The Future of Natural Gas: Why Pipeline Networks Will Look Different by 2030

Natural gas has a promising future with US reserves expected to last another 86 years. The United States leads global production by contributing nearly 25% of the world’s natural gas. Americans rely on this resource for 33% of their national energy needs.

Natural gas stands as the second most popular energy source in the US and plays a crucial role in the energy transition. The longevity of natural gas supplies depends substantially on our strong infrastructure development. Texas powers this promising future by producing 43% of our annual supply. New technologies emerge faster, especially when you have developments in carbon capture and pipeline modifications. The Sapphire FreeSpin® turboexpander system showcases innovation in energy recovery. The Trailblazer pipeline conversion project proves how companies can repurpose existing infrastructure effectively.

Our pipeline networks need reshaping by 2030. These modifications will alter the map of our energy sector for decades. Let’s explore what changes lie ahead and their impact on our future energy landscape.

Why Current Pipeline Networks Are Not Ready for 2030

Natural gas infrastructure faces big challenges as we look ahead to 2030. Our current pipeline networks were built to transport methane. They lack the right setup to handle future energy carriers like hydrogen and CO2. This mismatch could slow down natural gas’s role in the energy transition.

CO2 and Hydrogen Transport Limitations in Existing Pipelines

Hydrogen and CO2 behave very differently from methane, which creates major problems with our existing infrastructure. Hydrogen has the smallest molecules on Earth. These tiny molecules can squeeze into spaces in steel alloys where natural gas can’t go. This leads to hydrogen embrittlement – steel, copper, and iron become less flexible. When metals absorb hydrogen, cracks develop up to 30 times faster and the metal’s strength drops by half.

Hydrogen leaks just as fast as methane, sometimes even faster. The problem gets worse when hydrogen mixes with other gases because it becomes more “slippery”. This is a big deal as it means that hydrogen could act as a greenhouse gas, which might cancel out its environmental benefits.

CO2 brings its own set of challenges. Unlike hydrogen, CO2 can change its state under normal pipeline conditions. So while hydrogen stays as a gas under typical pipeline pressures (55-85 bar), CO2 doesn’t. Moving CO2 needs special equipment that most gas networks don’t have.

Projects like HyBlend are testing how pipeline materials react to different amounts of hydrogen at pressures up to 100 bar. In spite of that, we don’t fully understand the long-term effects on materials and equipment. This creates uncertainty for utilities planning to blend large amounts of hydrogen.

Pressure and Material Constraints in Natural Gas Infrastructure

Pressure control is another major challenge. Gas distribution networks use fixed pressure settings at their regulating stations. Adding hydrogen means we need new operational strategies. During peak times, minimum pressure points create bottlenecks that limit how much hydrogen we can add.

Safety concerns make pressure limits even more critical. Studies show that old gas pipelines used for hydrogen might need to run at just one-third of their original pressure to meet safety standards. This huge drop cuts down how much energy the pipeline can carry and reduces the “line pack” – the energy stored as compressed gas.

Energy density differences make things worse. Hydrogen carries only one-third of the energy that natural gas does in the same space. With lower pressure limits, pipelines carrying hydrogen might only transport one-ninth of the energy compared to natural gas.

The materials used in existing pipelines add more complications. Much of the U.S. natural gas pipeline system uses pre-1970s steel. These old pipes might have more defects from poor manufacturing and years of use. New gas mixtures could cause these aging materials to fail more easily.

We need complete testing and modernization before most natural gas infrastructure can handle alternative gases. Yes, it is challenging to adapt our vast pipeline network safely. But this also gives us a chance to develop new natural gas technologies as we move through 2030 and beyond.

Modifications Required for Fuel-Agnostic Pipelines

Natural gas pipelines need major changes to handle multiple types of fuel. A reliable infrastructure that can transport natural gas, CO2, and hydrogen needs an integrated approach to equipment, safety, and operations. These changes showcase key natural gas technologies that will determine how long natural gas remains in our energy mix.

