Lightweight Cascade Design Using Type IV Cylinders for Efficient Hydrogen Gas Logistics in India

Hydrogen mobility in India faces a key challenge in the form of high transportation and logistics costs, particularly in tier-II and tier-III cities where dedicated pipelines are not yet feasible. Current methods using traditional steel based cascades are heavy, inefficient, and limit payload capacity. This paper presents a novel lightweight cascade system designed to enhance the efficiency of hydrogen gas logistics using Type IV composite cylinders and an aluminium structural frame. The design adheres to PESO (Petroleum and Explosives Safety Organisation) standards and achieves a structural weight reduction of 52%, owing to the use of carbon fibre composite cylinders and aluminium framework. Field level analysis demonstrates that the gas transport efficiency is improved by a factor of 2.5 compared to conventional steel based systems when used in heavy duty trucks. This innovation offers a significant step forward in enabling economically viable hydrogen distribution for mobility applications in emerging Indian markets, aligning with national decarbonization goals.