The energy supply of the future increasingly relies on renewable sources. To make this energy usable, new concepts for transport and storage - especially in the form of hydrogen - are required. Materials such as thermoplastic fiber-reinforced polymers (FRTP) are therefore in the spotlight of research and development.

Hydrogen as a key element of the energy transition

Hydrogen is a promising, storable, CO2-free energy carrier that can be produced by water electrolysis using renewable energy. It can be used across multiple sectors - for example, as fuel, as a storage medium, or as a raw material in chemical processes.

Because production and consumption sites are often geographically separated, there is a significant need for a dedicated transport and storage infrastructure. Pipeline transport is considered the most efficient solution [1]. High-pressure gaseous hydrogen in such pipelines can both be transported and buffered.

Challenges of conventional pipeline systems

Currently, steel pipes dominate hydrogen transport. However, they face limitations: hydrogen can alter the microstructure of metals and cause hydrogen embrittlement, which particularly affects weld joints, increases the risk of cracking, and shortens pipeline life [2][3].

The main challenges for steel hydrogen pipelines are:

• Hydrogen embrittlement and associated safety risks
• Limited pressure resistance at higher operating pressures
• Complex quality control of welds
• Vulnerability to pressure fluctuations
• High material costs for hydrogen-compatible steels
• Limited flexibility in routing

Other issues include high weight, restricted deployability in difficult terrain, and the need for costly corrosion protection measures.

Potential of thermoplastic fiber-reinforced composites

Thermoplastic fiber-reinforced polymers (FRTP) offer an alternative. These materials combine a thermoplastic matrix with reinforcement fibers (e.g. glass or carbon) and show no signs of embrittlement under hydrogen exposure.

Key advantages:

• No hydrogen embrittlement
• High strength-to-weight ratio
• Low hydrogen permeability
• Corrosion resistance
• Thermoplastic recyclability
• Form flexibility via filament winding

Their mechanical properties allow operation at high pressures and suit both transport pipelines and storage solutions.

Requirements for the future infrastructure

The energy transition and Europe’s hydrogen strategy demand a comprehensive pipeline network. In Europe alone, up to 53,000 km of hydrogen pipelines will be needed - most of which must still be built [4].

At the same time, requirements for operational safety, pressure resistance, durability, and sustainability are rising. These can be addressed precisely with materials like FRTP.

Economic and ecological considerations

FRTP pipeline systems are not only technically advantageous but also economically competitive. Detailed benefits include:

• Lower maintenance requirements
• Longer service life
• Lower weight = easier installation
• Fewer machines and welds
• Possibility of industrial spool fabrication, ideal for modular deployment

Early Total Cost of Ownership (TCO) studies indicate that investment pays off through reduced operating costs and higher system availability [5].

Technological development status

Although fiber-reinforced polymers are widely used in pressure vessel technology, they have not yet become standard in pipeline applications. The main reason is the lack of standardized procedures and necessary certifications for practical use. Concretely, this means:

• Missing norms and standards for production and testing
• No unified certification processes for deployment
• Unclear regulatory frameworks
• Lack of long-term performance data

Conclusion

Given the growing demands on hydrogen infrastructure and the limitations of conventional materials, fiber-reinforced thermoplastics offer a future-proof alternative. Their outstanding material properties, coupled with sustainable processability, make them a potential key material for the energy transition - especially for pressurized hydrogen transport. Industrial implementation is still in its early stages, but the technical, ecological, and economic potential is enormous.