As Europe seeks to bolster its energy transition, the continent is exploring the feasibility of repurposing existing oil and gas pipelines for hydrogen transport. With ambitious targets established through the REPowerEU Plan, Europe plans to produce at least ten million tonnes of low-carbon hydrogen per year. This ambitious initiative is indeed poised to revolutionize the energy landscape. Most importantly, it will use existing infrastructure to lower the costs of laying new pipelines.
Europe today owns and operates the world’s only significant hydrogen pipeline network. The project—known as the European Hydrogen Backbone (EHB)—would significantly extend this network, to 39,700 kilometers by 2040 according to estimates. Developers and technology investors will need to work hand-in-hand to accelerate the transition toward hydrogen. They often create special purpose joint ventures to share risk and their own resources.
Robert Shelton, an outside industry expert, led the call for fossil fuel companies to change their ways. He stated, “Fossil fuel companies need to see themselves in the energy business and understand how to maximise profits today and tomorrow.” This change in thinking is, we would argue, indispensable to true collaboration. It’s guiding them through the energy transition to hydrogen—an essential building block of tomorrow’s clean energy game plan.
Economic Considerations and Infrastructure Challenges
Safety aside, the cost implications of constructing new hydrogen pipelines are enormous. Building new infrastructure can cost up to ten times as much as simply repurposing the existing gas pipelines. This unprecedented financial disparity requires stakeholders to acknowledge and address this unprecedented gap. They need to make decisions about investing in the infrastructure we have in place now versus building out brand new infrastructure.
The technical hurdles related to retrofitting gas pipelines to carry hydrogen aren’t minor either. Hydrogen indeed poses special risks—notably, embrittlement of pipeline steels, a problem exacerbated by hydrogen’s smaller molecular size. New research published by the International Journal of Hydrogen Energy reinforces these risks, calling for fundamental changes in materials and engineering practices.
This is why construction of new hydrogen pipelines with austenitic stainless steel piping is advised, due to its corrosion resistant properties. Furthermore, fibre-reinforced polymer is proving to be a material that needs less welding and has a reduced installation cost. Such innovations would make the repurposing process faster and more cost-effective while improving safety and efficiency.
“Hydrogen’s low ignition energy and high flammability require changes to hazardous zones and venting strategies.” – Peter O’Sullivan
The engineering challenges extend beyond material selection. Scaling up to continent-spanning, high-pressure transmission networks offers extensive additional challenges that merit new creative, synchrony-seeking solutions. Pipeline-in-pipeline systems in particular are a very promising solution. Through stranding effects, they allow a high-pressure hydrogen pipeline to safely operate within an already constructed pipeline.
Rinaldo Brutoco describes this system: “A high-pressure hydrogen pipeline runs inside an existing pipeline, with the interstitial space capturing any leaked hydrogen from the inner system to be scrubbed.” This design allows for frequent monitoring and reduces the risk of a leak or spill occurring while updating aging infrastructure.
Global Perspectives on Hydrogen Development
Globally, countries are moving quickly to establish the developing hydrogen markets, and each country’s approach has its own advantages and obstacles. Meanwhile, in South Korea, the SK E&S Boryeong Hydrogen Project will go live in 2026. That makes this initiative a clear sign of the country’s commitment to integrating hydrogen into its energy mix. In the meantime, Spain’s Project Catalina seeks to inject hydrogen into its natural gas pipeline by 2027.
Not all initiatives have proceeded smoothly. Just last week, Equinor announced it was scrapping its plans to export hydrogen from Norway to Germany. This judgment is a recognition of the rising hydrogen price, turbulent, and still uncharted market. Rajiv Sabharwal notes that “ongoing uncertainty in the hydrogen market and delays in capital investments for new projects means that companies are now focusing more on their conventional O&G operations.”
As different regions pursue their hydrogen ambitions, they must navigate financial constraints while balancing traditional oil and gas operations with emerging technologies.
Future Prospects and Considerations
The transition to hydrogen is more than just a tech shift — it’s part of a larger reimagining of the way we produce and distribute energy. Experts say that the best way to overcome technical and economic challenges is through a collaborative approach involving community and economic development professionals, transportation experts, and planners.
Shu Shu Wong and Conrad Purcell stress that “hydrogen development often hinges on collaboration between investors and technology providers.” These types of partnerships could spur important innovation while reducing the risks involved in pursuing new paths.
Shelton highlights the importance of adapting labor forces as well: “The answer is clearly moving into hydrogen and [redeploying labour, such as pipe-fitters].” This expeditious adaptation of the workforce will be essential as industries evolve from their fossil fuel reliance to greener, renewable alternatives.
Even though the benefits of adopting hydrogen technologies far outweigh the disadvantages, operational challenges still need to be addressed. O’Sullivan points out that “the lack of a visible flame and hydrogen’s higher combustion heat mean changes to operating practices and first responder procedures.” These changes will be critical for protecting public safety in a rapidly changing energy environment.