temperature Polymer Electrolyte Membrane Fuel Cell ICT IFC International Fuel Cells, USA IICT Indian Institute of Chemical Technology IISc Indian Institute of Science IIT Indian Institute of Technology M&M Mahindra & Mahindra Limited IMMT Institute of Minerals and Materials Technology MCFC Molten Carbonate Fuel Cell MEA Membrane Electrode Assembly MFC Microbial fuel cell MH Metal Hydride MHV Materials Handling Vehicle INAE Indian National Academy of Engineering INDC Intended Nationally Determined Contribution INL Idaho National Laboratory IOCL Indian Oil Corporation Limited IPHE International Partnership for Hydrogen and Fuel Cells in the Economy IPR Intellectual Property Right MJ/m 8 3 Mega Joule Per Cubic Meter MMP Mission Mode Project MNRE Ministry of New and Renewable Energy MPa Mega Pascal MWel Mega Watt Electric OEMs Original Equipment Manufacturers NASA National Aeronautics and Space Administration ONGC Oil and Natural Gas Corporation PAFC Phosphoric Acid Fuel Cells PEC Photo Electrochemical PEM National Environmental Engineering Research Institute Polymer Electrolyte Membrane PESO Petroleum Explosives Safety Organization National Fire Protection Association PFI Port Fuel Injection PGCIL Power Grid Corporation of India Limited PHEV Plug-in Hybrid Electric Vehicle POX Partial oxidation PNG Piped Natural Gas PPP Public Private Partnership PSI Pounds per square inch PSUs Public Sector Units Pt Platinum RCUK Research Councils UK RD & D Research, Development & Demonstration RDSO Research Designs & Standards Organization RESPOND Sponsored Research by ISRO SAE Society of Automotive Engineers SBR Steam-to-Biomass Ratio NATRIP NCL NEERI NFPA NFTDC NHAI National Automotive Testing and R&D Infrastructure Project National Chemical Laboratory Nonferrous Materials Technology Development Centre National Highways Authority of India NHEB National Hydrogen Energy Board NHERM National Hydrogen Energy Road Map NGV Natural Gas Vehicle Nl/h Normal Litre per Hour NHEB National Hydrogen Energy Board Nm 3 Normal Cubic Metre NMRL Naval Materials Research Laboratory NMTLI New Millennium Indian Technology Leadership Initiative NOx Nitrogen Oxides OEC ONGC Energy Centre 9 SCV Small Commercial Vehicle UNICEF United Nations International Children's Emergency Fund SCoE Standing Committee on Emissions UNIDO United Nations Industrial Development Organization U.S. Securities and Exchange Commission UPS Uninterruptible Power Supply SI Spark Ignition US DoE United States Department of Energy SIAM Society of Indian Automobile Manufacturers USPTO United States Patent and Trademark Office Static and Mobile Pressure Vessels (Unfired) VFCI Virtual Fuel Cell Institute SMR Steam Methane Reformer VSSC Vikram Sarabhai Space Centre SNG Synthetic Natural Gas YSZ Yttria Stabilized Zirconia SOA Siksha 'O' Anusandhan YVU Yogi Vemana University SOFC Solid Oxide Fuel Cell ZEV Zero Emission Vehicle SPE Solid Polymer Electrolyzer SPWE Solid Polymer Water Electrolyser SSF SPIC Science Foundation SUV Sport Utility Vehicle SWNT Single-Walled Nanotubes TBR Trickling Biofilter Reactor TC Topping Cycle TERI TERI - The Energy and Resources Institute TIFAC Technology Information, Forecasting and Assessment Council UKRC United Kingdom Resource Centre UNECE United Nations Economic Commission for Europe SEC SMPV(U) 10 Composition of Steering Committee on Hydrogen Energy and Fuel Cells Chairman: Dr. K. Kasturirangan, Former Member (Science), Planning Commission, Government of India; currently Chairman of Governing Council, Raman Research Institute, Bengaluru; Chancellor, Jawaharlal Nehru University, New Delhi and Satish Dhawan Chair of Engineering Eminence of INAE Members: 1. Secretary, Ministry of New and Renewable Energy, Government of India 2. Secretary, Department of Science & Technology, Government of India 3. Director General, Council for Scientific and Industrial Research and Secretary, Department of Scientific and Industrial Research, Government of India 4. Secretary, Ministry of Petroleum & Natural Gas, Government of India 5. Secretary, Ministry of Road Transport & Highways, Government of India 6. Secretary, Department of Defence Research & Development and Director General Defence, Research Development Organization, Government of India 7. Director, Bhabha Atomic Research Centre, Trombay 8. Director General, Bureau of Indian Standards, New Delhi 9. Chairman, Indian Oil Corporation Limited, New Delhi 10. Chairman & Managing Director, Bharat Heavy Electricals Limited, New Delhi 11. Director, Petroleum Explosive & Safety Organization, Nagpur 12. Director General, Confederation of Indian Industries, New Delhi 13. Director General , Society of Indian Automobile Manufacturer, New Delhi 14. Director, Automotive Research Association of India, Pune 15. Chairman, Sub-Committee on Research, Development and Demonstration and Chairman of Project Monitoring Committee on Hydrogen Production(Prof. S. N. Upadhyay, Former Director, Indian Institute of Technology (Banaras Hindu University)& Retired Professor and currently, DAE-Raja Ramanna Fellow, Department of Chemical Engineering, Indian Institute of Technology (Banaras Hindu University), Varanasi 16. Chairman, Sub-Committee on Hydrogen Storage and Applications other than Transportation and Project Monitoring Committee on Hydrogen Storage(Dr. S. Srinivasa Murthy, Retired and Emeritus Professor, Mechanical Engineering, Indian Institute of Technology Madras, Chennai and Currently, Visiting Professor, Interdisciplinary Centre for Energy Research, Indian Institute of Science, Bangalore) 17. Chairman, Project Monitoring Committee on Hydrogen Applications (Dr. R. P. Sharma, Retired and Henry Ford Chair Professor, 11 Department of Mechanical Engineering, Indian Institute Technology Madras); and 18. Chairman, Sub-Committee on Fuel Cells Development and Project Monitoring Committee on Fuel Cells(Dr. H. S. Maiti, Retired Director, CSIR - Central Glass and Ceramic Research Institute, Kolkata and Former INAE Distinguished Professor, Government College of Engineering and Ceramic Technology, Kolkata ) 19. Joint Secretary / Adviser (Hydrogen Energy & Fuel Cell), Ministry of New and Renewable Energy - Member Secretary Terms of reference i) ii) iii) iv) v) vi) vii) viii) To define measures for strengthening research and development capabilities in the country in existing organizations on different aspects of hydrogen energy e. g. production, storage, transportation and applications including fuel cells. To periodically review the projects and activities being undertaken in the area within the country. To guide in strengthening academia – industry interactions and setting up demonstration projects in these areas To guide and direct the patenting and intellectual property rights of protection of technologies developed under the R & D and demonstration projects. To guide in the development of safety measures, codes and standards of production, storage and distribution, handling the use of hydrogen as a fuel for various applications. To suggest policy initiatives and financial /fiscal / regulatory measures including other measures for promotion of hydrogen as clean fuel. To guide in the activities related to human resource development in these areas. To take such other measures which are considered necessary for spreading the use of Hydrogen Energy and fuel cells. 12 1. Introduction "Earth has enough resources to meet people's needs, but will never have enough to satisfy people's greed" and “The people on earth should act as 'trustees' and use natural resources wisely, as our moral responsibility to ensure that we bequeath to the future generations a healthy planet.” - Mahatma Gandhi “I believe that water will one day be employed as fuel, that hydrogen and oxygen which constitute it, used singly or together will furnish an inexhaustible source of heat and light of an intensity of which coal is not capable…………………water will be coal of the future” JULES VERNE Mysterious Island in 1876 …. “With a new national commitment, our scientists and engineers will overcome obstacles to taking these cars from laboratory to showroom, so that the first car driven by a child born today could be powered by hydrogen and pollution-free“….. George Bush On Freedom Fuel Man’s dependence on fossil fuels has made a deep impact on energy and food security. This has led to exhaustion of fossil fuels resources, emission of harmful gases like carbon monoxide, nitrous oxide, sulphur dioxide, etc., which pollute the environment and adversely affect the health of living beings on the earth. There is excessive emission of carbon dioxide also. As result of which, level of carbon dioxide is rising in the earth’s atmosphere and creating greenhouse effect on earth. Due to this effect, the heat generated (heat received from sun, generated in industries, households and automobiles etc.) on the earth, remains in the atmosphere. It can’t escape out of the earth’s atmosphere and remains in the earth’s atmosphere due to greenhouse effect. Hence, the atmospheric temperature of the earth rises, which is known as global warming. The global warming adversely affects weather, melting of glaciers, resulting unpredictable rainfalls, storms, floods creating havoc to living beings and the agriculture on the earth and ultimately, rise in sea level, which may endanger the lives of 14.2% of India’s population, which inhabits on the 7,517 km coastlineand1,238 Indian islands. The other reason of emission of CO2 is the growth of the population of living beings (According to the United Nations, world population is expected to reach 8 billion in the spring of 2024 & 9 billion by 2050) and industries. The vehicles are also responsible for emission of pollutants and CO2 (more than 1 billion 13 automobiles in use worldwide, which contribute ~13.1% of GHG emissions worldwide (5 billion tonnes of CO2 per year) into Earth's atmosphere. The increasing number of diesel vehicles on roads further worsens air quality. Tailpipe emissions are responsible for several debilitating respiratory conditions, in particular the particulate emissions from diesel vehicles. The global annual mean concentration of CO2 in the atmosphere has increased markedly since the Industrial Revolution. It is currently rising at a rate of approximately 2 ppm/year and also accelerating further. Doha Agreement was signed in 2001 among the countries, so that CO 2 level should not rise more than 450 ppm by 2050 (in 2009 it was 415 ppm and will be 430 by 2025). Similarly, in terms of temperature it may not be allowed to rise more than 20C by 2050 (with reference to the year 1850) as per this agreement. If the atmospheric temperature rises above 1.60C by 2015, carbon tax should be levied for the rise of remaining 0.40C. The Electronic Data Gathering, Analysis, and Retrieval (EDGAR) system performs automated collection, validation, indexing, acceptance, and forwarding of submissions by companies and others who are required by law to file forms with the U.S. Securities and Exchange Commission (SEC). Based on the EDGAR database, created by European Commission and Netherlands Environmental Assessment Agency released in 2014 (Annexure-III), India stands at the bottom for per capita CO2 emissions per annum with 1.8 tonnes in the list of top twenty emitters - Australia 17.3 tonnes, Saudi Arabia 16.8 tonnes, United States 16.5 tonnes, Canada was 15.9 tonnes, Russia 12.4 tonnes and Saudi Korea 12.3 tonnes in 2014 and Japan 10.1 tonnes and world total CO2 emissions are 35,667 million tonnes in 2014. The major countries, European Union from 1990 level by 2030 & Australia (Greenhouse gas only) from 2005 level by 2030 reduce emissions at least 40%, 26-28%, and USA & Brazil (Greenhouse gas only) reduce emissions 26-28% and 37% from 2005 level by 2025 respectively. China will achieve peak emissions by 2030 and will decline thereafter. China will cut carbon intensity (emissions per unit of GDP) by 60-65% from 2005 level by 2030. All these countries have also committed to increase share of renewable energy in their total energy mix. In the G-20 Summit held on 15-16 November 2015 at Antalya, Turkey, the Prime Minister of India proposed a seven point agenda on Climate change – (i) an effective role in supporting the multilateral goals of increasing research and development to develop affordable renewable energy may be played (ii) It should ensure that finance and technology is available to meet the universal global aspiration for clean energy (iii) The target of US$ 100 14 billion goal per year by 2020 may be met (iv) Every G20 country should increase the share of traffic on public transportation in cities by 30 per cent by 2030 (v) A shift from "carbon credit" towards "green credit" may be made (vi) Every G-20 country should not only reduce the use of fossil fuel, but also moderate our life style (vii) Development in harmony with nature is the goal of the proposal to launch alliance with solar-rich countries. India submitted to UN Framework Convention on Climate Change its Intended Nationally Determined Contribution (INDC) promising to reduce emission intensity by 33-35% by 2030 over the 2005 levels with a cost of $ 2.5 trillion, boost clean energy in electricity generation to 40% through nonfossil fuel sources such as solar, wind, hydro, biomass & nuclear, while adding carbon sinks — tree and forest cover to remove carbon. The Climate Action Plan would cost the nation $2.5 trillion. India would also raise investments in programmes to adapt to climate change in agriculture, water resources, Himalayas, coastal regions, health & disaster management. India Action Plan includes additional capacity of 175 GW (38 GW as 31.10.2015) of renewable energy (100 GW by solar, 60 GW from wind, 10 GW from biopower and 5 GW from small hydro-power) by 2022; cut in subsidies on fossil fuel and tax on coal and National Clean Energy Fund of $3 billion to promote clean technologies. India needs further to manage i) Efficient use through policies like National Mission for Enhanced Energy Efficiency, labeling electrical appliances on power consumption. ii) Smart Cities Mission to transform urban areas. Develop on cities that promise clean and sustainable environment. iii) For Waste Management, incentivizing waste to energy conversion projects. Investing in solid waste and waste water management projects. iv) In Low-carbon economy, dedicated transport systems like freight corridors, inland water transport. Moving people rather than vehicles through MRTS, Metro rail. As remedial measures toreduce dependence on fossil fuels, reduce local & global pollutants and CO2 emissions, ensure energy security (in terms of cooking, power supply and drive automobiles), keeping in view economic, financial, social and environmental considerations, carbon-based nonrenewable resources may be shifted to carbon-neutral renewable sources of energy. The possible alternative renewable sources of energy are solar, hydro-electric, wind power, biofuels, etc. The major drawback in all these cases is that periods of peak energy production do not necessarily coincide with periods of peak energy consumption. Therefore a complete transition to 15 such an alternative energy source relies on efficient capture, conversion and storage, which is currently being explored worldwide. The Intended Nationally Determined Contribution (INDC) also highlighted to initiate policies for coal cess, cuts in subsidies, increase in taxes on petrol and diesel and market based mechanisms such as Perform, Achieve and Trade, Renewable Energy Certificates and a regulatory regime of Renewable Purchase Obligations. A National Renewable Energy Act 2015 of India has been drafted to promote the production of energy through the use of renewable energy sources in accordance with climate, environment and macroeconomic considerations in order to reduce dependence