Green H2 Pilot Project at Bhusawal TPS – Maharashtra State Power Generation Co. Ltd
Green H2 Pilot Project at Bhusawal TPS
Problem
- The existing hydrogen gas generation plant at BTPS, commissioned in 1994 with 10 Nm³/hr capacity, has exhausted its 25-year useful life.
- Timely OEM (Original Equipment Manufacturer) support for the old plant is unavailable, creating operational challenges.
- Essential spares required for the old hydrogen plant are difficult to procure on time.
- Maintenance of the ageing system is increasingly difficult and unsustainable for the next 20–25 years.
- The rising demand from 210MW, 500MW, and 660MW units requires higher hydrogen generation (17.5 Nm³/hr), beyond the old plant’s capacity.
Solution
- Establishment of a new Green Hydrogen Plant with a daily production capacity of 20 Nm³/hr.
- Powered by a 500 kW solar plant within BTPS premises, ensuring renewable energy-based hydrogen production.
- Deployment of a modern electrolyzer with 99.99% hydrogen purity in molar fraction.
- First-of-its-kind Green Hydrogen pilot project by MSPGCL, marking a strategic transition to cleaner energy.
- Award of project implementation to M/s ORAIPL at a cost of ₹15.07 crore, including 5 years of O&M for sustainability.
Outcomes
- Successful trial hydrogen generation conducted on 12 March 2025, marking operational readiness.
- Parallel operation of solar and hydrogen plants achieved during trial run on 18 March 2025.
- Land parcel at 440 kV switchyard of 660MW Project finalized as suitable site after detailed assessments.
- Strengthened renewable energy integration at BTPS through in-house solar-powered hydrogen production.
- Experience gained will act as a blueprint for scaling up future Green Hydrogen projects across MSPGCL and beyond.
SKOCH Award Nominee
Category: Government Undertaking
Sub-Category: Government Undertaking
Project: Green H2 Pilot Project at Bhusawal TPS
Start Date:17.05.2024
Organisation: Maharashtra State Power Generation Co. Ltd
Respondent: Radhakrishnan B.
http://www.mahagenco.in/
Level: Club Star
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Case Study
Green H2 Pilot Project at Bhusawal TPS
The Green Hydrogen (H2) Pilot Project at Bhusawal Thermal Power Station (BTPS), undertaken by MAHAGENCO, represents a landmark initiative in clean energy adoption within state-run utilities. Conceived to replace the ageing 1994 hydrogen generation plant that had exhausted its useful life and faced challenges of limited capacity, unavailable OEM support, and spare parts, the project directly addressed the growing hydrogen requirements of BTPS’s 210 MW, 500 MW, and upcoming 660 MW units.
Awarded to M/s ORAIPL on 9th June 2023 at a value of ₹15.07 crores including five years of O&M, the project was designed to operate 10 hours daily, producing hydrogen of 99.99% purity. It integrated a 500 kW solar plant, ensuring renewable sourcing and alignment with the National Hydrogen Mission. Despite encountering groundwater at shallow depth during initial civil works, the team swiftly adapted to keep progress on track.
Implementation was closely overseen by senior leadership, ensuring coordinated execution of civil, equipment, and safety milestones. Trial runs in March 2025 successfully synchronized hydrogen and solar generation, proving the viability of this hybrid model. The project not only resolves urgent operational needs but also establishes a scalable template for future hydrogen initiatives, reinforcing Maharashtra’s renewable energy ambitions and India’s clean energy leadership.
For more information, please contact:
Radhakrishnan B. at md@mahagenco.in
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