The global shift toward a hydrogen economy is one of the defining infrastructure challenges of our time. While interest in hydrogen has waned significantly in the past year, it continues to hold immense potential as a clean energy carrier, its widespread adoption hinges on the ability to transport it efficiently and safely. Based on ADI’s extensive work with pipeline companies and government agencies, the consensus is clear: repurposing existing natural gas pipelines is strategically essential, but it demands a meticulous, technically informed approach. The journey to an “H2-ready” network is a balancing act of managing technical risks, maximizing economic viability, and securing essential policy support (see Exhibit 1).
Exhibit 1. Key challenges and approaches to repurposing hydrogen pipelines.
Managing hydrogen embrittlement
The most critical engineering hurdle is hydrogen embrittlement. This phenomenon is not an indiscriminate threat but a specific risk for carbon steel pipes, especially those with existing material imperfections. Under fluctuating operational loads, these flaws can expose a blank metal surface, allowing highly mobile hydrogen atoms to permeate the base material and compromise its structural integrity.
Extensive research, notably from institutions like Sandia National Labs, is actively informing and strengthening industry standards such as ASME B31.12. For operators, this means a rigorous, data-driven fitness-for-service evaluation is non-negotiable before any conversion. Mitigation strategies are crucial, focusing on specific material selection, optimized welding techniques, and the use of protective internal coatings to prevent direct hydrogen exposure. For a deeper dive into these technical challenges, read: Can natural gas pipelines handle hydrogen?
Additionally, the thermodynamics of hydrogen present an operational challenge. To maximize energy throughput, dedicated compressed hydrogen pipelines must operate at high pressures. While this is effective for large-scale energy transfer, the substantial energy required for compression significantly reduces the overall efficiency of the system, a factor that will drive future technological innovation in compression and transport.
Repurposing over new build
From an economic perspective, the case for repurposing is overwhelming. New hydrogen pipeline construction is estimated to be significantly more costly than a comparable natural gas line. This stark reality underscores the strategic importance of leveraging established natural gas networks to reduce massive capital expenditure and accelerate deployment.
The most pragmatic and immediate entry point into a hydrogen network is blending. Industry consensus suggests that blends of up to 20% by volume of hydrogen can be safely transported in most existing natural gas networks with minimal or no modifications. This low-cost, low-risk strategy allows for gradual market penetration, provides an immediate path for hydrogen consumers, and phases in the necessary infrastructure upgrades. As these initial projects mature, the long-term cost of ownership—including the true share of maintenance and repair costs—will become clearer, refining the overall business case. The transition starts here: Natural gas pipelines: Future of hydrogen transport?
Strategic implications
For industry stakeholders, success in this transition requires a multi-faceted strategy:
- Prioritize Materials Science: Pipeline operators must adopt a proactive, data-driven approach to asset integrity management. The technical challenges are manageable, but they demand a high degree of diligence and expertise in materials science and engineering.
- Immediate Market Entry: Developers should utilize blending to establish early projects, while manufacturers must capitalize on the market by developing robust components (valves, compressors, coatings, etc.) specifically designed for hydrogen service.
- Shape the Standards: Large-scale hydrogen projects, particularly the development of a national or regional hydrogen backbone, require substantial public investment. The development of a connected hydrogen grid across nations necessitates unified industry standards for safety and interoperability. Companies that actively participate in shaping the evolving regulatory and policy landscape will be best positioned for long-term success.
The foundation of the future hydrogen economy—built upon sound technical specifications, viable economic models, and committed government support—is being established right now. Learn more about the hydrogen ecosystem here: Hydrogen value chain.
– Uday Turaga
About ADI Analytics
ADI is a prestigious, boutique consulting firm specializing in oil and gas, energy, and chemicals since 2009. We bring deep expertise in a broad range of markets where we support Fortune 500, mid-sized and early-stage companies, and investors with consulting services, research reports, and data and analytics, with the goal of delivering actionable outcomes to help our clients achieve tangible results.
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