on fossil fuels, ensure security of supply and reduce emissions of CO2 and other greenhouse gases. This Act shall in particular contribute to ensuring fulfillment of national and international objectives on increasing the proportion of energy produced through the use of renewable energy sources. In the UN Framework Convention on Climate Change and its Intended Nationally Determined Contribution (INDC), it appears that hydrogen energy and fuel cells have not yet received a place world’s energy scenario. However, the kind of efforts and investments are being made world over, it seems that hydrogen energy and fuel cells would find an important place soon in the world’s energy scenario. The stress is being put to exploit various renewable energy sources like solar photovoltaic, wind, and hydro for power generation. Solar thermal and bio-energy sources have also different applications other than power generation. Similarly, hydrogen is an environmentally clean source of energy carrier to end-users, particularly in transportation applications, without release of pollutants such as particulate matter or carbon dioxide at the point of end use. It is being considered as the fuel for future, an environmentally friendly alternative to depleting fossil fuels. Its application in transportation can be a game changer in future, although stationary power may also be generated in the centralised and decentralized modes. It has very high energy content per unit mass, almost three times higher than gasoline. Molecular hydrogen is not available on Earth in convenient natural reservoirs. Most hydrogen on Earth is bonded to oxygen in water and to carbon in live or dead and/or fossilized biomass. It can be created by splitting water into hydrogen and oxygen. Water is again formed, when hydrogen is used. Currently, global hydrogen production is 48% from natural gas, 30% from oil, and 18% from coal; water electrolysis accounts for only 4%. The technical obstacles in hydrogen economy are hydrogen storage issues and the purity requirement of hydrogen used in fuel cells – with current 16 technology, an operating fuel cell requires the purity of hydrogen to be as high as 99.999%. Similarly, there are many issues and challenges with the different aspects on hydrogen energy and fuel cells like hydrogen production, transportation through hydrogen fueled vehicles, hydrogen storage and applications other than transportation. Intellectual Property Rights, PublicPrivate Partnership, Safety, Standards, Awareness and Human Resource Development are other important aspects, which are also required to be addressed before commercialization of the hydrogen devices / systems take place. All these aspects have been taken-up in the subsequent chapters of this report. These Chapters cover recommendations of the projects in the categories of (i) Mission Mode (for the technologies, which are mature or near maturity for commercialization and with the participation of the industry); (ii) Research & Development (for the technologies, which are at the stage of prototype development, their demonstration as a proof of concept and preferably with Industry participation); and (iii) Basic / Fundamental Research (for advanced research on new materials and processes) on the basis on gap analysis between international and national state of art of technologies. 17 2. Hydrogen Production in India Hydrogen is a by-product in Chlor-Alkali industries. Earlier, a part of it was used for non-energy applications and rest was either flared or vented out in the atmosphere. With the passage of time awareness about its usage for energy applications increased and up to 2013-14 around 90% of by-product hydrogen was utilized for production of chemicals and captive (mainly energy) applications. There are around 40 such units in India, which produced nearly 66000 tons of by-product hydrogen during 2013-14. Around (10% of total production i.e.) 6600 tons of this hydrogen remained unutilized. In addition to above, hydrogen is produced for non-energy applications e.g. in fertilizer industries and petroleum refineries. The ‘quantum of increase’ in hydrogen production will enable its mass scale utilization as a fuel. To have sustainable hydrogen production, the energy and raw material needed for this purpose ought to be renewable in nature. There are various methods for generating hydrogen from renewable and non-renewable resources. However, the challenge lies in the production of hydrogen in a cost effective manner. Hydrogen can be produced through the following processes: A. From carbonaceous sources i) ii) iii) iv) v) Steam Methane Reforming: These reformers are commercially available for hydrogen production and more than 90% with 99.999% pure hydrogen is produced from natural gas through this process. These reformers are most efficient, economical and available in small capacities also. Membrane reactors for steam reforming are another promising technology for producing very pure hydrogen. Partial Oxidation: These reformers are more compact and used to produce hydrogen from residual oil. Small capacity reformers are commercially available. Auto-Thermal Reforming: Best features of steam reforming and partial oxidation systems have been combined in these reformers. No external heat source and heat exchanger are required because heat generated by the partial oxidation is utilized to drive partial oxidation and hence such reformers are more compact with higher efficiency. These reformers require lower capital cost Methanol Reforming: Automakers took interest in such reformers, because of the advantages to store methanol on-board as liquid, compactness of reformer, faster start-up and potentially lower cost. These reformers were demonstrated in PEM fuel cell vehicles, but no fuel cell vehicle manufacturer is currently using this technology. Novel Reformer Technologies: There are other technologies for 18 producing hydrogen like (a) ammonia cracking, which is available at low cost in the country, but a costly unit of Pressure Swing Adsorption unit is required for separating H2 and N2; (b) Sorbent-enhanced Catalytic Steam-reforming system has been developed and is at the demonstration stage; (c) ceramic membrane technology for separation of hydrogen from syngas. Conceptual designs were carried out for a hydrogen-refueling station. This route is expected to be cheaper (d) Thermal plasma reformer technology can be used for the production of hydrogen and hydrogen-rich gases from methane (with maximum of 95% conversion) and a variety of liquid fuels. The power requirement is reduced by about half. This technology is under evaluation; (e) BioOil reformation: Bio-oil can be obtained by thermally decomposition / fast pyrolysis of biomass and reformed to produce hydrogen. Pressure Swing Adsorption (PSA) system is used to separate hydrogen from the reformed products. National Renewable Energy Laboratory (NREL) U.S.A. has developed and demonstrated this technology; (f) Pyrolysis, oxidation and reduction of biomass with injection of secondary air. This process has been optimized to generate a maximum of about 100 g of hydrogen per kilo gram of biomass. Netherlands has developed this process and installed a pilot plant of 800 kWth capacity. A combined heat and power (CHP) plant (8MW) is in operation since 2002 in Güssing, Austria. B. Electrolysis of water (i) Alkaline water electrolysis: It is a matured technology, less expensive and is commercially available (in MW range) technology with hydrogen production 760 Nm³/h. These electrolysers face major challenges of corrosion and poisoning of electrodes. The largest existing alkaline electrolysis plants are 160 MW plant in Aswan, Egypt and 22 MW plant operating in Peru (pressurized operation). (ii) Polymer Electrolyte Membrane (PEM) based water electrolysers: The drawbacks of alkaline water electrolysers were overcome by the development of solid PEM water electrolysers, which has lower stack life. These are costlier and available in lower capacity range from 0.06 to 75 Nm³/hr but are more reliable. Council of Scientific and Industrial Research - Central Electro-Chemical Research Institute (CSIRCECRI), SPIC Science Foundation (SSF), Chennai; Centre of Fuel Cell Technology (CFCT), Chennai and Jawaharlal Nehru Technical University (JNTU), Hyderabad developed alkaline water electrolysers. CSIR-CECRItransferred these technologies to M/s. Eastern Electrolysers, New Delhi for further development and commercialisation. SSF obtained energy consumption is around 2.0 kWh/Nm3 whereas CFCT, Chennai 1.40kWh/Nm3. 19 (iii) High temperature water electrolysis: It uses solid oxide electrolyte and offers advantage of lower capital cost. These require around 30% electricity (i.e. about 2.6-3.5 kWh/Nm3 hydrogen produced). These electrolysers have been developed for capacities 1.5,10 and 30 Nm3 /h. The Bhabha Atomic Research Centre (BARC), Mumbai has planned to develop these electrolysers for capacities of 1.0 Nm3 /h. C. Biological Route The economical way of hydrogen production is biological route, which carried through dark (continuous production) and photo (only in presence of light) -fermentation of organic materials. A prototype hydrogen bioreactor using waste as a feedstock is in operation at Welch's grape juice factory in North East Pennsylvania, USA. Major contributors in the research of this process are from United States of America, Canada, Malaysia, Indonesia, Thailand, China and India (Shri AMM Murugappa Chettiar Research Centre, Chennai; Indian Institute of Technology Kharagpur and Indian Institute of Chemical Technology, Hyderabad). Integration of bio-hydrogen with fuel cell was first mooted in 2012. The dark fermentation for hydrogen production can be commercialized, if it is integrated with biomethantion process. The integration of these two processes might lead to 50-60% gaseous energy recovery. D. Thermochemical Splitting of Water Water can be dissociated at very high temperatures into hydrogen and oxygen through. The required energy can be either provided by nuclear energy or by solar energy, or by hybrid systems including solar and nuclear energy. Around a dozen of thermo-chemical cycles such as the iron oxide cycle, cerium(IV) oxide-cerium(III) oxide cycle, zinc-zinc oxide cycle, sulfur-iodine cycle, copper-chlorine cycle and hybrid sulfur cycle are under research/in testing phase. The iodine-sulphur (I-S) cycle is one of the most promising and efficient thermo-chemical water splitting technologies for the mass production of hydrogen, on which BARC, Trombay, Mumbai is working. India is the 5th country to develop this process after USA (1980), Japan (2004), China (2010) and South Korea (2009). USA aims to demonstrate commercial scale production of hydrogen using nuclear energy by 2017. Japan initiated to set-up a pilot plant for production of 30 Nm3/h hydrogen. The Republic of Korea targets for 25 % (3 Mt/year) of the total hydrogen to be supplied by advanced 50 nuclear reactors by 2040 for generation of hydrogen for fuel cell applications for electricity generation, passenger vehicles, and domestic power and heating, and lowering hydrogen costs. People’s Republic of China initiated work to demonstrate I-S thermo-chemical cycle and high 20 temperature steam electrolysis technologies. They have target to commercialize nuclear hydrogen production by 2020.The Bhabha Atomic Research Centre has successfully demonstrated I-S process in closed loop operation in glass/quartz material in the laboratory. It is further planned to demonstrate closed loop operation in metallic construction. The ONGC Energy Centre (OEC) is working on three thermochemical processes, which are as Cu-Cl closed loop cycle, I-S closed loop cycle and I-S open loop cycle. E. Photo-catalytic and photo-electrochemical routes These routes for hydrogen production are also being explored globally by several research groups. In India also some groups, namely, Indian Institute of Chemical Technology, Hyderabad; Institute of Minerals and Materials Technology, Bhubaneswar; YogiVemana University, Kadapa; SRM University; Kancheepuram, Shiksha ‘O’ Anusandhan University, Bhubaneswar and Centre for Materials for Electronics Technology, Pune are active in this area. Efforts are being made to come out with effective and robust photo-catalysts and photo-electrocatalysts, electrode materials and materials for reactors. Till date no large scale unit has been successfully designed and demonstrated. Concerted intensive efforts, however, are required to generate basic information and knowhow to take this area to the production for decentralized applications. F. Non-thermal plasma assisted direct decomposition of hydrogen sulphide No commercial technology is available globally. Among the several techniques, Idemitsu Kosan Hybrid electrolysis process consumes 3.6 kWh/Nm3 hydrogen, whereas steam reforming of methane, demands still higher energy of 4.3 kWh/Nm3 hydrogen. Conversion efficiency is around 40%. Most of the research in this area in the country is focused under visible light may be solar light. Japan, Korea, U.S, Europe are engaged in to develop this process. Indian Institute of Technology Hyderabad developed the process with hydrogen production of 0.5 litre/minute. There is need to develop prototype batch photo-reactor using solar energy and their field trials using gas emitted at refinery site. BARC is working on photocatalytic degradation of nuclear waste as well as water purification. IISc, Bangalore is working on TiO2 based photocatalysts for organic waste degradation. IITs, Mumbai and Madras, CECRI, Karaikudi, IICT, Hyderabad and some universities in India are working on photodecomposition of organic pollutants. The Centre for Materials for Electronics Technologies (C-MET), Pune is working on hydrogen generation by photocatalytic decomposition of hydrogen sulphide. 21 Note: Draft report on “Hydrogen Production in India” prepared by SubCommittee on Research, Development & Demonstration is attached as Annexure - IV. Action Plan and Financial Projection The Action Plan and Financial Projections for hydrogen production in the country has been prepared as following: S. No. Name of Project Mission Mode Projects 1 Setting-up of purification unit / compression system to fill cylinders for power generating system / onboard application of hydrogen in vehicles / material handling vehicles(based on fuel cell technology) to utilize surplus hydrogen from the Chlor-Alkali Units / Refineries. 2 Scaling-up of the process of catalytic decomposition of natural gas for the production of H-CNG for the use in H-CNG fuelled vehicles (up to 2019) 3 Mission Mode Project for development and demonstration of biological hydrogen production from different kinds of wastes on bench scale, pilot scale and commercial production up to 2022 4 Mission Mode Project for Hydrogen production by water splitting using photolysis using solar energy upto 2022 Sub-Total A Research and Development 5 Hydrogen production by Auto-thermal Process (up to 2020) 6 Hydrogen production by gasification of biomass including demonstration of technology at pilot scale (up to 2020) 7 Development and demonstration afresh or deployment in place of old systems of electrolyser based on indigenous acid based SPE and alternate alkaline membrane up to 2018 8 Development and demonstration afresh or 22 Estimated Cost Rupees in Crore 20 40 20 40 120 20 10 10 10 deployment in place of old systems of alkaline 1 & 5 Nm3/hr high temperature steam solid polymer water electrolyser (up to 2020) 9 Development & demonstration of efficient alkaline water electrolyser (Upto 2018) 10 Development and demonstration of Hydrogen production by splitting water using renewable energies such as solar energy, wind energy and hybrid systems including electrolysis, photocatalysis and photo-electro-catalysis (up to 2022) 11 Hydrogen production by reformation of bio-oil obtained from fast pyrolysis of biomass 12 Development of technology for production of syngas (CO+H2) and hydrogen from reformation of natural gas / biogas using solar energy. 