For over a century, automobiles have shaped modern transportation, but their dependence on fossil fuels has led to rising pollution, climate change, and energy insecurity. As the world seeks cleaner alternatives, the focus has shifted to sustainable energy solutions that can power the next generation of vehicles. While electric vehicles (EVs) have gained traction, they come with limitations such as long charging times and battery disposal concerns.Green hydrogen is emerging as a breakthrough fuel, offering zero emissions, high efficiency, and rapid refuelling. By improving the efficiency and durability of electrochemical water splitting, scientists are reducing costs and making hydrogen production commercially viable for large-scale applications such as hydrogen-powered vehicles, clean energy generation, and industrial fuel substitution. This has the potential to revolutionise transportation and industrial production, making hydrogen a key enabler of decarbonisation in manufacturing, steelmaking, and chemical processing.
Science Behind Hydrogen Fuel Cells
Unlike internal combustion engines, which convert chemical energy from fuel into mechanical power through multiple inefficient steps, hydrogen fuel cells generate electricity by directly tapping the chemical energy of the hydrogen fuel. This process is far more efficient than traditional engines because it bypasses energy losses from heat and mechanical friction. In simple terms, it is like a battery that never needs recharging, as long as hydrogen is supplied. The only by-product is water vapour, making it a completely clean energy source. Moreover, hydrogen powered vehicles have advantages over battery electric vehicles, including longer driving range, faster refuelling times, and superior acceleration, making them an ideal choice for long haul and commercial transport. These benefitsare driving global interest in hydrogen fuel cell electric vehicles as well as industrial applications in factories where hydrogen can replace fossil fuel dependent machinery and production processes.
Challenges in Hydrogen AdoptionDespite its potential, scaling up hydrogen fuel cell production for industrial use remains a significant challenge. Currently, manufacturing fuel cells for hydrogen conversion is a complex and expensive process, requiring precision engineering and specialised materials. Automating the production of hydrogen fuel cells could significantly reduce costs, improve efficiency, and accelerate mass adoption. Companies are exploring robotic assembly lines, advanced material coatings, and AI-driven quality control to streamline manufacturing. Beyond vehicle production, hydrogen’s role in industrial manufacturing is gaining attention. Industries such as steel, cement, and chemicals, which traditionally rely on coal and natural gas, are exploring hydrogen-powered alternatives to decarbonise their processes. Hydrogen-based direct reduced iron (DRI) production in steelmaking, for instance, could eliminate carbon emissions from blast furnaces, marking a shift towards greener industrial production.However, integrating fuel cell technology into both automotive and industrial manufacturing lines presents logistical and financial challenges. Most auto factories are optimised for internal combustion engines or battery electric vehicles, requiring new infrastructure to accommodate fuel cell stacks, hydrogen storage systems, and high-pressure refuelling stations. Similarly, industrial manufacturers must invest in retrofitting facilities to handle hydrogen safely and efficiently.
One major hurdle to making green hydrogen mainstream is the cost and efficiency of electrolysis technology, which is crucial for large-scale hydrogen production. Electrolysis relies on catalysts to accelerate the reaction, with rare and expensive metals like iridium, platinum, and ruthenium currently being the industry standard. However, sourcing these materials poses a significant supply chain challenge, as they are scarce, geopolitically sensitive, and subject to price volatility. Manufacturers are now focusing on developing alternative catalysts using transition metals and other abundant materials to reduce dependency on rare elements and lower production costs.
Beyond materials, scaling up electrolysis-based hydrogen production requires significant investment in manufacturing infrastructure. Existing production facilities are not equipped for mass electrolysis deployment, necessitating large-scale gigafactories dedicated to hydrogen generation. Companies must invest in automated assembly lines, precision engineering techniques, and modular electrolyser designs to improve production efficiency and make green hydrogen cost-competitive with fossil fuel-derived alternatives. As economies of scale come into play and supply chains
stabilise, the cost of hydrogen production is expected to decrease, paving the way for widespread adoption in both transportation and industrial manufacturing fuelling India’s Hydrogen Revolution.
Recognizing the potential of green hydrogen, Indian automakers and industrial manufacturers are making significant investments in hydrogen technology. Tata Motors, in collaboration with Indian Oil Corporation, has unveiled hydrogen-powered buses, signalling a shift towards sustainable public transport. Ashok Leyland is working on hydrogen internal combustion engine (H2ICE) trucks, targeting commercial freight transportation. Toyota India has launched pilot projects to test the feasibility of hydrogen fuel cell vehicles on Indian roads. Hyundai India is exploring partnerships to set up hydrogen refuelling infrastructure.
On the industrial front, Reliance Industries and Larsen & Toubro are investing in large-scale electrolysis-based hydrogen production plants, ensuring a steady supply of green hydrogen for automotive and industrial use. Steel manufacturers such as JSW Steel and Tata Steel are testing hydrogen-based production methods to reduce carbon emissions from steel manufacturing. With India’s National Green Hydrogen Mission allocating ₹19,744 crore until 2029-30 to boost hydrogen infrastructure, create demand in heavy industries, and promote domestic manufacturing of
electrolysers, the country is positioning itself as a key player in the global hydrogen economy.
The Road Ahead
For hydrogen fuel cell vehicles and industrial applications to become mainstream, investment in infrastructure is equally important. Hydrogen refuelling stations remain limited compared to conventional fuel stations and EV charging points. Governments and private enterprises must expand the hydrogen supply chain, invest in storage and distribution networks, and implement incentives for fuel cell vehicle adoption. Additionally, research and development in high-efficiency electrolysers, advanced fuel cell designs, and cost-effective catalysts will be crucial in making
hydrogen-powered vehicles and factories commercially viable. With continued technological advancements and collaborations between policymakers, industry leaders, and research institutions, hydrogen fuel cells could soon rival conventional engines and fossil fuel-powered industrial processes.