Compression Equipment for High-Pressure CO2 and Hydrogen

CO2 transport needs more than double the pressure of regular natural gas to keep the gas dense above its critical temperature. Hydrogen also needs higher pressure levels, but for different reasons. The energy content of hydrogen is only one-third of natural gas by volume, so pipeline operators must boost either pressure or volume to deliver the same energy.

Reciprocating compressors are now the best option for pipelines carrying 100% hydrogen. These systems compress gas in cylinders effectively. More cylinders and drive power can help achieve transport capacity up to 750,000 Nm³/h.

Turbocompressors struggle with hydrogen efficiency. The pressure increase in a turbocompressor links directly to gas molecular weight, and hydrogen weighs about 1/16th of methane. Getting similar pressure ratios needs either much faster impeller tip speeds or extra compressor stages across multiple casings.

Compressors can work without major changes when hydrogen makes up less than 10% of the gas mixture. Gas mixtures with 10-40% hydrogen need impeller adjustments and gear modifications. Any concentration above 40% requires new compressors.

Filtration and Dehydration Systems for Corrosion Prevention

Moisture poses the biggest threat to fuel-agnostic pipelines. CO2 must be completely dry before compression, transport, and injection for enhanced oil recovery or carbon capture. This prevents water condensation and hydrate formation. Water can damage compressors, and when it mixes with CO2, it creates corrosive carbonic acid.

Kinder Morgan’s CO2 Pipeline requirements highlight this issue. Their rules state that the product must be free of water and can’t have more than 30 pounds of water vapor per million standard cubic feet.

Standard dehydration equipment has:

• Contactor/absorber columns to remove water vapor
• Filter separators and scrubbers that reduce glycol contamination
• Regeneration systems with flash tanks, filters, heat exchangers, and pumps

Pipeline materials for hydrogen transport need careful assessment for hydrogen embrittlement risk. High-strength steels (>100 ksi yield strength) face the biggest risk, but even low-strength steels lose tensile ductility. Hydrogen-induced cracking usually needs pre-existing crack-like defects, which makes regular inspection vital.

Crack Arrestors and Leak Prevention Mechanisms

Special mechanisms help control propagating fractures. Crack arrestors limit uncontrolled ductile fractures in pipelines. Old arrestor designs often led to “ring-off” failures, where pipeline sections broke off completely and flew up to a quarter-mile from installation sites.

New crack arrestor designs look at both strength and ductility. The Battelle Two-Curve Method helps determine the minimum toughness needed for pipe specifications. The National Energy Technology Laboratory has created innovative self-healing cold spray coatings that protect against internal corrosion.

CO2 pipelines face unique challenges with ductile fractures. This has led to strict rules about CO2 purity and strategic crack arrestor placement. Full composite pipes (FCP) made from thermoplastic composites offer a promising solution. Their polymeric structure resists corrosion even with significant impurities.

Better leak detection systems are essential because hydrogen molecules are smaller and leak more easily. Hydrogen moves through steel pipes four to five times faster than methane. These next-generation natural gas networks need complete updates to their fittings, seals, valves, and monitoring systems for safe operation.

New Natural Gas Technologies Enabling Pipeline Flexibility

New technologies are emerging faster to tackle the challenges of future-proofing natural gas infrastructure. These advances extend natural gas’s lifespan as a transitional fuel and have ended up creating pipeline networks that can transport multiple fuel types with minimal changes.

FreeSpin® In-line Turboexpander for Energy Recovery

The FreeSpin® In-line Turboexpander (FIT) is a game-changing innovation in energy recovery from pressure reduction in natural gas pipelines. The system uses a hermetically sealed design that merges a high-speed turboexpander with a permanent magnet generator. A single spinning rotor levitated on non-contact magnetic bearings drives both components. The FIT is better than conventional systems because it removes dynamic seals, lubrication systems, and gearboxes. This creates a maintenance-free solution without oil contamination risks.

