Type 1 500 Bar Cylinder for Hydrogen Refilling Station Solution

Introduction

As India scales up green hydrogen under the National Green Hydrogen Mission, setting up reliable hydrogen refilling stations (HRS) is critical for clean mobility and industrial decarbonisation. At the core of every HRS is high-pressure stationary storage — and Type 1 500 bar cylinders provide a pragmatic, proven solution for refuelling stations, depot systems, and industrial refuelling hubs. Made from high-strength steel and designed for repeated pressurisation cycles, Type 1 cylinders balance safety, cost-efficiency, and manufacturability — making them ideal for early and medium-stage hydrogen infrastructure rollouts across India.

Why Type 1 500 Bar Cylinders for Hydrogen Refilling Stations?

Hydrogen stations need storage that’s durable, serviceable, and economical. Type 1 cylinders meet those needs:

• Proven mechanical reliability: Full-steel construction gives predictable behavior under cyclic loading and simple inspection regimes.
  
  
• Cost-effective at scale: Lower procurement cost per kg H₂ than composite alternatives, reducing station CAPEX.
  
  
• Ideal for stationary banks: Heavier weight is acceptable for fixed installations with engineered foundations.
  
  
• Compatibility with 500 bar operations: 500 bar banks support 350 bar vehicle classes and act as effective buffers for cascade systems feeding higher-pressure dispensers.
  
  
• Simplified manufacturing & certification: Easier to localise under “Make in India” and to certify under PESO/BIS compared to advanced composite vessels.

Why 500 Bar — a Practical Choice

Vehicle storage standards vary (commonly 350 bar and 700 bar). A 500 bar stationary storage bank offers a practical compromise for station owners:

1. Dual-pressure flexibility: Supports stations serving both 350 bar and higher-pressure use cases via cascade and compressor logic.

   
   
2. Improved volumetric density vs 350 bar: More hydrogen per cylinder without the full cost/complexity of 700 bar composite systems.
   
   
3. Optimal for fleet depots & industrial hubs: High throughput requirements can be met without immediately investing in full 700 bar stationary infrastructure.
   

Policy & Industry Context (India)

India’s policy push is accelerating HRS investment:

1. National Green Hydrogen Mission: Drives production, storage, and distribution investment, creating demand for station storage solutions.
   
   
2. State and OEM pilots: Bus and truck pilots require robust depot storage for frequent refuelling cycles
   
   
3. O&G & refinery participation: Public and private players building corridor stations need economical stationary storage banks.
   
   
4. Regulatory framework: PESO, BIS and relevant international standards guide design, testing and operation—Type 1 cylinders align well with these regimes.

Applications & Deployment Models

• Buffer Storage Bank — Primary supply to compressors/dispensers, smoothing supply during peaks.
  
  
• Cascade Systems — Multiple 500 bar cylinders in staged draws increase effective usable volume and refuelling throughput.
  
  
• Skid-mounted Mobile Units — Temporary or remote refuelling applications for demonstrations or mining/depot operations.
  
  
• Industrial & Depot Refuelling — Bus depots, captive industrial fleets, and mining operations benefit from Type 1 banks’ economics.

Comparison with Other Cylinder Types

Feature	Type 1 (Steel) — 500 bar	Type 3/4 (Composite/Plastic) — 700 bar
Cost	Lower	Higher
Weight	Heavier — OK for stationary	Lighter — needed for onboard
Durability	High fatigue resistance	Complex lifecycle & inspections
Suitability	Stationary banks & cascades	Onboard vehicle storage
Local manufacture	Easier to set up	Needs composites industry

Deployment Challenges

• Foundation & space requirements: Heavy cylinders need engineered supports and safety setbacks.
  
  
• CAPEX for full station: Compressors, dispensers, purification add to the system cost..
  
  
• Inspection & corrosion management: Hydrostatic testing, NDT and coatings are necessary.
  
  
• Regulatory & safety compliance: Strict adherence to PESO/BIS and industry best practices.
  
  
• Green H₂ availability: Station benefits depend on access to green hydrogen sources.

Emerging Solutions & Localisation

• Domestic fabrication scaling: Local steel cylinder production reduces lead times and costs.
  
  
• Improved alloys & coatings: Longer life, reduced maintenance.
  
  
• Integrated on-site electrolysis: Co-location with electrolyzers reduces logistics and ensures green H₂.
  
  
• Financial models: PPPs, subsidies, and concessional finance to reduce upfront station costs.

The Road Ahead

For early networks — depot refuelling, industrial hubs, and corridor pilots — Type 1 500 bar cylinder banks will form the backbone of HRS infrastructure. As demand matures and onboard pressures evolve, composite tanks will grow in vehicle use. Still, stationary Type 1 systems remain attractive due to economics, safety familiarity, and local manufacturing potential.

Conclusion

Type 1 500 bar cylinders are practical, safe, and cost-effective building blocks for India’s hydrogen refuelling infrastructure. With proper safety enforcement, localisation, and integration with green hydrogen supply chains, Type 1 cylinder banks can accelerate the deployment of hydrogen mobility and industrial decarbonisation across India.

References

• https://mnre.gov.in/national-green-hydrogen-mission
• https://peso.gov.in/web/
• https://www.services.bis.gov.in
• https://www.iea.org/reports/global-hydrogen-review
• https://pib.gov.in