The transition toward zero-carbon propulsion technologies has highlighted the urgent need for specialized test infrastructure to support hydrogen and alternative fuel research. This paper presents the conceptualization, design, and operation of a High-Pressure Direct Injection (HPDI) Hydrogen Internal Combustion Engine (H2 ICE) test facility with integrated ammonia fuel testing capability, marking a significant advancement in India’s sustainable automotive research efforts. Drawing from practical experience, it outlines crucial technical specifications, safety protocols, and best practices for establishing robust, adaptable, and secure testing environments. Addressing the industry’s need for dedicated infrastructure, it is engineered for adaptability across various engine types—including heavy-duty, light-duty, and multi-utility vehicles—while aligning with global technical standards.
Key technical considerations include the use of a transient dynamometer that features an advanced automation system for precise control of both hydrogen and ammonia test cycles. Emission measurement systems, such as hydrogen analyzers, ammonia-specific FTIR, particle number counters, and particle size distribution analyzers, are essential for analyzing regulated and unregulated emissions critical to sustainable fuel development. The hydrogen fuel storage and distribution system supports pressures up to 500 bar, incorporating certified compressors, buffer cylinders, and stainless-steel piping with compatible seals and three distinct supply lines operating at 350 bar (for HPDI), 100 bar (for Low Pressure Direct Injection), and 20 bar (for Port Fuel Injection) to accommodate diverse engine configurations. Modular designs ensure future scalability, compliance with international safety standards (ISO, SAE), and rigorous safety audits. A separate ammonia delivery system is designed to address its unique chemical and safety considerations, enabling dual-fuel capability.
Safety remains a cornerstone of the facility's design due to hydrogen’s flammability and ammonia’s toxicity. Essential measures include a high-capacity ventilation system with continuous gas detection, ATEX-rated electrical infrastructure, and an inert-gas fire suppression system integrated with flame and gas sensors. To minimize explosion risks, real-time monitoring through CCTV, thermal imaging, and acoustic sensors replaces traditional observation windows. Automated safety logic ensures continuous oversight, initiating shutdowns as required.
The facility serves as a benchmark for scalable hydrogen and ammonia ICE research in emerging markets, offering best practices, insights, and technical recommendations. The insights presented are intended to inform and inspire broader efforts across the automotive value chain, encouraging proactive engagement, technology adaptation, and aligned infrastructure development in support of a zero-carbon mobility future.