13 Integration of large capacity electrolysers with wind / solar power units when there are not in a position to evacuate power to grid for providing hydrogen. Sub-Total B Basic / Fundamental Research 14 Dissociation of gaseous hydrocarbon fuels to hydrogen using solar energy (up to 2022) 15 Demonstration of closed loop operation of I-S in metallic reactor and both I-S open & closed loop process and Cu-Cl cycle using solar / nuclear heat in Mission Mode up to 2022 16 Other innovative method for hydrogen production like hydrogen production by non-thermal plasma assisted direct decomposition of hydrogen sulphide, Photo-splitting of Hydrogen Sulphide including developmental effort for reduction in energy consumption for hydrogen production(up to 2022) Sub-Total C Total 23 10 10 5 5 5 85 10 50 20 80 285 3. Hydrogen Storage Transportation and Applications other than Hydrogen storage needs special attention due to hydrogen being smallest molecule, density-wise lightest, lowest ignition energy and wide range of explosion limit with air, which lead to embrittlement of materials of construction of hydrogen storage vessels and safety hazards. Therefore, safe and efficient storage and delivery of hydrogen is essential for the success of hydrogen economy. Hydrogen can be stored by the following ways:(i) (ii) (iii) (iv) (v) (vi) High-pressure gas cylinders (up to 800 bar) Liquid hydrogen in cryogenic tanks (at 21oK) Physi-sorbed hydrogen on materials with a large specific surface area Chemi-sorbed on interstitial sites in host metals and Inter-metallics Chemically bonded in covalent and ionic compounds Oxidation of reactive metals such as. Li, Na, Mg, Al, Zn with water Hydrogen is widely used in pressure vessels for on-board mobile applications, stationary application for dispensing hydrogen at re-fueling stations and at sites for stationary power generation. The pressure vessels are made of special alloys and also with reinforced composite carbon fiber so as not to face problem of brittleness. Currently, hydrogen is being stored in compressed form at 350 bar (5,000 psi) in on-board in demonstration vehicles and 700 bar (10,000 psi) in Type IV carbon composite cylinders. Carbon composite cylinders to store hydrogen at 700 bar (10,000 psi) are not being manufactured in the country. The cryogenic hydrogen is to be stored in specially insulated vessels at (-) 252.880C. The storage vessels may be made of FCC with special insulation, comprising double walled with vacuum in between, opacifiers and multi-layer insulations. Liquid organic hydrides are also potential candidates for hydrogen storage and delivery. The concept has been demonstrated successfully at laboratory level. Further work is being pursued. Rare earth systems based on La, transition metals based on Ti and of late light metal based such as Mg have been identified as the candidates. Two crucial parameters determine the performance metrics of metal hydrides, namely gravimetric percentage and desorption temperature. La Ni5 with additions of Ce and Al have desorption temperature in the range from 40 C to 140 C, with maximum storage of 1.2wt% H2 and Mg based materials with as high a storage as 6wt% with desorption temperature of 250 - 3000C. The lowest desorption temperature achieved is 2100C with 3.5 wt% storage capacity. 24 Although a number of intermetallic alloys have been prepared and their hydrogenation potentials assessed, a few have suitable combination of properties that permit their use for hydrogen storage or other applications. The most viable candidates include alloys with the following compositions: A2B (e.g.,Mg2Ni), AB (e.g.,TiFe), AB2 (e.g.,ZrMn2) and AB5 (e.g.,LaNi5). A variety of solid-state hydrogen storage materials viz. MgH2, Mg2NiH4, NaAlH4, other alanates, borohydrates (gravimetric capacity of >7wt%), commercial hydrides such as FeTiH2 and LaNi5H6, adsorbents like carbon, nano-structured carbons (including CNTs) MoFs and hydrogen clathrate hydrate have been investigated for hydrogenation and dehydrogenation reaction conditions and their kinetics, retention of cycling capacity, susceptibility to impurities and reversible capacities. The need for material with practical operative conditions of pressure (1-10 bar) and temperature (300C-1000C) has simulated the interest of many researchers. Other major areas of research are improvement of kinetics of hydrogen uptake/release and enhancement of cycling capacity. Pure hydrogen physisorption has been demonstrated at cryogenic temperatures (up to ca. 6 wt% H2) for which extremely high surface area carbon is required. Pure atomic H-chemisorption has also been demonstrated to ca. 8 wt% H2, but the covalent-bound H is liberated only at impractically high temperatures (above ca. 400°C). The activated carbon materials made from carbon nanotubes, graphite nanofibers, known as next generation of energy systems are capable of storing hydrogen. Utilizing the exothermic and endothermic processes during sorption and desorption of hydrogen respectively in metal hydrides, highly efficient, compact and cost-effective chemi-sorption thermal energy storage devices can be developed. This could significantly contribute to the widespread utilization of solar thermal energy. Such demonstration systems suitable for small capacity ORC power packs are being studied at IISc-Bangalore. The hydrogen chemisorption – desorption heat exchanges during the hydrogen sorption process in metal hydrides can also be utilized to develop a variety of thermal devices, especially refrigeration and heat pump systems. The temperatures can range from cryogenic to very high values. Exhaust heat operated automobile airconditioners have been built by several agencies. One such prototype was developed by IIT Madras in collaboration with Thermax. Nanostructured systems including carbon nanotubes, nano-magnesium based hydrides, complex hydride / carbon nanocomposites, boron nitride nanotubes, sulphide nano-tubes of titanium and molybdenum, alanates, 25 polymer nanocomposites, and metal organic frameworks are considered to be potential candidates for storing large quantities of hydrogen. In addition, various carbonaceous nanomaterials and novel sorbent systems (e.g. carbon nanotubes, fullerenes, nanofibers, polyaniline nano-spheres and metal organic frameworks etc.) and their hydrogen storage characteristics are considered. In spite of these consistent and persistent efforts, these materials are yet to satisfy the required characteristics like storage capacity of around 6 weight percent, favourable and tuning thermodynamics around 30-55 KJ/mol of hydrogen and temperature of operation around 373 K with about 1000s of cycles of operation. Liquid organic hydrides (more than 6 wt% hydrogen and 60 kg/m3) consisting of various cycloalkanes can react with hydrogen under specific conditions and hydrogen may be recovered by the dehydrogenation of the cyclohexane at or near fueling stations for dispensing hydrogen into vehicles / other applications. Cyclohexane is transported back for reuse. Hollow microspheres or microcapsules have high gravimetric energy density, in which hydrogen may also be stored through permeation inside. Hollow microspheres are also known as microcapsules, microcavities, microbubbles, or microballoons. Hydrogen-filled hollow glass microspheres are also easy and safe to handle at atmospheric pressure and ambient temperature and can be poured or pumped in tanks. The technology is inexpensive and requires low energy consumption for producing large quantities of micro containers. In addition to meeting high degrees of safety, efficiency and cost effectiveness, the main challenges in all hydrogen storage systems design is use of lightweight materials and components, balanced storage capacity and kinetics for a given application, energy efficiency, the energy required for reversible solid-state materials, the energy associated with compression and liquefaction and liquid hydrogen technologies, durability of hydrogen storage systems is required with a lifetime of 1500 cycles, refueling time may be targeted to less than three minutes, to reduce cost of on-board hydrogen storage systems, applicable codes and standards for hydrogen storage systems and interface technologies, and assure safety and public acceptance, are to be established. APPLICATIONS OTHER THAN TRANSPORTATION Hydrogen has the potential to replace LPG and CNG for cooking because it has superior characteristics to LPG and PNG fuel in terms of ignitability, low ignition delay and higher flame stability. Catalytic burning of the hydrogen in the home cooker is the best way to use the hydrogen for 26 cooking. Several catalysts such as metals like Cu, Zn, Fe, Ni, Co; alloys like Co-Mn-Ag; storage alloys like MmNi5, ZrFe2 can dissociate H2. Catalytic techniques for hydrogen fueled catalytic cookers (i) are porous ceramic plate embedded with platinum in pores for flameless situation and (ii) new catalysts for hydrogen catalytic combustion Action Plan and Financial Projection High Pressure Hydrogen Gaseous Storage: CNG cylinders may be deployed in demonstration fleets of vehicles up to a pressure of 200 bar. For pressure more than 200 and up to 400 bar, hydrogen cylinders may be imported for the vehicle like buses and trucks. Such 50 vehicles may be taken-up for public demonstration. Simultaneously, 500 to 1000 hydrogen fueled vehicles be prepared in about 5 to 8 years for large scale demonstration. Consortium collaboration approach may be followed among HINDALCO, Indore; NPL, New Delhi; IOCL Nasik and BHEL (Hyderabad) to produce Al cylinders reinforced with carbon fibre tapes and other high strength wrappings. This consortium may prepare 50 such high pressure cylinders up to 400 bar and test them. Solid State Storage (Metal, Intermetallic and Complex Hydrides): Production of optimized, well known and already deployed Mischmetal based hydride e.g. Mm-Ni-Fe may be taken-up on pilot plant level (100 kg to 1 Ton Level) and simultaneously, its demonstration in the vehicles for on-board applications in around 50 three wheelers (hydride requirement around 2000 kg); 10 small cars (hydride requirement around 500 Kg). Solid State Storage (Metal, Intermetallic and Complex Hydrides): The off-board (Stationary) application for power generation in around 1000 Gen-Sets of 5-15 kW capacity (required hydride quantity 10 Tons) may be deployed. R&D efforts may be intensified for obtaining gravimetric and volumetric efficiencies of 5 to 6wt% and 60 kg/m 3 for metal hydrides particularly catalyzed MgH2 and gravimetric efficiency of 3 to 6 wt% for other intermetallic hydrides e.g. Zr Fe2, Mg2Ni type. R&D efforts may be upgraded for evaluation of reproducible high efficiencies 5 to 6wt% in complex hydrides with particular emphasis on catalyzed MgH2, NaAlH4, LiAlH4, NaAlH4- MgH2, Li-Mg-N-H system. Enhancement of R&D efforts are required to increase hydrogen storage capacity from 1 to 3wt% at ambient conditions and 5 to 8 wt% at Liquid N2 temperature in nano/porous carbons. Intensive Research & Development efforts may be taken up on Liquid Hydrides. Petroleum industry may also be networked to support the pilot runs. A demonstration may be done by setting up pilot facilities near a refinery and providing hydrogen to telecom towers in the range of 50 to 100 Km. 27 An Interdisciplinary, Inter-Institutional Center may be set up to evaluate the thermodynamic, thermophysical and kinetic properties, cyclic stability, performance augmentation based on mechanical and thermal design of solid state storage devices. Testing and certification of such devices should also be done by this facility. Development of miscellaneous energy related applications of hydrogen such as High Intensity Thermal Energy Storage and Heat Pump/Heat Transformer may be encouraged at the Institutions which have shown the feasibility, through demonstration projects. Action plan may include efforts for the development, distribution and monitoring of 1000 to 10,000 hydrogen fueled home cookers. It will sensitize the public and this may be followed by 25% to 50% replacement of LPG by hydrogen through manufacturing and use of home cookers through publicprivate partnership. Further developments on High Pressure Hydrogen Gaseous Storage may be taken up based on the feedback received about the cylinders, 1,000 nos. may be procured from the companies abroad and 9,000 nos. may be manufactured by Bharat Pumps and Compressors and other similar companies in India. Efforts are to be made to have 100% indigenous production during 2020-2035. These cylinders may be used in hydrogen fueled 3 wheelers, buses, vans, cars and in stationary systems like power generating system (>10kW) around 1000 IC engine Gen Sets and 500 in fuel cells power generating systems. Area-wise replacement of 50% diesel Gen Sets (10kW and higher) may be taken-up in crowded areas in the country. Efforts may be made to use such vehicles and Gen Sets to reach at least 30% of the total such devices in specific cities. Solid State Storage (Metal, Intermetallic and Complex Hydrides): Manufacturing of mischmetal based hydrides on pilot plant scale (1 Ton) may be taken up. These may be manufactured on large scale for (i) on-board applications in 500 three wheelers and 150 cars (ii) stationary application in 1000 Gen-Sets of 5 to 15 kW capacity and 500 fuel cells vehicles with 5 kW to 15kW fuel cells systems. The non- mischmetal based viable intermetallic hydride developed out of R&D efforts in Phase-I may be picked-up for initiation of manufacturing at pilot plant level (1 to 10 Tons). R&D efforts may be intensified on Mg/MgH2 hydrides to produce large quantities (100kg to 1 ton), to decrease desorption, absorption temperature to about 2000C through the use of effective catalysts, to enhance the desorption / absorption kinetics, to improve recyclability from 100 to 1000 cycles through Mg agglomeration checking systems, to develop MgH2 based vehicular transport, to optimize 28 gravimetric and volumetric efficiencies of complex hydrides (catalyzed NaAlH4, Mg (AlH4)2, LiAlH4 types) coming out of R&D in phase-I, to evaluate reversibility and cyclability, to adopt PEM fuel cell instead of IC Engines for 25% of the above said vehicles, to enhance hydrogen storage in nano/porous carbon and to use it in small vehicles. Storage, Transportation and Distribution of hydrogen are important for the success of ‘Hydrogen Economy’. Traditional methods of storage may not be directly applicable for use of hydrogen as a ‘fuel’. The technologies and devices should satisfy various stringent requirements such as; safety, economy, efficiency, flexibility, durability and environmental / ecological standards. The abovementioned actions can go a long way in facilitating the widespread use of hydrogen in our country. Note: Draft report on “Hydrogen Storage and Applications other than Transportation” is attached as Annexure - V. 29 ACTIVITIES ON HYDROGEN STORAGE & OTHER APPLICATIONS MMP: Mission Mode Projects; RD&DP: Research & Development Projects; B/FRP: Basic / Fundamental Research Projects Sl. No. Time Frame (Year) Financial Outlay Category of Projects 2016 2017 2018 2019 2020 2021 2022 (Rs. in Crores) Development and On-Field Deployment of 100 High Pressure Gas Cylinders Phase I Phase II Phase III Type III Type III & IV Type IV (Up to 250 bar) (Up to 350 bar) (Up to 700 bar) Mission Mode 1 Projects Development of Solid-State Storage Devices & Cartridges for Small Vehicles & Stationery Power Packs (PPs) Phase I Phase II Phase III (2-wheelers & (3-wheelers & other (Large Capacity up to 