NTPC Limited is undertaking multiple green hydrogen initiatives across India, spanning hydrogen blending, hydrogen mobility, renewable energy-based hydrogen microgrids, hydrogen locomotives and an integrated green hydrogen hub in Andhra Pradesh. The PSU’s green hydrogen strategy is driven by two key objectives: strengthening India’s energy security and supporting its decarbonisation efforts.
Key green hydrogen initiatives
One of NTPC’s flagship pilot projects is the commissioning of India’s first green hydrogen blending project at Kawas in Surat, Gujarat. The project blends green hydrogen generated from renewable energy sources with piped natural gas (PNG), which is supplied through Gujarat’s gas network to approximately 200 households. The blending ratio has increased gradually from 5 per cent to approximately 8 per cent by volume. The incremental cost of blending remains relatively limited because the facility features an existing captive power station and gas network. Hydrogen blending offers a practical decarbonisation pathway for cooking fuel applications, where LPG and PNG remain widely used across households. Safety and supply stability have been prioritised within the project, particularly during nighttime operations.
In the mobility segment, NTPC is implementing hydrogen fuel cell bus projects in Leh and Greater Noida, with five buses operational in both places. The Leh project uses 9 metre hydrogen buses designed for high altitude, while the Greater Noida project involves larger 12 metre buses intended for wider urban mobility deployment. The Leh project incorporates 1.7 MW of solar power, while the Greater Noida project incorporates 6.2 MW of renewable power. Both projects use alkaline electrolysers. Obtaining equipment and regulatory approvals for hydrogen mobility infrastructure remains a significant challenge both in India and globally. The buses function similarly to battery electric vehicles, with water vapour being the primary emission. Each hydrogen bus reportedly costs approximately Rs 25 million. Successful operations in Ladakh demonstrate the ability of hydrogen mobility systems to perform reliably under some of the harshest environmental conditions in India. The hydrogen mobility projects have collectively achieved operational running distances of 200,000-300,000 km.
Another major initiative is NTPC’s 200 kW hydrogen-based microgrid project at Chushul in Ladakh. The project, located in a remote high-altitude region with limited grid connectivity, integrates 3.7 MW of solar power generation and a battery energy storage system of 0.3 MW/2.1 MWh with hydrogen production (200 kg at 250 bar) through PEM electrolysers (2×500 kW). During the daytime, renewable electricity is supplied directly to nearby areas, while excess electricity is used to generate hydrogen. The stored hydrogen is later reconverted into electricity through fuel cells during nighttime operations to provide round-the-clock clean energy access. Although the system remains relatively expensive, it offers a long-term alternative to diesel generator-based systems that currently provide limited electricity access in remote mountainous regions. Going forward, hydrogen microgrid solutions are capable of addressing energy access challenges in remote areas where grid expansion may take several years.
NTPC is also developing a 1.2 MW hydrogen fuel cell locomotive with a 100 km range at Sipat. One locomotive previously used for transporting coal wagons was selected for retrofitting, with all major diesel components replaced with hydrogen fuel cell systems, hydrogen cylinders, battery systems and storage infrastructure. The project also includes a dedicated hydrogen refuelling station comprising 2×500 kW electrolysers with 200 kg of hydrogen storage. It is expected to become one of the most powerful hydrogen-powered locomotives developed globally while potentially reducing operational costs over time.
The company’s largest proposed initiative is a green hydrogen hub at Pudimadaka in Andhra Pradesh. Spread across approximately 1,200 acres, the hub is planned to operate using 7 GW of round-the-clock renewable energy to produce 1,400 tonnes per day (tpd) of green hydrogen. Downstream products will include 4,300 tpd of green ammonia, 1,500 tpd of green methanol, and around 1,500 tpd of sustainable aviation fuel and green urea. The coastal location of the project will support exports through jetty infrastructure while desalinated water and renewable energy will support large-scale production despite regional water scarcity challenges. The Pudimadaka project will operate as a multi-tenant industrial ecosystem under the NTPC Green Chemical initiative, where developers and industrial partners can establish production facilities with shared infrastructure support. An integrated hub model may reduce production costs as compared to standalone green ammonia projects.
Large-scale hydrogen commercialisation cannot be achieved independently due to capital and time constraints. As a result, NTPC is actively pursuing strategic partnerships across infrastructure, production and offtake segments. NTPC’s initiatives in a diverse set of pilot projects are commendable. Going forward, the focus should shift towards commercial-scale deployment to support the country’s decarbonisation journey.
Based on a presentation by
D.M.R. Panda, Executive Director, NTPC Limited, at Renewable Watch’s 11th Green Hydrogen in India conference.
