High-temperature, high-pressure hydrogen pipelines are specialized systems designed for the safe transport and storage of hydrogen under extreme conditions. These pipelines must withstand hydrogen embrittlement, high mechanical pressure, and elevated temperatures to ensure long-term reliability and safety.
This article provides a structured overview of the technical requirements, major applications, recent technological breakthroughs, market trends, and industry challenges based on the latest developments.
Hydrogen behaves differently from other gases due to its extremely small atomic size and high diffusivity, making pipeline material selection a critical engineering challenge.
Hydrogen atoms diffuse into metal lattices, causing brittleness and reduced strength.
Preferred materials include:
Austenitic stainless steels
Nickel-based alloys
These metals offer strong resistance to hydrogen-induced degradation.
Hydrogen delivery pressures frequently reach:
70 MPa at fueling stations
Up to 90 MPa in onboard hydrogen storage
Pipeline materials must therefore exhibit exceptional mechanical endurance.
Industrial hydrogen processes—such as petroleum refining—operate at temperatures as high as 650°C.
Such extreme conditions require special heat-resistant alloys.
Hydrogen molecules are extremely small (≈0.289 nm), making leakage a critical safety concern.
Solutions include:
Metal seals
Composite sealing structures
Multi-layer barrier coatings
Hydrogen pipelines play an essential role in the hydrogen energy ecosystem, including transportation, storage, and chemical manufacturing.
Long-distance hydrogen pipelines:
Example: China’s first cross-provincial green hydrogen pipeline (Wulanqab → Beijing-Tianjin-Hebei) uses X52 grade straight seam submerged arc welded pipes, operating at 6.3 MPa.
Hydrogen refueling station pipelines:
Built according to T/SSTA 202-2022 standards, capable of pressures up to 138 MPa, typically using stainless steel seamless tubing.
High-pressure hydrogenation units:
Used in refinery hydrocracking processes. Must meet JB/T11484-2025 and offer strong H₂S corrosion resistance.
Liquid hydrogen pipelines:
Operating at cryogenic −253°C, requiring materials with high low-temperature toughness.
In recent years, domestic Chinese companies have achieved notable progress in the hydrogen pipeline field.
Zhejiang Zhongda New Materials developed seamless austenitic stainless steel hydrogen pipes using electroslag remelting + vacuum induction melting, with a graphene–polysilazane composite coating to strengthen hydrogen embrittlement resistance.
Baoji Steel Pipe achieved breakthroughs with HFW welded pipes, successfully passing 6.3 MPa hydrogen charging tests, with performance surpassing traditional seamless pipes.
Lanzhou Valve Company led development of the JB/T11484-2025 High-Pressure Hydrogen Valve Standard, accelerating localization.
Baoshi Pipe Industry initiated the Hydrogen Gas Long-Distance Pipeline Material Evaluation Specification, filling crucial industry gaps.
With China’s Dual Carbon (Carbon Peak/Neutrality) goals, hydrogen transmission pipelines—such as the Ulanqab green hydrogen project—are expanding rapidly.
Projections estimate over 5,000 km of hydrogen pipelines by 2030.
High-performance hydrogen pipelines for refueling stations were once dependent on imports.
Domestic suppliers are now closing the technology gap.
Future trends include:
Smart leak detection systems
Advanced anti-permeation coatings
Real-time pipeline health monitoring
Despite progress, significant challenges remain:
Ultra-high-pressure (100 MPa+) liquid hydrogen pipelines still rely on imported nano-crystalline alloys.
Breakthroughs in high-strength hydrogen-resistant alloys are urgently needed.
A comprehensive set of standards covering:
Welding
Manufacturing
Inspection
Whole lifecycle management
…is essential for the sustainable development of the industry.
High-temperature, high-pressure hydrogen pipelines form the backbone of the future hydrogen economy. As material innovation, standard development, and domestic manufacturing continue to advance, the industry is rapidly moving toward safer, more efficient, and more scalable hydrogen infrastructure.
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