The system works through a simple process. High-pressure gas enters the turboexpander, expands through a radial turbine wheel, and exits at lower pressure ready for distribution. The system captures energy usually wasted in pressure reduction and converts it to electricity. Tests at pressure letdown stations in Italy showed impressive results. Each unit should generate over 1.6 million kWh yearly per installation.

Tallgrass Energy leads the largest US rollout of these systems. They plan to install 72 turboexpanders in three years. This technology works especially when you have fuel flexibility needs. It adapts well for hydrogen liquefaction and pressure letdown processes with different gas types.

Self-Healing Cold Spray Coatings for Corrosion Resistance

Internal pipeline corrosion is a constant threat. It caused 12% of natural gas pipeline incidents in the last two decades, with costs over $197 million. The National Energy Technology Laboratory (NETL) created an innovative self-healing cold spray coating technology to curb this issue.

This zinc-rich material protects against internal corrosion in natural gas, hydrogen, and CO2 pipelines. The coating applies through a cold spray process. Metal powders accelerate through a supersonic nozzle for particle adhesion. Robotic devices attached to pipeline pigs can deploy this coating.

Tests at NW Natural’s gas storage facility proved the coating works well. Protective corrosion products form on damaged areas and stop further deterioration. The technology stays stable whatever the temperature or pressure changes. It also acts as a hydrogen barrier to protect steel pipelines from hydrogen embrittlement.

Digital Twin Simulations for Pipeline Stress Testing

Digital twin technology changes how we manage pipeline integrity. Virtual models mirror physical assets with amazing accuracy. These twins combine sensor data, CAD models, and simulation tools to give immediate, detailed views of piping system performance.

Digital twins allow dynamic scenario testing. They simulate thermal expansion, seismic activity, and pressure surges. This ensures designs meet performance criteria under all expected conditions. Traditional stress analysis methods rely on assumptions. Digital twins use live field data to monitor stress levels immediately and find potential failure points before they become critical.

Digital twins are a great way to get insights into aging infrastructure. This matters because many US pipelines are over 50 years old. The technology doesn’t need shutdowns or intrusive inspections. These virtual models aid damage detection, localization, quantification, and prediction while considering uncertainty propagation.

Case Studies of Pipeline Conversion Projects

Real-life projects show how pipeline networks evolve to support natural gas as a transitional energy source. These trailblazing initiatives showcase practical applications of technologies that extend the viability of natural gas infrastructure in a changing energy world.

Trailblazer Pipeline Conversion to CO2 Transport

The Federal Energy Regulatory Commission (FERC) approved Trailblazer Pipeline Company’s plan to convert its 400-mile natural gas pipeline system for CO2 transport on October 23, 2023. This project gives new life to infrastructure from the 1980s by carrying CO2 from ethanol plants and other emissions sources in Nebraska and Colorado to Wyoming’s permanent geologic formations. The Trailblazer Conversion Project stands out among multistate CO2 pipeline projects because it employs existing pipeline infrastructure instead of requiring new construction. The system will capture, transport, and permanently store over 10 million tons of CO2 each year once operational.

National Gas Hydrogen Blend Testing in the UK

DNV Spadeadam’s FutureGrid high-pressure test facility in the UK has shown that existing pipeline networks can safely transport hydrogen – a world first. Researchers tested natural gas transmission assets with hydrogen blends of 2%, 5%, and 20%, and ended up progressing to 100% hydrogen during extensive trials. The first phase of testing reported “no issues,” and researchers found no major obstacles to repurposing the network. National Gas develops innovative deblending technology that could help extract hydrogen from blended gases for vehicle fueling. The UK government plans to decide on transmission blending by 2024, and implementation could begin by 2025-26.