250 kW) PPs up to 20 kW) apps to 50 kW) 30 100 Manufacture of Solid-State Storage Materials 100 In Large Scale Phase I Phase II Phase III (Pilot Plants for Mishmetal / Mg based hydrides ) (Large Scale manufacture) (Advanced & Complex hydrides) SUBTOTAL 300 Development and Field Demonstration of Research, 2 Home Cookers with LPG mix & with Complete Hydrogen Development & Phase I Phase II Phase III Demonstration (Cookers with up to (Cookers with up to (Cookers with 75% LPG) 25% LPG) 100% Hydrogen) Projects 100 Development and Field Demonstration of High Intensity Thermal Energy Storage Systems Phase I Phase II Phase III (Capacity up to 250 kWth (Large Capacity up to 1 MWth) (Integrated Systems with CSP) Temp.up to 200 Deg C) SUBTOTAL 31 100 200 Synthesis & Characterization of 3. Basic / Fundamental Research Projects New / Novel Storage Materials and Devices Phase I Phase II Phase III Complex Hydrides, Carbons, MOF, etc) (Scale up of Quantities) (Fabrication of Grand Total 32 50 (10%) Devices) 550 4. Fuel Cell Development in India Different kinds of fuel cells have been developed. A few of them have been commercalised and remaining are under development. Important features of the well know fuel cells are given below: (i) Polymer Electrolyte Membrane Fuel Cell Low Temperature Polymer Electrolyte Membrane (PEM) Fuel Cells have high power density and can be easily started-up and stopped at low temperatures ranging from -35 to 400C, which have been found suitable for application in light and heavy duty vehicles. These fuel cells have been commercialized in many applications like vehicular and stationary power generation. The low temperature PEM fuel cells require high purity hydrogen, whereas the high temperature PEM fuel cells operate at higher temperature i.e. around 1200C and does not require very pure hydrogen (up to 3% CO content). Many companies have commercialized low temperature PEM fuel cells but high temperature PEM fuel cells are still under development. Large capacities (MW range) of stationary power generating systems based on low temperature PEM fuel cell technology have been installed and buses / cars are under demonstration / field trials in many countries like Canada, USA, Japan, Germany, United Kingdom. Soon these vehicle would be available to public. USA is the world leader in deployment of fuel cell based forklifts and more than 1500 units have been deployed at various locations. China will get support for 300 fuel cell buses, development of fuel cell tram engines. European Union will import fuel cell modules for 21 buses during 2016 and 2017. United Kingdom will extend the operation of 8 fuel cell powered buses for 5 more years and import 10 fuel cell modules to power buses. India is also putting efforts in developing and commercialising this technology. India has recently imported 150 fuel cell systems for deployment in telecom networks. Globally, it is expected that Power supply system of 25 lakh telecom towers will be converted to fuel cell based power system by 2020 and potential of global market for stationary fuel cells will reach 50 GW by 2020. In the country, many organizations like Centre for Fuel Cell Technology-International Advanced Research Centre for Powder Metallurgy, Hyderabad, CSIR-Network Labs, Naval Materials Research Laboratory, Ambernath, Vikram Sarabhai Space Centre, Thiruvananthapuram, Bharat Heavy Electrical Limited, Hyderabad; Thermax Limited, Pune are engaged in complete development of PEMFC system including stack and system developments. In addition, a number of academic institutions like Indian Institutes of Technology, Universities, National Institute of Technology are 33 also involved in the research, design, development and demonstration of components / Sub-systems / systems of different types of fuel cells. Despite the support from the Ministry for around two decades, the development of fuel cell system is not reached to the stage, at which these may be taken up for manufacturing due to various reasons like (i) lack of engineering input (ii) infrastructure for producing the systems in large numbers for trials / demonstration (iii) reliance on pressurized bottled hydrogen procured at high cost, since on-site hydrogen generation units (reformers) operating on commercial fuels such as LPG, methanol or natural gas are not available in the country and (iv) other issues like power density at a given cost, weight, and life time, which are of commercial importance, are also to be taken-up for further R&D. (ii) Phosphoric Acid Fuel Cell The phosphoric acid fuel cell (PAFC) have developed and commercialized with modules in the range of 100 - 400 kW for stationary power generation applications. It operates on propane/LPG/CNG / landfill gases with a life time of more than 45000 hours. It can tolerate fuel with less than 2% CO. Bharat Heavy Electrical Limited (BHEL) imported, installed and operated a 200kW PAFC unit with LPG as fuel. Later BHEL developed and demonstrated 50 kW PAFC system using hydrogen from the Chlor-Alkali industries. The Naval Materials Research Laboratory (NMRL), Ambernath also developed such systems of 1-15 kW capacity and demonstrated successfully for field applications. The technology has been transferred to the industry. (iii) Alkaline Fuel Cell Alkaline Fuel Cell (AFC) is a low cost technology, because of its components are made from inexpensive materials. Initially, it was used in space rockets. Now these fuel cells are not in use because of their inherent problems, which have not been overcome. However, if further development take place, these can be deployed in various other applications such as telecommunication towers, scooters, auto-rickshaws, cars, boats, household inverters, etc. (iv) Solid Oxide Fuel Cell The Solid Oxide Fuel Cell (SOFC) are multi-fuel compliant like gasoline, alcohol, natural gas, biogas etc. can be used. The fuels are reformed internally to producing hydrogen. SOFCs have been developed in two different designs i.e. tubular and planar types. Both have their merits and de-merits in their fabrication and operation. SOFC systems have been 34 developed in the power range 250- 300 watts operating on propane, butane and LPG in the countries like USA, Canada, Germany, UK, Denmark, Australia, Japan etc. Tubular type SOFC of 100kW capacity and Planar configuration up to 25kW capacity have been developed. In India, CSIRCGCRI, Kolkata has recently demonstrated a 1000W anode supported stack with planar configuration. Another major effort in development of the 3 rd generation technology (metal supported SOFC) has been underway by NFTDC, Hyderabad in collaboration with University of Cambridge, United Kingdom. (v) Direct Methanol/ Ethanol Fuel Cell Direct Methanol/ Ethanol Fuel Cell (DMFC / DEFC), uses methanol / ethanol to generate power less than 100 W. These fuel cells may be deployed in the devices with low power consumption like computerized notebooks, mobile phones, military equipment and such other electronic devices. DEFC faces problem of incomplete oxidation of ethanol to produce hydrogen gas. The researchers are trying to find suitable solution. The electronics OEMs, such as Samsung and Toshiba, and other companies developed such fuel cells with power density of 110 mW/cm2. Similarly, ternary PtRhSnO2/C electro catalyst have been synthesized in USA, which produces currents 100 times higher than those produced with other catalysts. However, Japanese scientists has also succeeded in getting short circuit current increased from 2.8 to 9.0 mA/cm2. In the country, some academic institutions / universities / engineering colleges are trying to get solution of the problems like i) electrocatalysts which can effectively enhance the electrode-kinetics of methanol oxidation ii) electrolyte membranes which have high ionic conductivity and low methanol crossover and iii) methanol tolerant electro-catalysts with high activity for oxygen reduction. (vi) Molten Carbonate Fuel Cell Molten Carbonate Fuel Cell (MCFC) operates at a temperature of about 6500C, which offers greater flexibility to the choice of fuels with higher efficiencies and simultaneously, imposes limitations in the selection of suitable materials of construction for long time operations. All the carbon monoxide is oxidized to carbon dioxide at anode, which requires proper management. The power plants based on MCFC technology have been installed from hundreds of kW to MW level in the world. In India R&D activities were taken-up but later discontinued. (vii) Bio-fuel Cell Biological fuel cells (or Bio-fuel cells) are of two types viz.: 1) Microbial fuel cells employ living cells such as microorganisms as the catalyst and 2) 35 Enzymetic bio-fuel cells, which use different enzymes to catalyze the redox reaction of the fuels. The production / consumption cycle of bio-fuels is considered to be carbon neutral and, in principle, more sustainable than that of conventional fuel cells. The potential areas for its power application are portable electronics, biomedical instruments, environmental studies, military and space research etc. In India, many institutions are active to develop suitable electrodes materials or tweak the microorganism. Mediator-less and membrane-less MFCs have been demonstrated on laboratory scale. (viii) Direct Carbon Fuel Cell Direct Carbon Fuel Cell (DCFC) converts fuel (granulated carbon powder ranging from 10 to 1000 nm sizes) to electricity directly with a maximum electrical efficiency up to 70% (with 100% theoretical efficiency). The systems, which may operate on low grade abundant fuels derived from coal, municipal and refinery waste products or bio-mass are under development. The byproduct is nearly pure CO2, which can be stored and used for commercial purpose leading to zero emission. Several laboratories in USA and Australia are active in the development of such a device that can easily be scaled up. No work in this area is reported so far from India. (ix) Micro fuel cells Micro fuel cells (MFCs) are the miniature form of either PEMFC or DMFC or SOFC and have the potential to replace batteries as they offer high power densities, considerably longer operational & stand-by times, shorter recharging time, simple balance of plant, and a passive operation. Micro fuel cells are ideal for use in portable electronic devices (fuel cell on a chip).Polymer electrolyte micro fuel cells can be used in 3D printing, which is effectively carried out on a large area. Low cost lithographic techniques have been developed for fluid flow micro channels. The other type based on monolithically integrated SOFC on a Si ship is also very important as planar configurations can be effected using modern manufacturing processes to make Li-batteries obsolete for certain type of applications. Currently, there is no activity on micro fuel cells in India. Action Plan and Financial Projection Based on the level of maturity of the expertise and the importance of the type of Fuel Cells, there may be three different categories of projects, which may be funded to the different extents. These are: i) Mission Mode Projects 36 It is proposed to form consortiums consisting of R&D laboratories, academic institutions and industries for each of the systems; one of them preferably a R&D laboratory may be identified as the lead organization. a) HT-PEMFC with combined cycle: Joint Lead Institutes - CSIR-NCL, Pune and CSIR-CECRI, Karaikudi) b) LT- PEMFC: Lead Institutes - CFCT, Chennai and/or CSIR-CECRI, Karaikudi/ BHEL R&D, Hyderabad. c) Planar SOFC: Lead Institute - CSIR-CGCRI, Kolkata d) PAFC: Lead Institute NMRL, DRDO, Ambernath and/or BHEL R&D, Hyderabad ii) Research & Development Projects With the objective of laboratory demonstration of critical systems and subsystems preferably with innovative approaches. Industry collaboration is preferred but not essential for this category. a) DMFC/DEFC b) MCFC c) BFC iii) Basic/ Fundamental Research Projects aiming at carrying out basic/ fundamental research (including modeling) on different aspects of any fuel cell system except the ones mentioned above. Budgetary Provisions It is recommended that an overall budgetary provision of Rs.750 Crore is allocated for the complete fuel cell development programme over a period of next 7 years (up to the financial year 2022-23); 80% of this may be earmarked for category I projects, 10% each for the other two categories. Supply chain for Hydrogen A parallel developmental activity is to be initiated for supply of around 1,500 million liter of high purity hydrogen for testing of the different capacities and different types of fuel cells proposed to be developed under this programme. Expression of Interest Particularly for the “Mission Mode Projects” the ministry should invite expression of interest from the interested research groups and industry followed by formation of the consortium and identification of lead organization. Virtual Fuel Cell Institute 37 For the purpose of efficient formulation and project management including rigorous monitoring a Virtual Fuel Cell Institute may be created under the aegis of the Ministry of New and Renewable Energy to bring all the concerned stakeholders such as Ministries, Departments, academicians, researchers and industry under one umbrella to work together in a systematic and focused manner. This Institute may undertake following activities: Development of a mechanism to pool the resources of different Ministries, Departments, International Funding Agencies and other agencies. (ii) Identification of expertise available with various institutions / industries and develop Mission Mode Projects utilizing the available expertise with the aim to develop components, sub-systems and integrate them, which can be mass produced and deployed in the country. (iii) Monitoring the progress of the work done under the projects to achieve the targeted goals in the time bound manner. (iv) Co-ordination among the institutions for demonstration of developed systems in field and comparison of various fuel cell technologies. (v) Development of a mechanism / modality to incentivize the individuals and the institutions involved in the development of a product. (vi) Conducting market survey for business potential of fuel cell in India (vii) Testing & benchmarking the components / prototypes / systems of fuel cell. (viii) Development of safety guidelines and standardization of on-board cost effective storage / transportation (i) The Institute should have a Directorate with required administrative and financial autonomy. All the members of the project team working at different locations (including the PIs) would be collectively responsible to this directorate, so far as the project activities are concerned. Note: Draft report on “Fuel Cell Development in India” is attached as Annexure - VI. 38 39 40 41 5. Transportation through Hydrogen Fuelled Vehicles As India moves ahead in the implementation of Euro 5 and Euro 6 emission norms for automobiles in the coming years, the impact on diesel car and SUV will give a jolt to these industry and users. Hydrogen may get a place automatically in the automobile sector to replace petrol and diesel vehicles and even coal for large scale power generation. Hydrogen fuel cell cars hit the streets of Great Britain during 2016 and have initial sales to early adopters up until 2020. United Kingdom has its plan to put 1.5 million hydrogen drivers on the British roads by 2030. Hydrogen fueled automobiles use hydrogen on-board to generate motive power either directly through internal combustion engine or indirectly, I,e, first to electrical energy through fuel cell then to motive power. Hydrogen can be used in different configurations of Internal Combustion (IC) engine such as spark ignition (SI) engine, compression ignition (CI) engine / dual fuel engine, CNG dual fuel engine and