The transition from fossil-based energy systems to renewable alternatives is a defining challenge for Europe’s future. Hydrogen has emerged as a promising candidate to enable this shift, but the materials and infrastructure needed to realise a hydrogen economy remain under-researched. Jussu, a soon-to-graduate Master’s student in Chemical & Process Engineering at Aalto University, has addressed this gap in his thesis, ”Polyolefins in the emerging European hydrogen infrastructure: Overview of applications and Monte Carlo simulation of future demand.” His graduate thesis, conducted as part of the SPIRIT programme, provides a look at the role of polyolefins in the developing European hydrogen network.
Bridging disciplines for a complex challenge
Jussu’s academic background is in chemical process engineering with additional interests in economics and machine learning. These interdisciplinary skills supported his study, which required extensive data gathering and integration from diverse fields.
The thesis was inspired by the BalticSeaH2 project and the broader transformation of the hydrogen economy. Borealis has an interest in understanding the role of polyolefins – particularly as the hydrogen sector investigates the options for storage, transport and utilisation. This work also connects to the SPIRIT programme’s goals, as it explores the potential of polyolefin plastics in new energy systems. Sanna Martin from Borealis has been acting as the advisor of this Master’s thesis.
Mapping polyolefin applications in hydrogen economy
A central aim of the thesis was to identify all potential applications of polyolefins within the hydrogen economy and to single out those with the greatest business relevance. After careful analysis, hydrogen transport infrastructure emerged as the most promising area, particularly the use of polyolefins in pipelines and related components. Looking ahead, polyolefin-based materials could play a vital role in the future European Hydrogen Backbone, i.e. the planned pipeline network for hydrogen transport across the continent.
Key applications include:
- Protective coatings for steel pipes: Polyethylene layers are critical for protecting steel pipelines, especially in subsea environments.
- Hydrogen fuel storage vessels: Type IV composite tanks, featuring polymer liners (often HDPE), are lightweight and handle high pressures effectively.
- Fibre-reinforced composite pipes: Layered pipes available with both chemically bonded and non-chemically bonded structures offering additional possibilities for safe, efficient hydrogen transport.
Quantifying future demand: Monte Carlo simulations
To estimate future material needs, Jussu reviewed hydrogen demand in Europe for 2030–2045 based on various scenarios. These scenarios were used as input for Monte Carlo simulation models to assess the growth of hydrogen transport infrastructure. He assessed various usage scenarios, generating probability distributions for different segments in the hydrogen economy. The results suggest that most likely, the European demand for polyolefin in the applications is in the scale of 1-10 kt/a.
For the highest-demand applications, such as three-layer coated pipes and flexible composite pipes, the thesis calculated annual polyolefin requirements of 4–13 kt and up to 29 kt, respectively. These figures depend on the total length and build rate of the backbone pipeline, as well as the number of connections between hydrogen producers and consumers.
Key findings and conclusions
- Polyolefins have a clear niche: While the quantities required for hydrogen infrastructure are modest compared to overall plastics production, polyolefins are the best available option for many critical components, especially pipelines.
- HDPE versus polyamide-6: Polyamide-6 may be preferable to HDPE in some applications due to its lower hydrogen permeability, but HDPE remains viable, especially with controlled multi-layer structures to minimise hydrogen leakage.
- Safety and standardisation: Ensuring safety is paramount, given hydrogen’s ability to permeate polymers. Multi-layer solutions and pressure-resistant designs can effectively contain hydrogen, and ongoing standardisation efforts will solidify best practices.
- Market potential for renewable or bio-based polyolefins: As Europe moves towards a circular economy, renewable or bio-based polyolefin plastics could find new markets in hydrogen infrastructure, aligning with SPIRIT’s sustainability goals.
Sanna Martin from Borealis says: “Jussu’s thesis was linked to key innovation activities, namely the SPIRIT programme and BalticSeaH2 EU project. The thesis served a dual purpose. First, it gave Borealis valuable insights in the development of the polyolefin demand linked to hydrogen economy and secondly, it provided expert insights for the work package in which the infrastructure of the BalticSeaH2 was being planned.”
After his graduation, Jussu hopes to work with renewable energy systems, keenly aware that leaving fossil fuels behind demands not just new energy sources, but also the right materials to deliver them safely and efficiently.