Engineering consultancy
Arun Babu
Mechanical and green hydrogen engineer with nearly 15 years in
R&D product development. Led India’s first membrane-less alkaline electrolyzer
from concept to pilot commissioning with ONGC and BPCL.
- 15years in engineering R&D
- 60%CAPEX reduction vs PEM systems
- 99.9%hydrogen purity achieved
- $135Kmanufacturing cost removed at Xylem
What I work on
Green hydrogen systems
Electrolyzer development from concept through prototype, pilot and scale-up.
Alkaline and membrane-less architectures, balance of plant, gas purity and
cost-down engineering.
Mechanical R&D and product development
End-to-end lifecycle under Stage-Gate and Agile: concept design, CAD, FEA and
CFD validation, DFM/DFA, VA/VE and pilot commissioning.
Water and fluid systems
Treatment trains, chlorination and clarifier systems, hydraulic calculations,
pumps and valves — from Xylem water technology and electrolyzer feedwater work.
Engineering process and PLM
PLM/PDM workflow, CAD standards, BOM governance, ECN/ECO management, SAP ERP,
and CMMI Level 3 / ISO 9001 process implementation.
Track record
Project Lead, R&D — Green Hydrogen
- Led the full R&D lifecycle for India’s first membrane-less alkaline green
hydrogen electrolyzer, from concept and CAD through pilot commissioning and validation. - Took the membrane-less electrolyzer from concept to pilot for ONGC and BPCL.
- Delivered a 60% CAPEX reduction versus PEM systems at
99.9% hydrogen purity, using SolidWorks, FEA and CFD. - Established PLM workflow, CAD standards and BOM governance across R&D,
manufacturing and supply chain. - Contributed to national recognition under India’s Green Hydrogen Mission (PLI Award).
Senior Engineer — Water Technology
- Led VA/VE on chlorinator systems with simulation-driven design optimization,
cutting manufacturing cost by ~$135K. - Drove design improvements for clarifier systems through structured design review.
Technical Consultant — Engineering & AI Workflows
- Designs prompt-engineering frameworks, AI evaluation methodology and technical
rubrics for engineering-domain models. - Engineering consulting and project management across renewable energy and
industrial sectors.
Tools and methods
- SolidWorks
- AutoCAD
- Autodesk Inventor
- FEA
- CFD
- Hydraulic calculations
- GD&T
- PLM / PDM
- ECN / ECO
- BOM management
- SAP ERP
- Stage-Gate NPD
- DFM / DFA
- VA / VE
- CMMI Level 3
- ISO 9001 QMS
- Python
Engineering tools on this site
LCOH Calculator
Levelised cost of hydrogen against electricity price, utilisation and CAPEX.
Electrolyzer Calculator
Stack sizing and output for a given duty.
Water Consumption & Treatment
Feedwater demand and treatment duty for an electrolyser plant.
Consultancy enquiries
Electrolyzer development, balance of plant, water treatment trains, mechanical
R&D and engineering process governance.