Snam’s Hydrogen-Compatible Compressor Trials

Snam completed groundbreaking tests at its Istrana compression station by using hydrogen to power gas turbines. The company showed the compatibility of existing turbines with a 10% hydrogen-natural gas blend – a global first. Two different turbines underwent testing: a hydrogen-ready NovaLT12 and a conventional PGT25. A permanent 10% hydrogen blend in all Snam’s PGT25 turbines would prevent almost 20,000 tons of CO2 emissions yearly, based on 2021 operating data. The company aims to test hydrogen compatibility across its entire turbocompressor fleet and might establish consistent standards for all future compression units.

How These Changes Shape the Future of Natural Gas

Pipeline networks’ adaptability is the lifeblood of our evolving energy landscape. This will revolutionize industry fundamentals for decades.

Fuel-Flexible Infrastructure as a Decarbonization Strategy

Modernized pipelines that can transport natural gas with hydrogen and CO2 show a clear path to decarbonization. Research by the Electric Power Research Institute shows the natural gas infrastructure’s significant role in all net-zero scenarios. It “provides firm capacity for a transitioning power sector and delivers low-carbon fuel to industry and buildings, especially when you have colder climates”. Pipeline capacity remains vital to serve peak demands even as we move toward cleaner energy sources. Studies show U.S. natural gas consumption could stay at today’s levels, even in a net-zero energy future.

Revenue Generation from Recovered Energy

Modernized pipeline systems create new revenue streams through energy recovery technologies beyond environmental benefits. The FreeSpin® In-line Turboexpander is a chance to convert previously wasted pressure reduction energy into electricity. This innovation makes it possible to:

• Generate green electricity from pressure letdown processes
• Create additional revenue for pipeline operators
• Offset higher costs from hydrogen and CO2 compression

These technologies ended up transforming cost centers into profit generators while reducing carbon footprints.

Natural Gas as a Transitional Fuel in a Net-Zero Future

Natural gas will be the backbone of grid reliability as renewable energy expands. Gas-fired power plants provide vital flexibility to compensate when “intermittent renewables are at low generation levels”. This flexibility’s value grows as renewable penetration increases. Natural gas demand will become “more volatile going forward—lower on average, but potentially much higher on peak-demand days”.

Natural gas produces only half the carbon dioxide of coal and 70% of oil when burned. This gives us immediate emissions reduction chances while longer-term solutions develop. Natural gas also helps advance other low-carbon technologies, including carbon capture and storage and low-carbon hydrogen. These are vital parts of any complete decarbonization strategy.

Conclusion

Natural gas will remain the lifeblood of our energy world beyond 2030, but not in its current form. This piece explored why today’s pipeline infrastructure needs major changes to handle future energy carriers like hydrogen and CO2. These networks, built for methane transport, don’t deal very well with pressure requirements, material compatibility, and safety concerns when moving alternative gases.

Fuel-agnostic pipelines will revolutionize our energy infrastructure. Compression equipment must handle higher pressures, filtration systems must prevent corrosion, and specialized mechanisms must address fracture risks. The good news is that promising technologies show this transformation can work.

FreeSpin® turboexpanders, self-healing coatings, and digital twin simulations are just the start of innovations that enable pipeline flexibility. Ground projects like the Trailblazer Pipeline conversion and National Gas hydrogen blend testing prove that existing infrastructure can adapt to tomorrow’s energy needs.

Natural gas’s future depends less on having enough resources—U.S. reserves should last 86 more years—and more on knowing how to modify pipeline networks for multiple uses. These changes serve two purposes: they extend the infrastructure’s lifespan and support decarbonization through efficient CO2 transport and hydrogen integration.

Natural gas consumption will likely stay at current levels as we move toward a net-zero future. This trend emphasizes natural gas’s key role as a transitional fuel that balances renewable intermittency while advancing carbon capture and hydrogen technologies.

The 2030 pipeline network will look very different from today’s system. It will be more versatile, technologically advanced, and ready to support multiple energy carriers at once. This transformation goes beyond a simple infrastructure upgrade—it reimagines how energy systems can meet climate goals while maintaining reliability and economic viability.