Darmstadt--How can existing gas networks be upgraded for hydrogen and residual materials simultaneously used as a raw material source? At the Hydrogen Technology World Expo 2026 in Hamburg, booth 6B25, the Fraunhofer Center for Hydrogen Performance Hessen, "GreenMat4H2," will present two application-oriented developments. Fraunhofer LBF will introduce evaluation methods for internal coatings of high-pressure pipelines, designed to protect materials from hydrogen embrittlement. Fraunhofer IWKS will demonstrate a microwave reactor that uses plasma pyrolysis to extract hydrogen and usable carbon from hydrocarbon-containing residual materials. Both approaches address key challenges in establishing a safe, sustainable, and circular hydrogen economy.

Evaluating coated pipelines under real-world conditions:
How can existing high-pressure pipelines remain safe for the long term when transporting hydrogen? The Fraunhofer Institute for Structural Durability and System Reliability LBF is developing realistic testing methods for materials, components, and systems in collaboration with industry. At the Hydrogen Technology World Expo, a real pipeline section illustrates how internal coatings protect the steel pipe wall and what verifications are required for reliable long-term operation.

Converting decades-old pipelines to hydrogen places high demands on metallic materials and protection systems. Operating pressures of 100 bar and more, as well as high gas flow rates, can place additional stress on the pipe materials and promote hydrogen embrittlement. Thin internal coatings are intended to reduce direct contact between hydrogen and steel. Fraunhofer LBF is developing methods to evaluate the adhesion, resistance, and service life of these coatings under realistic loads. This creates a solid foundation for sound investment decisions, extended service lives, and the transfer of existing gas networks to the hydrogen economy.

Plasma pyrolysis produces hydrogen and carbon from residual materials.

The Fraunhofer Institute for Materials Cycles and Resource Strategy IWKS is presenting a model of a compact reactor for microwave-based plasma pyrolysis. The process decomposes solid, liquid, or gaseous hydrocarbon-containing feedstocks using a highly reactive microwave plasma. No elaborate pretreatment is required. When renewable energy is used, the process does not directly release CO₂ during the conversion.

The reactor produces hydrogen, synthesis gases, and high-quality carbon material that can be used for energy recovery or material processing. The modular process can flexibly adapt to different waste streams and available renewable energy. Plasma pyrolysis thus opens up new avenues for companies to combine hydrogen production, waste recycling, and circular value creation. The trade fair exhibit vividly illustrates the conversion process and potential industrial applications.

The Hessian Hydrogen Competence Center "GreenMat4H2":

At the Hessian Hydrogen Competence Center "GreenMat4H2," the Fraunhofer Institute LBF and the Fraunhofer Institute IWKS are pooling their expertise to develop concepts for a sustainable, geopolitically independent, efficient, and secure hydrogen economy. The entire life cycle of products and systems within a hydrogen economy is considered, from production, storage, and transport to use and recycling. Fraunhofer LBF focuses on the reliability and operational robustness of hydrogen-powered systems. Fraunhofer IWKS focuses on the circularity and recyclability of components.

In the Rhine-Main region and beyond, the Hydrogen Performance Center Hesse has established itself as a center of expertise and exchange platform for stakeholders in the hydrogen economy.

The Fraunhofer Institute for Materials Cycles and Resource Strategy IWKS develops circular materials and materials science technologies for a sustainable, waste-free circular economy. Working closely with universities, other Fraunhofer Institutes, and industrial partners, the institute researches the substitution of critical raw materials with more sustainable alternatives and develops solutions for the intelligent regeneration of future-oriented materials as well as their energy-efficient recovery as sustainable precursors for production. As part of the Fraunhofer-Gesellschaft, Fraunhofer IWKS pursues the goal of making research findings applicable to industrial companies. Together with its partners, it thus makes a valuable contribution to the transformation of industry and a healthy planet.

Source:  FCW Team