HCCI engine. High power outputs and low NOx emissions can be achieved by direct injection of hydrogen in SI engine. Hydrogen may also be used with biogas or other low grade gaseous fuels in this mode for the applications in locomotives and in stationary power generation. Hydrogen can be a good additive in the case of biogas diesel HCCI operation, as it raises the efficiency and extends the load range. Engine control units for dual fuel, HCCI and direct hydrogen injection engines with effective control strategies, in some cases to switch between modes have to be developed. There is need to develop after treatment device for NO x reduction (Lean NOX trap, SCR etc.), which will be helpful in improving power output while engine operates at a higher equivalence ratio. This is very relevant for heavy duty engines operating on hydrogen. The application of hydrogen blends with various fuels like CNG, LPG, Diesel etc. also need to be studied. Globally, several R&D project have been undergoing in various parts of the world for developing hydrogen based Internal Combustion Engines. Some of the significant project were (i) HyICE programme in Europe by European Commission and BMW in collaboration with various industry and academia for both single and multi-cylinder engines for various fuel injection strategies like Direct Injection and Cryogenic Fuel Injection (ii) Next Generation Environment Friendly Vehicle Development and Commercialization project in Japan for heavy duty engines Direct Injection Hydrogen IC engines (iii) Development of two hydrogen engines at Tokyo City University turbocharged with Port Fuel 42 Injection for light duty trucks with hybrid power train (iv) Homogeneous charge compression ignition (HCCI) with high compression ratio to overcome the issue of low emission versus better combustion rate and thermal efficiency (iv) Direct Injection to keep combustion confined and away from combustion chamber walls to lower NOx and have longer durability and sustained performance of Direct Injection Injectors. Thus, presently hydrogen powered IC engines are more suitable for heavy vehicle rather than fuel cells vehicles due to the higher specific power output. Many automotive companies have taken initiatives for the development of fuel cell vehicles like Daimler (A fleet total of 200 vehicles is now in operation across the world, including more than 35 in a Californian lease scheme), Ford (testing in the US, Canada and Germany with target to commercialise vehicles upto 2020, when the technology will be pricecompetitive), General Motors (developed more than 120 test vehicles), Honda (provided cars on a limited lease in California, extended to Japan and Europe, start selling before Rio Olympics-2016), Hyundai (provided on lease and will start selling before Rio Olympics- 2016), Nissan (near commercialisation), Toyota (numerous demonstrations in Japan and USA, sale will start before Rio Olympics – 2016, declared cost of vehicle as $55,000), Volkswagen (Began trials in 2013). A number of automotive companies came forward to take up joint initiatives like BMW and Toyota (Planned to market car from 2015 in Japan, the US and Europe), Daimler, Ford and Renault Nissan (to jointly develop common fuel cell system for use in separate mass-market cars from 2017), GM-Honda (collaboration on next-generation fuel cell systems and hydrogen storage technologies) Nationally IIT Delhi in collaboration with Mahindra & Mahindra has developed a fleet of fifteen hydrogen fueled three wheelers with hydrogen storage in gaseous phase, which are on field trials to generate awareness among public. Similar hydrogen powered three wheelers and motorbikes with hydrogen storage in metal hydride were also demonstrated by IIT BHU. The focus of R&D being. IIT Delhi in collaboration with Mahindra & Mahindra has developed Mahindra’s Tourist or Model Mini Bus with multi cylinder IC Engine and will be put for field trials. Mahindra & Mahindra developed hydrogendiesel dual fuel vehicles with hydrogen substitution of over 50%. Society of Indian Manufacturers conducted trials with Hydrogen-CNG blend fuel (18%) for three wheelers, cars, buses in collaboration with IOCL. Hydrogen requires safe handling, while being produces, stored, transported delivered / dispensed. Therefore, regulations and standards become key requirements for commercialization of hydrogen-fuelled vehicles and facilitate manufacturers to invest in this area. Bureau of Indian Standards 43 is the agency looking after the adoption of ISO standards, formulation of standards. Various standards regarding systems and devices for the production, storage, transport, measurement and use of hydrogen are in place and many others are to be formulated.). The Petroleum Explosives Safety Organization (PESO) is entrusted to ensure safety and security of public and property from fire and explosion. It is the agency to grant permission to deploy refueling stations and hydrogen storage containers of Type III and Type IV for fuel cell vehicles and other related equipment for usage of explosive corrosive, toxic and permanent flammable gases. Testing of vehicle and its components is mandatory before rolling out the vehicle on road. Hydrogen / hydrogen mixed fuelled vehicles also require all types of fitness. It evaluates hydrogen and HCNG internal combustion engine vehicles in closed-track and laboratory environments, as well as in field applications. Emission testing is also conducted as per Euro norms. Testing facilities include vehicle fuel cylinder testing (including gunfire, environmental chamber, hydrogen cycling, bonfire and burst testing), sensor testing, virtual testing, and vehicle emission using chassis dynamometer, engine dynamometer, noise and vibration testing. Action Plan and Financial Projections Based on the Gap Analysis and the strategy mentioned to overcome the gap areas, the following action plan has been identified by the Committee to execute time bound projects in the area of fuel cell and hydrogen based IC engines. A. Mission Mode Project : Hydrogen for Transportation through Research & Innovation driven Program – HyTRIP With the objective to demonstrate hydrogen FCEVs, establish infrastructure for the operation of vehicles and understand the technological challenges, market aspirations, price targets and safety requirements for commercializing the fuel cell technologies for mobility sector. B. Initiatives on other Technologies: HCNG, Fuel Cell Range extended Vehicles and Hydrogen energy based retrofitment solutions C. New Assessment Studies Other Projects D. Initiatives in other technologies – Proposed Budget Rs. 70 crores Note: Draft report on “Transportation through Hydrogen Fuelled Vehicles” is attached as Annexure - VII. 44 Time schedule and Financial implications Year 1 2 3 4 5 Total Project HyTRIP 12 88 165 110 15 390 a. Design of fuel cell drivetrains for each category of vehicle and Development of 50 fuel cell vehicles by OEMs including field trials of fuel cell vehicles for 3,000 hours of fuel cell operation b. Design of hydrogen DI engine based vehicles and Development of 20 vehicles for long term durability studies for 30,000 kms c. Design & Deployment of 10 Dispensing station for fuelling vehicles on hydrogen fuel at 350 bar 5 45 75 65 7.5 197.5 2 23 30 15 7.5 5 20 60 30 Cost (Crores) 115 Centre of Excellence d. Setting up of Centre of Excellence (CoE) for testing & certification of fuel cell stack / fuel cell and hydrogen engine based vehicle / hydrogen storage cylinders 77.5 200 50 20 30 50 50 200 Other Activities ‘e’ & ‘f’ 80 e. Initiatives in other Technologies HCNG activities Fuel cell range extenders Hydrogen based Retrofitment solutions for IC engines 70 45 f. New Assessment Studies 10 680 crore Grand Total 46 Phase-wise Financial Projections Plan - HyTRIP Year 1 2 3 4 5 Total Cost (Crores) Activity 1. Design of Dispensing station for fuelling vehicles on hydrogen fuel at 350 bar 5 5 2. Deployment of dispensing stations at recommended sites 20 60 30 110 3. Design of fuel cell drivetrains for each category of vehicle and prototype development of FC vehicles by OEMS 5 5 10 4. Development of 50 fuel cell vehicles by OEMs including integration and control strategy, selection of battery pack, Battery Management system (BMS) and drive train design including motor selection 40 5. Design of hydrogen DI engine based vehicles and prototype 47 75 65 180 development 2 3 5 6. Development of 20 hydrogen IC engine based vehicles for durability studies 20 30 15 65 7. Durability studies of fuel cells & IC engine protoypes / driving cycle simulation studies on test bench 10 10 3 5 50 200 8. Field trials of fuel cell vehicles for 3,000 hours and 30,000 kms for hydrogen IC engine based vehicles 2 Phase-wise Financial Projections Plan – Centre of Excellence 9. Setting up of Centre of Excellence (CoE) for testing & certification of fuel cell stack / fuel cell and hydrogen engine based vehicle / hydrogen storage cylinders 50 20 30 50 1. Four dispensing stations shall be designed for fuelling 50 vehicles per day and another 6 to be designed for 10 vehicles per day 2. Deployment cost of dispensing station for fuelling 50 vehicles is considered to be ~17 crores each while the cost of dispensing station for fuelling 10 vehicles is considered to be around 7 crores per station. 48 3. Rs. 10 crores has been allocated for designing the fuel cell based powertrains 4. Out of 50 fuel cell vehicles, 10 vehicles are for each category including two-wheelers, 3-wheelers, Passenger cars, SUV and Buses 5. Rs. 5 crores have been allocated for design of hydrogen DI engine based vehicles 6. 20 hydrogen IC engine based vehicles include 5 vehicles each in 3-wheeler, passenger car, SUV and heavy-duty category. 7. Durability studies to be conducted at IOC R&D and ARAI 8. Assumptions for fields trials include: Landed Hydrogen price: Rs 500/kg (Hydrogen to be sourced from different industries including refineries) 2 wheeler for 10,000 kms 80 km/kg of hydrogen 3 W for 20,000 kms : 60 km/kg of hydrogen Passenger Car for 30,000 km: 40 km per kg of hydrogen SUV for 30,000 km: 25 km per kg of hydrogen Buses for 30,000 kms: 10 km per kg of hydrogen CoE include the land cost of 50 crores and 150 crores as infrastructure development cost distributed for the next 4 years. 49 6. Intellectual Property Rights, Public Private Partnership, Safety, Standards, Awareness and Human Resource Hydrogen is being explored as a fuel for passenger vehicles. It can be used in fuel cells to power electric motors or burned in internal combustion engines (ICEs). This report focuses on the important dimensions with respect to introduction of Hydrogen and fuel cell technology namely IPR, Safety, Standards, Awareness and HRD. A Hydrogen internal combustion engine (ICE) vehicle uses a traditional ICE that has been modified to use Hydrogen fuel. One of the benefits of Hydrogen-powered ICEs is that they can run on pure Hydrogen or a blend of Hydrogen and compressed natural gas (CNG). That fuel flexibility is very attractive as a means of addressing the widespread lack of Hydrogen fuelling infrastructure in the near term. Fuel cell vehicles (FCVs), which run on Hydrogen, are currently more expensive than conventional vehicles, and they are not yet available for sale to the general public. However, costs have decreased significantly, and commercially available FCVs are expected within the next few years. Intellectual Property Rights As efforts for commercialization of patented technologies have increased, greater focus has been placed on Manufacturability at volume and cost effectively- patents have been generated in this area e.g. reducing components, alternative and cheaper materials, and manufacturing process driven improvements. It is easier to identify where innovation is likely, possible, required rather than which patents might be filed. There remains scope for innovation around durability, performance and cost reduction. They will be iterative changes unless and until someone identifies a real game changing step. Innovation is also likely to center around what technology is being used and for which applications. To promote fuel cell technology based innovation there must be proper strategies and plans which enhance IPR activities in India in those specific fields. Gas Storage Regulations The Gas Cylinders Rules, 2004 are required to be amended for incorporation of Hydrogen dispensing layout/facilities once Government of India permits inclusion of Hydrogen as an automotive fuel and CMVR are suitably amended in this regard. The international standard ISO: 20012 Gaseous Hydrogen – Fuelling Station may be useful for establishment of fuelling stations in the country on trial basis. At present ISO: 15869 is in the 50 draft stage for Gaseous Hydrogen and Hydrogen blend – Land Vehicle Fuel Tanks. Since ISO: 15869 (ISO/TC-197) is going to be internationally accepted code, the same may also be followed in this country as India being ‘P’ Member of the ISO/TC-197 Committee. IS: 15490 & IS: 7285(Part 2) are also required to be suitably amended for to incorporate Hydrogen-CNG blend and Hydrogen as automotive cylinders. Compressed hydrogen gases filled in metallic container pose potential hazard and threat to public life and property let the container explode. Hence, the Govt. of India vide Notification No.M-1272(1) dated 28/09/1938 has declared compressed gas filled in a metallic container to be deemed to be an explosive under Section 17 of the Explosives Act, 1884. Subsequently, in exercise of powers vested in Section 5 & 7 of the Act, the Govt. framed the Static & Mobile Pressure Vessels Rules, 1981 to regulate filling, possession, transport and import of compressed gases in pressure vessels. The Government of India has authorized the Petroleum and Explosives Safety Organization (PESO), Nagpur to administer responsibilities delegated under the Explosives Act 1884 and Petroleum Act 1934 and the rules made thereunder related to manufacture, import, export, transport, possession, sale and use of Explosives, Petroleum products and Compressed gases. Provisions have been made for hydrogen cylinders, valves including hydrogen dispensing under Gas Cylinders Rules, 2004 and Static & Mobile Pressure Vessels (Unfired) Rules, 1981. Safety In order to ensure safety of vehicles and for technical solutions to these issues following regulations and standards are critical. Government has identified the development of regulations and standards as one of the key requirements for commercialization of Hydrogen-fuelled vehicles. Regulations and standards will help to overcome technological barriers to commercialization, facilitate manufacturers’ investment in building Hydrogenfuelled vehicles and facilitate public acceptance by providing a systematic and accurate means of assessing and communicating the risk associated with the use of Hydrogen vehicles, be it to the general public, consumer, emergency response personnel or the insurance industry. Hydrogen is a flammable fuel with backfire and pre-ignition tendencies and safety aspects are critical in safe handling of the fuel. Standards Lack of Codes and standards have repeatedly been identified as a major institutional barrier to deploying Hydrogen technologies and developing 51 a Hydrogen economy. International Hydrogen Industry has come a long way in the past 10 years identifying needed standards for commercialization of Hydrogen energy systems, and participating with Standards Development Organizations to develop Hydrogen standards. Much of these standards writing is taking place at the International Organization for Standardization (ISO) level in ISO Technical Committee 197 (Hydrogen Technologies) with input through the national organizations. The International Electrotechnical Committee, IEC TC 105 (Fuel Cells}, ISO TC 197, and ISO TC22 SC 21 (Electric Vehicles) are all involved in fuel cell standards activities. Human Resource Development Human resource development is the key to sustained R&D program on Hydrogen. Hydrogen and fuel cells are considered in many countries as an important alternative energy vector and a key technology for future sustainable energy systems in the stationary power, transportation, industrial and residential sectors. The realization of Hydrogen based economy can generate a lot of employment throughout the country. Hydrogen production process and Fuel cell technology requires expertise from various fields such as electrical, mechanical, chemistry, physics, biotechnology, management etc. In order to produce skilled manpower resource training needs have to be identified. It is recommended to constitute Hydrogen chair faculty positions in IITs for professors working on Hydrogen technologies for the duration of 3 years. Further 50 fellowships should be given to bright scholars for pursuing their masters or doctoral programs related to Hydrogen technologies. Awards should be constituted on a national scale with prizes around 1 lakh for professionals and academia working in promotion of Hydrogen. Educational programs should include a hydrogen education program for school teachers and students providing them with educational materials, training program and curricula evaluation. Awareness The most important factor for fostering support and decreasing opposition to the introduction of Hydrogen technologies is increased knowledge. The general public must be given further education, along with decision-makers within government and industry, regulators and policy developers, academics etc. Therefore, information as well as an active demonstration projects for use of Hydrogen is necessary. Results from previous projects have shown that more extensive information efforts are needed in conjunction with demonstration projects, such as Hydrogen bus trials, fork lifts, stationary power etc. Awareness resources include traditional print materials, such as fact sheets, and information available on the Web, and via other forms of media including audio, CD, and video. 