Hydrogen is emerging as a key energy solution for various industries, including mining, oil, petrochemicals, offshore, water treatment, and energy. Its potential goes far beyond simply replacing traditional fossil fuels; it promises to revolutionize the efficiency and sustainability of industrial operations. However, adopting hydrogen as a fuel also presents significant technical challenges, particularly concerning the integrity of materials used in pipelines and equipment due to the unique properties of hydrogen.

Energetic Advantages of Hydrogen

Hydrogen possesses characteristics that make it extremely attractive for the industrial sector:

1. High Specific Energy Density: Hydrogen has an energy density of approximately 120 MJ/kg, which is nearly three times higher than gasoline (44 MJ/kg). This high specific energy density allows a relatively small amount of hydrogen to generate a substantial amount of energy, making it ideal for industrial applications with high energy demands.
2. Clean Combustion: When burned in internal combustion engines or used in fuel cells, hydrogen does not produce carbon emissions, only water vapor. This process occurs at temperatures that can exceed 1,000°C, depending on the application, which is sufficient to power industrial processes that require high temperatures, such as steel and glass production.
3. Versatility and Energy Storage: Hydrogen can be produced by water electrolysis using renewable energy (green hydrogen), stored in gaseous or liquid form, and transported to locations with high energy demand. Its ability to be stored at high pressure (up to 700 bar) or at extremely low temperatures (−253°C for liquid hydrogen) makes it an excellent medium for storing energy efficiently.

Impact of Hydrogen on Pipelines and Equipment Structures

Despite its advantages, the use of hydrogen as a fuel presents considerable technical challenges, particularly regarding the durability of pipelines and equipment. Due to the small size of the hydrogen molecule (0.29 nm), it can easily diffuse into metallic materials, causing a phenomenon known as hydrogen embrittlement.

Hydrogen Embrittlement

Hydrogen embrittlement is a complex process where hydrogen penetrates metallic materials, resulting in a significant decrease in ductility and fracture resistance. This process is exacerbated by harsh operational conditions, such as high pressures and temperatures. The penetration of hydrogen can lead to the formation of internal cracks, reduced equipment lifespan, and, in extreme cases, catastrophic failures.

• Real-Life Disasters:
• In 2010, an incident at the Anacortes refinery in Washington occurred due to hydrogen embrittlement in a heat exchanger. The failure resulted in an explosion that killed seven workers. The investigation revealed that hydrogen had penetrated the carbon steel of the heat exchanger, causing catastrophic fracture.
• Reduced Lifespan: The lifespan of metallic components in contact with hydrogen can be significantly reduced. Studies indicate that the lifespan of carbon steels in hydrogen-rich environments can be reduced by up to 50%, depending on hydrogen concentration, pressure, and operating temperature.
• Critical Temperatures and Pressures: Hydrogen becomes particularly aggressive at temperatures above 400°C and pressures exceeding 10 MPa. Under these conditions, hydrogen diffusion into metallic materials is accelerated, increasing the risk of embrittlement and sudden fractures.

Mitigating the Effects of Hydrogen

To minimize the adverse effects of hydrogen on industrial structures, a combination of technical strategies must be implemented:

1. Selection of Resilient Materials: The use of high-strength stainless steels (such as austenitic steels), nickel alloys, and titanium is recommended for applications where hydrogen is present. These materials are less susceptible to hydrogen embrittlement, increasing the durability of pipelines and equipment.
2. Advanced Protective Coatings: The application of internal coatings, such as fluoropolymer (e.g., PTFE) or ceramic coatings, can act as a physical barrier against hydrogen diffusion. These coatings are especially important in high-pressure pipelines and storage tanks, where hydrogen penetration could be more severe.
3. Real-Time Integrity Monitoring: Advanced monitoring systems using non-destructive testing (NDT) techniques such as high-frequency ultrasound, eddy current inspection, and positron emission tomography (PET) can be implemented to detect the presence of hydrogen, internal cracks, or changes in material structure before critical failures occur.
4. Strict Hydrogen Purity Control: Hydrogen purity must be rigorously controlled. Contaminants such as oxygen and water vapor can catalyze material embrittlement, accelerating crack formation. Therefore, hydrogen purification before use is a crucial measure.
5. Scheduled Maintenance and Replacement: Establish preventive maintenance programs that include regular inspections and replacement of critical components based on wear and embrittlement data. The lifespan of components can be extended by up to 30% with proper maintenance practices.

Conclusion

Hydrogen represents a powerful and clean energy solution for industries, offering high energy density and carbon-free combustion. However, the use of hydrogen requires a sophisticated technical approach to address the challenges posed by hydrogen embrittlement and material degradation over time. The selection of appropriate materials, the use of protective coatings, and the implementation of continuous monitoring and rigorous maintenance practices are essential to ensure that industries can fully harness the benefits of hydrogen while maintaining the integrity and safety of their operations.