52 Public Private Partnership Coordination between industry and government can facilitate smooth commercialization of Hydrogen and fuel cell systems. By working together, timely priorities can be identified to promote commercial deployment of Hydrogen technologies. Continuation of dialog among all stakeholders, as well as applicable state agencies, to study the range of codes, standards, and regulatory activities that are needed to ensure a smooth transition to a Hydrogen economy, as well as the research to support them is the key. Gap Analysis From the above, it is clearly seen that the research activities in the field of Fuel Cell & Hydrogen are still in their early phase compared to other nations. Since the activities of fuel cell and Hydrogen are in early stages, it is inevitable to have more focus on creating indigenous technology for its commercialization and industrialization in India. To promote fuel cell technology based innovation, there must be proper strategies and plans which enhance Hydrogen activities in India in those specific fields. The imortant specific gap issues between India and the developed countries are After Market Vehicle Enforcement and development of hydrogen infrastructure. Action Plan A. National Mission Project Development of National Hydrogen Vehicle Certification and Research Laboratory The development of National Facility for Certification of Hydrogen and Fuel Cell Vehicles as per future Central Motor Vehicle Rules (CMVR) may have the following facilities: B. Research & Development Projects The Research & Development Projects should be supported by inviting proposals from industry and Research Institutions / academia. The projects should be evaluated by Expert Committee of the Coordinating Ministry / Department for their suitability for the Hydrogen program in India. C. Basic Research Projects These projects should be supported by inviting proposals from academic institutions like IITs, IISC, NIT etc. The projects should also be evaluated by 53 the Expert Committee for their suitability for the Hydrogen program in India. The costing for such basic studies should be worked out based on a standard format and defined timelines. Financial Outlay An overall budget provision of around Rs.500 Crores may be made available for a period of next 7 years (till 2022) for technology development and research on all categories of the activity mentioned above; 60% of which may be earmarked for mission mode projects (category I), 20% for Research and Development projects (category II) and 20 % for knowledge base generation (category III). As a part of the mission mode activity, it would be essential to establish a national hydrogen and fuel cell certification facility. Note: Draft report on “Intellectual Property Rights, Public Private Partnership, Safety, Standards, Awareness and Human Resource” is attached as Annexure - VIII. 54 Time Schedule of Activities Sr. No. Year 2016 2017 2018 2019 2020 Chassis Dynamometer for HCV/LCV Vehicles – suitable for both hydrogen and Fuel cell buses -1 Nos. Chassis Dynamometer for SUV/Passenger Cars/SCV 2 Nos. Chassis Dynamometer for 1 Mission Mode Projects 2/3 Wheelers - 1 Nos Development of National Hydrogen Vehicle Certification Transient dynamometers, 550 kW and Research Laboratory capacity -1 Nos. Transient dynamometers upto 300 kW - 2 Nos. Hydrogen Cylinder Storage and Dispensing Facility Hydrogen Component Certification Equipment Hydrogen fuel quality testing and material embrittlement testing Hydrogen engine combustion development and simulation centre 55 2021 2022 Sr. No. Year 2016 2017 2018 2019 2020 Development of on board safety systems for hydrogen vehicles After treatment solutions for hydrogen vehicles 2 Research & Development Projects Development of Indigeneous sensors for fuel cell vehicles Development of materials for lightweight hydrogen cylinders Advanced combustion HCCI engines for hydrogen fuel Development of hydrogen fuel cell demonstration kits for schools Enhancement of Fire Safety Measures for Hydrogen Vehicles CFD simulation of hydrogen release patterns Optical engine studies on Hydrogen Combustion Suitable odorants and dyes for hydrogen fuel 3 Basic / Fundamental Research Projects Study of hydrogen regulations and projection of requirement of regulation in near future Hydrogen flame studies - Visualisation Awards, Scholarships, Training, Awareness Seminars, Advertisements 56 2021 2022 Financial Projections S. No. Activity Budgeted Amount (INR Crore) A HR Activity Budget 1 Standards and Regulations Development 20 2 Awards and Scholarships for Students 30 3 Training and Awareness Seminars for 50 Manpower Development 4 Hydrogen Chair in IITs 25 5 IPR Budget 6 Hydrogen demo Kit for schools 100 Subtotal A B 25 250 Mission Mode Project - National 50 Hydrogen Vehicle Certification Facility C Research and Development Projects 1 Development of on board safety 40 systems for Hydrogen vehicles 2 After treatment solutions for hydrogen 20 vehicles 3 Advanced combustion HCCI engines 40 for Hydrogen fuel Subtotal C 100 D Basic Research 1 Optical Engine Studies on Hydrogen 70 engine 2 Hydrogen Flame Studies 20 3 Odorants and Dyes for Hydrogen 10 Subtotal D 100 Grand Total (INR Crore) 500 57 7. Recommendations Stationary power generation and transportation sector are the backbone of economic development and human welfare. Policymakers are worried about air pollution and petroleum dependence with increasing activities. Transport emissions are about three quarters from road vehicles. Over the past decade, transport’s greenhouse emissions have increased at a faster rate than any other energy using sector. The harmful emissions are nuisance to the health of living beings on the earth, for which huge infrastructure for hospitals, clinics, dispensaries is required to counter health hazards. The Ministry of New and Renewable Energy is working to combat this ugly situation by supporting a broad based research, development and demonstration on hydrogen energy and fuel cells programme in the country. Use of hydrogen as fuel for the stationary power generation and transportation sectors may lead a permanent solution to the aforesaid problems. The following recommendations have been made for different aspects of hydrogen energy and fuel cells: A. Hydrogen Production 1. In view of the India’s Climate Action Plan, the technologies for hydrogen production may be targeted accordingly. The first target may be focused on the efficient utilization of byproduct hydrogen of the Chlor-Alkali units. At the end of the financial year 2014-15, only 10% of byproduct hydrogen is available. Remaining 90%byproduct hydrogen (~40% in chemical industries, ~37% as fuel in boiler heating for captive use and ~13% being bottled for sale) is being utilized,. Target may be made (i) To utilize surplus un-utilized 10% byproduct hydrogen, (ii) Next target may be made to utilize ~37% hydrogen efficiently, which is currently being used as fuel in boiler heating for captive use. Alternate sources may be used for heating purpose. (iii) In-house stationary power generation may be one of the most effective ways of utilizing hydrogen. The government may consider incentivizing this application of hydrogen for its cost effective utilization. 2. The present facilities of hydrogen production may be utilized to supply hydrogen for purpose of carrying out the activities on the research, development and demonstration for the applications like hydrogen fuelled vehicles etc. 3. From the gap between international and national state of art of technologies, it has been visualized that India has to take a leapfrog to come at par with the international level. This gap is to be planned in time bound 58 project mode (with foreign collaboration, if required) and therefore, the projects may be classified in the following three categories viz. National Mission Projects, Research & Development projects and Basic / Fundamental Research projects: 4. The Mission Mode Projects may cover projects with the participation of the industry for the technologies, which are mature or near maturity for commercialization after the short development time and those may be taken up on large scale demonstration. Such projects would be multi-disciplinary in nature. These projects may involve more than one institution (with a lead institution), which are already involved in the implementation of research & development activities. The outcome of such projects should be a compact, comprehensive, marketable and user friendly product. The resources and the infrastructure facilities of the involved institutions may be pooled together to achieve the common goal. 5. The Research & Development projects may include the projects in which the technology is at the stage of prototype development and its demonstration as a proof of concept. Industry participation should be preferred for these projects. Such projects may be undertaken on different subjects like design, research & development of the individual system components, sub-systems, integration of systems after the basic research has shown encouraging results. Engineering research and development must be a part of such projects. B. Hydrogen Storage and Applications other than Transportation Considering merits and de-merits of all the modes of hydrogen storage and specific applications other than transportation, following are recommended: (i) Institution of cost analysis study for the use of solid state hydride storage of hydrogen with compressed gaseous hydrogen in composite cylinders for specific applications to be developed in the Mission Mode projects. (ii) Project for acquisition of reformer technology and development of indigenous reformer technology by Thermax and BHEL jointly with possible association of IICT, Hyderabad and NCL, Pune. (iii) Project for commercialisation of Type III cylinders for buses and Type IV cylinders for small vehicles (like 4- & 3-wheelers) by Tata Motors in collaboration with ISRO. DRDO and BHEL may also be involved in this effort. (iv) Project for the development of a hydrogen storage device / cartridge for specific purpose for fuel cell power pack jointly by BHU, IIT Guwahati, NFTDC, IIT Indore and IISc Bangalore. 59 (v) Metal hydride based high intensity high efficiency thermal energy storage system development of the type ongoing at IISc Bangalore should be widened in terms of capacities and applications such as CSP and standalone Steam Generators. (vi) Organisation of a Workshop with CII / FICCI for possible commercialisation of the devices / systems developed by the academic / research institutions. MNRE may facilitate organisation of the workshop. (vii) Review of the activities of Hydrogen Energy Centre at BHU by a suitable Expert Committee and utilization of their recommendations to establish a Centre of Excellence. Also, establish a few Satellite Centers for specific tasks such as development of high pressure cylinders, development of sensors and controls, thermal, thermo-physical and mechanical properties evaluation, etc. C. Fuel Cell Development 1. Based on the level of maturity of the expertise and the importance of the type of Fuel Cells, the projects may be divided in three categories, which are: (i) Mission Mode Projects having the ultimate objective of limited scale manufacturing of different capacities standalone systems, which may be demonstrated under field condition for the purpose of performance evaluation. Industry participation is compulsory for this category. Fuel Cell systems proposed to be developed under this category are: a) HT-PEMFC (Some IPRs on the fuel cell components have already been developed in the country) b) LT- PEMFC (Membrane material is still being imported in the country; but stacks up to 25kW capacity have been fabricated and tested in the country) c) Planar SOFC (Success has been obtained in lower capacity (up to 1 kW range in the country) d) PAFC (Taken-up on large scale manufacturing (up to 3 kW) for application in the strategic sector. It is yet to be taken-up for the civilian sector) Formation of consortiums consisting of R&D, academic institutions and industries for each of the systems; one of them preferably a R&D laboratory may be identified as the lead organization. Following are the lead institutes identified for the purpose: e) HT-PEMFC with combined cycle: Joint Lead Institutes - CSIRNCL, Pune and CSIR-CECRI, Karaikudi) 60 f) LT- PEMFC: Lead Institutes - CFCT, Chennai and/or CSIRCECRI, Karaikudi/ BHEL R&D, Hyderabad. g) Planar SOFC: Lead Institute - CSIR-CGCRI, Kolkata h) PAFC:Lead Institute NMRL, DRDO, Ambernath and/or BHEL R&D, Hyderabad iv) Research & Development Projects with the objectives of laboratory demonstration of critical systems and sub-systems for (a) DMFC/DEFC (b) MCFC (c) BFC v) Basic/ Fundamental Research Projects. 2. The Budgetary Provision for the development of fuel cells may be kept around Rs.750 Crore over a period of next 5 years (up to the financial year 2022-23); 80% of this may be earmarked for category I projects, 10% each for the other two categories. Complete milestone of the programme together with the approximate financial outlay (sector wise) is given in the attached chart. 3. A Virtual Fuel Cell Institute may be created under the aegis of the Ministry of New and Renewable Energy to have efficient formulation and project management including rigorous monitoring and to bring all the concerned stakeholders such as Ministries, Departments, academicians, researchers and industry under one umbrella to work together in a systematic and focused manner with the specific objectives. The Institute should have a Directorate with required administrative and financial autonomy. All the members of the project team working at different locations (including the PIs) would be collectively responsible to this directorate, so far as the project activities are concerned. D. Transportation through Hydrogen Fuelled Vehicles (i) Fuel Cell Vehicles a. Design & development of a fleet comprising of 10 passenger cars, 10 two-wheelers, 10 SUVs, 10 three-wheelers, 10 buses operating on fuel cell technology may be taken-up as a Mission Mode Project alongwith the 10 dispensing stations at different sites. MNRE may support this initiative through proposed Centre of Excellence on Hydrogen & Fuel Cells being set-up by IOC R&D. b. Fleet demonstration trials of the fuel cell buses run by STUs. 61 c. R&D institutes and leading research labs may undertake Simulation studies of BoP components & hydrogen storage & supply system to be installed in the vehicle leading to indigenize development of the same. d. Development & demonstration of Fuel cell Range Extended vehicles & their performance evaluation. Optimization of control system & fuel (hydrogen) quality for maximization of durability with minimal operating cost. e. Establishment of test facilities for fuel cell components, stacks and systems. f. Establishing the hydrogen safe labs for fuel cell / hydrogen vehicle testing at ARAI, NATRIP and proposed MNRE/IOC Centre of Excellence for Hydrogen & Fuel cells. g. Development & standardization of fuel cell vehicle and stack testing standards for Indian conditions. h. Understanding the global quality control standards for different stack components / systems and their modification for indigenous conditions. i. Undertake the contamination studies both on fuel side as well as on air side to establish the long term durability impact on the fuel cell vehicle performance j. Development of required human resources for various activities like carrying out further RD&D activities, indigenous production, repair & maintenance services etc. (ii) Hydrogen Fuelled IC Engine The following Work has been proposed for the research, development, demonstration and commercialization of Hydrogen Fuelled IC Engine Technology: a. 20 vehicles based on Hydrogen direct injection technology to developed and demonstrated as a part of Mission Mode project discussed above. b. Pilot studies to be initiated for conversion of CNG buses may be converted into H-CNG buses in the initial phase based on the Compact Reformer technology developed by IOC R&D. Performance monitoring of the buses to be carried out for establishing the on-field long term durability c. Combustion chamber designs and cylinder head designs for direct injection SI engines running on hydrogen have to be developed. d. Engine control units for dual fuel, HCCI and direct hydrogen injection engines with effective control strategies in some cases to switch between modes have to be developed. Academic institutions could do the initial part of working out modes of operation and strategies using experiments and simulation models. However, industry partners have 62 e. f. g. h. (iii) to take it to the level of making ECU hardware and software that matches industry standards. Strategies to combine HCCI operation with dual fuel and CI modes to extend the load range can be developed. This will enable the effective use of HCCI for applications like generator sets and locomotives. Here academic institutions can do the basic experimental work and perform simulation studies while industries may implement the strategies in the field for evaluation. Development of after treatment device for NOx reduction (Lean NOx trap, SCR etc.), which will help to reduce NOx emission while operating the engine at a higher equivalence ratio to improve the power output. This is relevant for development of heavy duty engines with hydrogen. Application of hydrogen blends with various fuels like CNG, LPG, Diesel, Biogas in the existing SI engines etc. Combustion research to be undertaken by the leading labs and institutes to establish the performance of hydrogen fuelled engines Hydrogen infrastructure The establishment of hydrogen infrastructure may be planned in the following steps: a. Hydrogen supply must be ensured at the workshop / industry / testing facility, where prototype hydrogen vehicle is developed and tested. Therefore, Oil Companies may set-up 10 additional hydrogen dispensing stations and supply hydrogen from refineries as a part of Mission mode project to facilitate the pilot studies to be conducted on hydrogen IC engine based as well as fuel cell vehicles b. Studies on understanding the purity of hydrogen required for both IC engines and fuel cells must be carried out by the research institutes to be ensured as per its application as fuel for the IC engine / fuel cell based vehicles. c. Opportunities to use hydrogen produced in Oil Refineries and ChlorAlkali plants may be explored. Inter-ministerial group may be formed to expedite the supply of hydrogen from refineries for different hydrogen applications. d. The delivered cost of hydrogen through steel cylinders at 200 bar is too high. It is therefore required to have alternate means of transportation of hydrogen like compressed hydrogen tube trailer or cryogenic liquid hydrogen trailer. The fuel cell buses use composite cylinders for storing hydrogen on-board at 350 bars. These cylinders are not manufactured in the country. Efforts should be made to have indigenous production of these cylinders. 63 e. The composite cylinders, which are imported, can withstand up to 350 bar pressure, but the valve deployed on the cylinder is Indian and can withstand only up to 200 bar pressure. In case of cylinder and valve are imported and have test certificate up to 350 bars, the same shall be allowed in our country. f. Research activities on pipeline to be undertaken for examining the long term efficacy of hydrogen transportation through pipelines and the utilization of existing pipeline network. g. Adequate establishment of test facilities for cylinders and other components of the hydrogen fuelled vehicles in any Government / autonomous institutions to for timely testing and certification of the vehicles. h. Creation of following test facility for certification of the hydrogen fuelled vehicles (like passenger cars and light duty vehicles, motorcycles and heavy duty vehicles (on/off road)) and their components. i. E. The institutions like, ARAI, and MNRE / IOC R&D’s proposed CoE for Hydrogen & Fuel Cells to provide support by creating testing and certification facilities for components, sub-systems and systems. Intellectual Property Rights, Public Private Partnership, Safety, Standards, Awareness and Human Resource Notification of Hydrogen as a fuel in India Promote and strengthen R&D activities on Hydrogen, fuel cells, safety & manufacturing by providing necessary autonomy and freedom for all academic and R&D institutions, while ensuring social responsibilities and commitments Establishment of Centre of excellence at ARAI for Hydrogen vehicle certification and research. Development of facilities for Hydrogen component and cylinder evaluation Accelerate business innovation with the R&E tax credit Rewards can be given at various stages like filing, grant and commercialization of patents by companies to promote activities in the area of Hydrogen and Fuel Cell. Conduct strategic, selective demonstrations of innovative technologies Industry cost share and potential to accelerate market transformation Continue to conduct key analyses to guide R&D and path forward – Life cycle cost; economic & environmental analyses, etc. Support and protect effective intellectual property rights Leverage activities to maximize impact and facilitating commercialization of IPRs 64 F. Training and education: To train enforcement officers, in-house counsels, and school students. Identified Prioritised Mission Mode Projects The following seven prioritized Mission Mode Projects were identified out of sixteen (recommended in the reports of the five Sub-Committees on various aspects of Hydrogen Energy and Fuel Cells) Mission Mode Projects: (i) (ii) (iii) (iv) (v) (vi) (vii) Demonstration of H-CNG fueled buses in select cities: For implementation of this project infrastructure need to be created for catalytic reformation of natural gas to H-CNG (18% hydrogen by volume) with capacity of about 5000 kg H-CNG/day in selected Depots of Delhi Transport Corporation (DTC), Delhi for the use in buses and suitable capacity for the production of H-CNG at suitable locations in Pune for refueling of 3-Whelers. Demonstration of 10 hydrogen fueled mini-buses based on IC engine technology along with setting up hydrogen production-cum-dispensing facilities at a suitable locations and development of six cylinder hydrogen fueled IC engine, preferably with direct injection of fuel into the cylinder. Development and demonstration of 5 kW and 25 kW capacity HT- & LTPEM fuel cell systems and planar solid oxide fuel cell systems and their applications for stationary power generation and transportation sectors. Development and demonstration of Type-III composite cylinders for onboard storage of hydrogen at pressures up to 350 bar in vehicles and high strength steel cylinders for high pressure hydrogen storage on the ground (for stationary use). Augmentation of the Testing and Certification facilities for H-CNG and hydrogen fueled vehicles at the existing centre / centres of automobile testing. Demonstration of hydrogen fueled 3-wheelers/auto (based on IC engine technology) using metal hydride establishment of production of metal hydride and its cartridge and cartridge recharging facility. Solar / wind energy based electrolyser for production of hydrogen and oxygen for cryogenic rocket propulsion by the Indian Space Research Organization (ISRO) and other organizations. Note: A report on these projects is under preparation with the Team of Experts. 65 Annexure - I I. Sub-Committee on Research, Development Demonstration for Hydrogen Energy and Fuel Cells 1. Prof. S. N. Upadhyay, Former Director, Indian Institute of Technology (Banaras Hindu University) and Retired Professor and currently, DAE-Raja Ramanna Fellow, Department of Chemical Engineering, Institute of Technology (Banaras Hindu University), Varanasi- Chairman Ms. Varsha Joshi, Joint Secretary, MNRE Dr. Sanjay Bajpai, Scientist ‘F’, Representative of Department of Science and Technology, Ministry of Science and Technology, New Delhi Dr. Ashish Lele, Representative of CSIR-National Chemical Laboratory, Pune Dr. S. Aravamuthan, Scientist/Engineer ‘H’ & Deputy Director, Representative of Vikram Sarabhai Space Centre, Indian Space Research Organization, Thiruvanthapuram Shri A. Srinivas Rao, SO/G, Chemical Technology Division, Representative of Bhabha Atomic Research Centre, Mumbai Dr. K. S. Dhathathreyan, Head, Centre for Fuel Cell Technology, Chennai Prof. O.N. Srivastava, Retired &Emeritus Professor, Department of Physics, Banaras Hindu University, Varanasi Prof. B. Viswanathan, Retired &Emeritus Professor, National Center of Catalysis Research, Department of Chemistry, Indian Institute of Technology, Madras, Chennai Prof. Debabrata Das, Department of Biotechnology, Indian Institute of Technology, Kharagpur Prof. L. M. Das, Retired (on 30.06.2014) & Emeritus Professor, Centre for Energy Studies, Indian Institute of Technology, Delhi Executive Director, Centre for High Technology, Noida Dr. P. K. Tiwari, Head, Desalination Division, BhabhaAtomic Research Centre- Representative of Principal Scientific Adviser to Govt. of India (Retired on 31.01.2015 and currently Raja Ramanna Fellow at Professor HomiBhabha National Institute, Mumbai) Shri Nitin R. Gokarn, CEO, NATRIP, New Delhi (Repatriated to his parent Office) / Shri Neeraj Kumar, Director-Representative of Ministry of Heavy Industries & Public Enterprises, Govt. of India, New Delhi 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. & Note: Since the Sub-Committees on different aspects (Fuel Cells, Hydrogen Storage & Other Applications of Hydrogen Energy and Transportation) of hydrogen energy and fuel cells, covered activities relating to Research, Development & Demonstration (RD&D) in their respective areas, the Sub66 Committee on Research, Development & Demonstration (RD&D) focused only on hydrogen production. Terms of Reference 1. To review national and international status of Research & Development, Technology Development and Demonstration with a view to identify the gap. 2. To suggest the strategy to bridge the identified gaps and the time frame for the same. 3. To assess R & D infrastructure in the country. 4. To identify projects and prioritize them for support with the result oriented targets. 5. To identify institutes to be supported for augmenting R&D facilities including setting-up of Centre(s) of Excellence and suggest specific support to be provided. 6. To suggest strategy for undertaking collaborative R & D among leading Indian academic institutions and research organizations and also with international organizations. 7. To examine setting-up of a National Hydrogen Energy and Fuel Cell Centre as an apex facility. 8. To suggest strategy to take-up projects in Public-Private Partnership mode for the development of technologies based on transparency, accountability and commitment for deliverables. 9. To identify the technologies, which can be adopted for applications with time line? 10. To re-visit National Hydrogen Energy Road Map with reference to Research, Development & Demonstration and Technology Development activities II. Sub-Committee on Fuel Cell Development 1. Dr. H. S.Maiti, Retired Director, CSIR - Central Glass and Ceramic Research Institute, Kolkata and Currently, INAE Distinguished Professor, Government College of Engineering and Ceramic Technology, Kolkata – Chairman Representative of MNRE - Ms. Varsha Joshi, Joint Secretary Representative of BARC - Dr. Deep Prakash, SO/G, Energy Conversion Materials Section Representative of BHEL-Shri M.R. Pawar, AGM (FCR), Corporate BHEL R&D, Hyderabad Representative of DRDO – Dr. R. S. Hastak, Outstanding Scientist and Director, Naval Materials Research Laboratory (NMRL), Amarnath 2. 3. 4. 5. 67 6. 7. 8. 9. 10. 11. 12. 13. 14. Representative of CSIR - Dr. Ashish Lele, NCL, Pune Dr. K. S. Dhathathreyan, CFCT, Chennai Shri Shailendra Sharma, Retired General Manager, BHEL Corporate R&D, Hyderabad and currently, Project Director, Non Material Technology Development Centre, Hyderabad Dr. K. Vijaymohanan, Director, Central Electro-Chemical Research Institute, Karaikudi Prof. S. Basu, Department of Chemical Engineering, Indian Institute of Technology, Delhi Dr. R. N. Basu, Chief Scientist and Head, Fuel Cell and Battery Division, CSIR-Centrel Glass and Ceramic Research Institute, Kolkata Representative of Tata Group (Tata Chemicals) - Dr. Rajiv Kumar, Chief Scientist Representative of IOCL R&D Faridabad - Shri Alok Sharma, Deputy General Manager, (Alternate Energy), Representative of Confederation of Industry Industry - Dr. R. R. Sonde, Executive Vice President, Thermax India Ltd., Pune Terms of Reference 1. 2. 3. 4. 5. 6. 7. To specify different kinds of fuel cell systems with technical parameters relevant for various applications in India. To review R & D status of fuel cell technologies in the country and to identify the gap with reference to the international status. To suggest strategy to fill-up the gaps and quickly develop in-house technologies with involvement of industries or acquiring technologies from abroad. To identify applications for demonstration of technologies developed globally under Indian field conditions and suggest policy measures for deployment of such technologies in the country. To identify institutes to be supported for augmenting infrastructure for development and testing of fuel cells including setting-up of Centre(s) of Excellence and suggest specific support to be provided. To suggest strategy for undertaking collaborative projects among leading Indian academic institutions, research organizations and industry in the area of fuel cells. To re-visit National Hydrogen Energy Road Map with reference to fuel cell technologies. 68 III Sub-Committee on Transportation through Hydrogen Fuelled Vehicles 1. Dr. R. K. Malhotra, Chairman &Director, IOCL R&D, Faridabad (Retired on 30.06.2014) and Currently, Director General, Petroleum Federation of India, New Delhi – Chairman Representative of MNRE –Ms. Varsha Joshi, Joint Secretary, MNRE Shri K. K. Gandhi, Executive Director (Technical), Society of Indian Automotive Manufacturers (SIAM), New Delhi Representative of Ministry of Petroleum & Natural Gas - Dr. R K Malhotra, Chairman & Director, IOCL R&D Faridabad Representative of Indian Space Research Organization (ISRO) – Dr. S. Aravamuthan, Scientist / Engineer ‘H’ & Deputy Director, Vikram Sarabhai Space Centre, Thiruvanthapuram Representative of Automotive Research Association of India, Pune - Dr. S. S. Thipse, Deputy Director Dr. Mathew Abraham, Sr. General Manager, Alternative Fuel Technology, Mahindra & Mahindra, Chennai Representative of Tata Motors - Dr. Raja Munusamy, Assistant General Manager, Engineering Research Centre, Tata Motors Ltd., Pune Prof. A. Ramesh, Department of Mechanical Engineering, IIT Madras, Chennai Representative of Petroleum Explosives & Safety Organization, Nagpur Shri D.K. Gupta, Joint Chief Controller of Explosives Representative of Defence Research & Development Organization (DRDO) – Dr. R.S. Hastak, Outstanding Scientist and Director, Naval Materials Research Laboratory (NMRL),Amarnath Representative of Ministry of Heavy Industry – Shri Neeraj Kumar, Director / Shri Vikram Gulati, Director (Operations), NATRIP, New Delhi (Repatriated to his parent Office) Representative of Gujarat State Petroleum Corporation (GSPC), Gandhinagar – Shri P.P.G.Sarma, Chief Executive Officer Representative of Department of Scientific & Industrial Research (DSIR) - Dr. Hari Om Yadav, Scientist, Planning and Performance Division, DSIR, New Delhi Representatives of SIAM – Shri Jaishankar& Shri SudeepDalvi, Toyota Kirloskar Motor Pvt. Ltd. & Shri M. Ravi, Ashok Leyland 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. II. Terms of Reference B. To assess national and international technological status in the area of internal combustion engine and fuel cell based transport applications. 69 C. D. E. F. G. H. I. J. To specify the technologies to be developed within the country for niche transport applications and strategy to be adopted for the same. To identify gaps and suggest strategy to fill-up the gaps and quickly develop in-house technologies with involvement of industries or acquiring technologies from abroad. To suggest demonstration projects to be taken up with industry and infrastructure development required to be created for such projects. To identify different stakeholders for implementation of such projects. To examine regulatory issues related to transport sector such as notifying hydrogen / hydrogen blended fuel as automotive fuels, on-board storage of such fuels, use of composite cylinders for storage of fuels as per international practices, type approval of vehicles using such fuels, setting-up of refueling stations of such fuels etc. To identify institutes to be supported for augmenting infrastructure for development and testing of hydrogen / hydrogen blends fuelled vehicles including setting-up of Centre(s) of Excellence and suggest specific support to be provided. To suggest strategy for undertaking collaborative projects among leading Indian academic institutions, research organizations and industry in the area of hydrogen fuelled vehicles. To re-visit National Hydrogen Energy Road Map with reference to transport sector. IV Sub- Committee Applications 1. 2. 3. 4. 5. 6. 7. on Hydrogen Storage and other Dr. S. Srinivasamurthy, Retired & Emeritus Professsor, Mechanical Engineering Indian Institute of Technology Madras, Chennai and currently,Visiting Professor, Interdisciplinary Center for Energy Research, Indian Institute of Science, Bangalore - Chairman Representative of MNRE – Ms. Varsha Joshi, Joint Secretary Dr. O. N. Srivastava, Retired &Emeritus Professor, Department of Physics, Banaras Hindu University, Varanasi Dr. L. M. Das,, Centre for Energy Studies, Indian Institute of Technology, Delhi (Retired on 30.06.2014 & Currently, Emeritus Professor at Centre for Energy Studies, IIT Delhi) Dr. B. Viswanathan, Retired &Emeritus Professor, National Center of Catalysis Research, Department of Chemistry, IIT Madras, Chennai Representative of ISRO – Dr. S. Aravamuthan, Sci. Engr. ‘H’ & Deputy Director, Vikram Sarabhai Space Centre, Thiruvanthapuram Representative of DRDO - Shri R.S. Hastak, Outstanding Scientist and Director, Naval Materials Research Laboratory (NMRL), Ambernath 70 8. Dr. P. K. Tiwari (In-position as Head, Desalination Division &Retired later), Bhabha Atomic Research Centre, Mumbai 9. Representative from CII - Dr. R. R. Sonde, Executive Vice President, Thermax India Limited, Pune 10. Dr. K. Balasubramanian, Director, Non-Ferrous Technology Development Centre, Hyderabad 11. Dr. Rajesh Biniwale, Principal Scientist, Environmental Materials Unit, CSIR-National Environment & Energy Research Institute, Nagpur 12. Dr. V. Shrinet, Electrical Research Development Association, Vadodara 13. Dr. R. Ramamurthi, Former Deputy Director, Liquid Propulsion Systems Centre, Indian Space Research OrganizationandVisiting Professor, Indian Institute of Technology, Madras, Chennai 14. Shri S. B. Menon, Scientific Officer ‘G’,, Chemical Technology Division, Bhabha Atomic Research Centre, Mumbai 15. Representative of DSIR - Dr. Hari Om Yadav, Scientist, Planning and Performance Division, DSIR, New Delhi Terms of Reference 1. 2. 3. 4. 5. 6. To identify other applications of hydrogen and fuel cell technologies suitable for Indian conditions and suggest technologies relevant for such applications with their specifications. To identify gaps in technology at national level compared to international status of the technologies and to suggest strategy for bridging the gaps quickly by developing in-house technologies with involvement of industries or acquiring technologies from abroad. To review national and international status of hydrogen storage methods and suggest suitable strategies for on-board as well as stationary hydrogen storage for Indian conditions. To identify technological constraints in developing suitable hydrogen storage materials to store adequate amount of on-board hydrogen for a given range of travel and accordingly suggest RD&D projects to be supported. To identify institutes to be supported for augmenting infrastructure for development and testing of hydrogen storage materials / systems / other applications of hydrogen including setting-up of Centre(s) of Excellence and suggest specific support to be provided. To provide recommendations for promoting use of surplus hydrogen for supplying back-up power to telecom towers and for captive power generation. 71 7. 8. To examine use of light weight composite for on-board hydrogen / CNG storage and suggest the strategy to be adopted for indigenous production of such cylinders. To re-visit National Hydrogen Energy Road Map with reference to other applications of hydrogen including storage. V Sub-Committee on Awareness and HRD 1. 2. 3. Mrs. Rashmi. H. Urdhwareshe, Director, ARAI, Pune - Chairman Representative of MNRE - Ms. Varsha Joshi, Joint Secretary Representative of Ministry of Road Transport and Highways – Ms. Iren Cherian, Deputy Secretary (Motor Vehicle Legislation) Representative of Ministry of Petroleum and Natural Gas – ShriAlok Sharma, Deputy General Manager (Alternate Energy), IOCL R&D Centre, Faridabad Representative of Ministry of Heavy Industry – Shri. Niraj Kumar Director (Automobile) Representative of DSIR – Dr. Hari Om Yadav, Scientist, Planning and Performance Division Dr. B. Basu, Executive Director, IOCL R&D, Faridabad – represented by Shri Alok Sharma, Deputy General Manager (Alternate Energy) after his retirement Prof. Debbrata Das, Department of Biotechnology, Indian Institute of Technology, Kharakpur Representatives of Bureau of Indian Standards – Shri T.V. Singh Scientist ‘F’. Renga Rajan, Scientist ‘E’ and Shri Chandan Gupta, Scientist ‘B’, Mechanical Engineering Department, Bureau of Indian Standards, New Delhi Representative of Confederation of Indian Industry – Dr. R.R. Sonde, Executive Vice President, Thermax India. Representatives of Society of Indian Automobile manufacturers - Shri Jaishankar, Toyota Kirloskar Motors Limited, Shri. M. Ravi, Ashok Leyland & Mr. Saurabh Rohilla, SIAM Representative of ISRO – Dr. S. Aravamuthan, Deputy Director, Vikram Sarabhai Space Centre. Representative of PESO – Dr. S. Kamal, Chief Controller of Explosives, PESO Executive Director, Centre for High Technology, Noida Shri. Ravi Subramaniam / Shri Piyush Katakwar, Air Products Dr. Sukrut .S. Thipse, Deputy Director, ARAI 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. IPR, 72 Safety, Standards, PPP, Terms of Reference 1. 2. 3. 4. 5. 6. 7. To review present status of filed/granted patents and to suggest the ways to encourage generation of more intellectual property rights under the R&D and demonstration projects being supported by Government of India. To guide development of safety measures/ manuals, codes and standards in accordance with international practices for production, storage, distribution and handling of Hydrogen as a fuel for various applications. To suggest policy initiatives and financial/ fiscal / regulatory measures including other measures for promotion of Hydrogen as a clean fuel. To give suggestions for creating awareness among different stakeholders in the area of Hydrogen energy and fuel cells in the country. To review availability of trained human resource in the area of Hydrogen energy and fuel cells in the country and suggest ways and means for development and training of adequate skilled manpower in this emerging technological area in India and abroad for meeting the requirement of R&D institutions and the industry in the years to come. To suggest strategy to take up projects in Public-Private Partnership mode for the development of technologies based on transparency, accountability and commitment for deliverables. To revisit National Hydrogen Energy Road Map with reference to IPR, public-private partnership, safety, standards, awareness & HRD. Composition of Team of Experts i) Dr. N. Ved ach alam, ISRO Honorary Distinguished Professor, Vikram Sarabhai Space Centre, Trivandrum ii) Dr. Narayana Moorthi, Former Director, Launch Vehicles Programme Office (WPC), ISRO, Yeshwanthpur, Bengaluru iii) Dr. Vidya S. Batra, Adjunct Faculty, Department of Energy and Environment, The Energy and Resources Institute, New Delhi iv) Prof. B. Viswanathan, Emeritus Professor, National Centre of Catalysis Research, Dept. of Chemistry, Indian Institute of Technology Madras, Chennai Terms of Reference i) Review of Reports of Sub-Committees on various aspects of hydrogen energy and fuel cells and mapping out interrelated points from the reports of Sub-Committee 73 ii) Finalization of the draft report on ‘Hydrogen Energy and Fuel Cells – A Way Forward’. iii) Projectisation of a few themes (for a period upto 2022) arising out of the study report, which will draw upon the inputs from the reports of different Sub-Committees for inclusion in the Report of the Steering Committee. The projects could focus on areas like development of fuel cells for specific applications, hydrogen energy driven transportation systems and other two or three areas, in consultation with both the Ministry and the Chairpersons of the Sub-Committees would identify. iv) Projectisation of a few themes as mentioned in the aforesaid points, which may give concrete outcome by 2017. v) The specific project proposals would include the technical elements, financial aspects (including year-wise), schedules, human resources, institutional & organizational systems and any other related matters. 74 Annexure - II Details of Meetings of Steering Committee on Hydrogen Energy and Fuel Cells and its Sub-Committees Sl. No. 1 Steering / Sub- Chairman of Steering Committees on Committee &SubCommittees Dates of Meetings Hydrogen Dr. K. Kasturirangan Energy and Fuel Former Member (Science), Cells Planning Commission, Govt. of India and currently at Raman Research Institute, Bengaluru 18.06.2012 (1st ) 11.06.2014 (2nd ) 26.03.2015 (3rd ) 10.07.2015 (4th ) 11.08.2015 (5th ) 2 Meeting of Chairpersons, Sub-Committees 11.09.2015 (1st) * 16.12.2015 (2nd) 18.01.2016 (3rd) * Meeting with Team of Experts 18 & 19.04.2016* 11 to 15.05.2016 3 Research, Development & Demonstration (Hydrogen Production) 4 Fuel Cell Development Prof. S.N. Upadhyay 9.12.2013 (1st ) Ex-Director, Institute of 03.03.2014 (2nd ) Technology, BHU and For Thrust Areas currently DAE – Raja Ramanna Fellow in IIT (BHU), 18.11.2014 (3rd ) Varanasi Prof. H.S. Maiti Retired Director, Central Glass and Ceramic Research Institute, Kolkata and currently, INAE Distinguished Professor, Govt. College of Engineering and Ceramic Technology, Kolkata 29.11.2012 (1st ) 02.09.2013 (2nd ) 26.02.2014 (3rd ) For SOFC & Thrust Areas 02.09.2014 Fuel Cell Experts Group 75 22.05.2015 (4th ) 5 Transportation Dr. R.K. Malhotra 26.08.2013 (1st ) Retired Director & Chairman, 13.09.2013 (2nd ) IOCL R&D Centre, Faridabad, 24.09.2014 (3rd ) Haryana 29.05.2015 (4th ) 6 7 8 9 10 Other Applications IPR, Public Private Partnership, Safety, Standards, Awareness & HRD Dr. S. Srinivasa Murthy 28.10.2013 (1st ) Professor (Retired), Indian Institute of Technology, Madras, & currently Visiting Professor , Indian Institute of Sciences, Bangalore 03.07.2015 (2nd ) Mrs. Rashmi Urdhwareshe, 16.12.2013 (1st ) Director, 31.10.2014 (2nd ) 22.07.2015* Automotive Research Association of India, Pune Meeting with Stakeholders of Mission Mode Project on HCNG fueled buses in Pune at ARAI, Pune Meeting with Stakeholders of Mission Mode Project on Hydrogen fueled 3-Wheelers with solid hydride storage at B.H.U. Varanasi Meeting with Stakeholders of Mission Mode Project on HCNG fueled buses in PMPML office, Pune 20.05.2016 30.06.2016 08.06.2016 * Under the Chairmanship of Dr. K. Kasturirangan, at Raman Research Institute, Bangalore 76 Annexure - III Carbon Dioxide Emissions by various Countries The following are the 2014 annual CO2 emissions estimates (in thousands of CO2 tonnes) along with emissions per capita (in tonnes of CO2 per year) from same source of various countries. The data only considers carbon dioxide emissions from the burning of fossil fuels and cement manufacture, but not emissions from land use, land-use change, and forestry. Emissions from international shipping or bunker fuels are also not included in national figures, which can make a huge difference for small countries with important ports. The top 10 largest emitter countries account for 68.2% of the world total. Other powerful, more potent greenhouse gases are not included in this data, including methane. Country CO2 emissions (kt) Emission per capita (t) Australia 409,000 17.3 Saudi Arabia 494,000 16.8 United States 5,334,000 16.5 Canada 565,000 15.9 Russia 1,766,000 12.4 610,000 12.3 1,278,000 10.1 Germany 767,000 9.3 Iran 618,000 7.9 Poland 298,000 7.8 China 10,540,000 7.6 392,000 7.4 3,415,000 6.7 U. Kingdom 415,000 6.5 Italy 337,000 5.5 France 323,000 5.0 Turkey 353,000 4.7 Mexico 456,000 3.7 Brazil 501,000 2.5 India 2,341,000 1.8 452,000 1.8 35,669,000 - International Shipping 624,000 - International Aviation 492,000 - South Korea Japan South Africa European Union Indonesia World 77