Transmission, Distribution & Storage

This review provides a comprehensive examination of artificial intelligence methods applied to the design optimization and performance prediction of composite-based hydrogen storage vessels with a focus on composite overwrapped pressure vessels. Targeted at researchers engineers and industrial stakeholders in materials science mechanical engineering and renewable energy sectors the paper aims to bridge traditional mechanical modeling with evolving AI tools while emphasizing alignment with standardization and certification requirements to enhance safety efficiency and lifecycle integration in hydrogen infrastructure. The review begins by introducing HSV types their material compositions and key design challenges including high-pressure durability weight reduction hydrogen embrittlement leakage prevention and environmental sustainability. It then analyzes conventional approaches such as finite element analysis multiscale modeling and experimental testing which effectively address aspects like failure modes fracture strength liner damage dome thickness winding angle effects crash behavior crack propagation charging/discharging dynamics burst pressure durability reliability and fatigue life. On the other hand it has been shown that to optimize and predict the characteristics of hydrogen storage vessels it is necessary to combine the conventional methods with artificial intelligence methods as conventional methods often fall short in multi-objective optimization and rapid predictive analytics due to computational intensity and limitations in handling uncertainty or complex datasets. To overcome these gaps the paper evaluates hybrid frameworks that integrate traditional techniques with AI including machine learning deep learning artificial neural networks evolutionary algorithms and fuzzy logic. Recent studies demonstrate AI’s efficacy in failure prediction design optimization to mitigate structural risks structural health monitoring material property evaluation burst pressure forecasting crack detection composite lay-up arrangement weight minimization material distribution enhancement metal foam ratio optimization and optimal material selection. By synthesizing these advancements this work underscores AI’s potential to accelerate development reduce costs and improve HSV performance while advocating for physics-informed models robust datasets and regulatory alignment to facilitate industrial adoption.

Underground hydrogen storage (UHS) in salt caverns is emerging as a promising solution for the transition to a sustainable energy future. However a thorough understanding of hydrogen flow mechanisms through salt rock is essential to ensure safe and efficient storage operations. In this study we conducted hydrogen flow experiments in salt rocks using the pressure pulse decay (PPD) method covering a range of hydrogen pore pressures from 0.4 MPa to 7.5 MPa within the slip and transitional flow regimes (Knudsen numbers between 0.04 and 1.5). The Knudsen numbers were determined by measuring the pore size distribution (PSD) of the salt rock samples and assigning an average pore size to each sample based on the measured PSD. Our results indicate that the intrinsic permeability of the tested salt rock samples ranges from 5 × 10− 21 m2 to 1.0 × 10− 20 m2 . However a significant enhancement in apparent permeability up to 10 times the intrinsic permeability was observed particularly at lower pressures. This permeability enhancement is attributed to the nanoscale pore structure of salt rocks where the mean free path of hydrogen becomes comparable to the pore sizes leading to a shift from slip flow to the transitional flow regime. The results further reveal that the first-order slip model underestimates the apparent permeability in the transitional flow regime despite its satisfactory accuracy in the slip region. Moreover the higher-order slip model demonstrates acceptable accuracy across both the slip and transitional flow regimes.

As industry moves from fossil fuels to green energy substituting hydrocarbons with hydrogen as an energy carrier seems promising. Hydrogen can be stored in salt caverns depleted hydrocarbon fields and saline aquifers. Among other criteria these storage solutions must ensure storage safety and prevent leakage. The ability of a caprock to prevent fluid from flowing out of the reservoir is thus of utmost importance. In this review the main factors influencing fluid flow are examined. These are the wettability of the caprock formation the interfacial tension (IFT) between the rock and the gas or liquid phases and the ability of gases to diffuse through it. To achieve effective sealing the caprock formation should possess low porosity a disconnected or highly complicated pore system low permeability and remain strongly water-wet regardless of pressure and temperature conditions. In addition it must exhibit low rock–liquid IFT while presenting high rock–gas and liquid–gas IFT. Finally the effective diffusion coefficient should be the lowest possible. Among all of the currently reviewed formations and minerals the evaporites low-organic-content shales mudstones muscovite clays and anhydrite have been identified as highly effective caprocks offering excellent sealing capabilities and preventing hydrogen leakages.

The global energy sector is aiming to substantially reduce CO2 emissions to meet the UN climate goals. Among the proposed strategies underground storage solutions such as radioactive disposal CO2 NH3 and underground H2 storage (UHS) have emerged as promising options for mitigating anthropogenic emissions. These approaches require rigorous research and development (R&D) often involving laboratory-scale experiments to establish their feasibility before being scaled up to pilot plant operations. Microorganisms which are ubiquitous in laboratory environments can significantly influence geochemical reactions under variable experimental conditions of porous media and a salt cavern. We have selected a consortium composed of Bacillus sp. Enterobacter sp. and Cronobacter sp. bacteria which are typically present in the laboratory environment. These microorganisms can contaminate the rock sample and develop experimental artifacts in UHS experiments. Hence it is pivotal to sterilize the rock prior to conduct experimental research related to effects of microorganisms in the porous media and the salt cavern for the investigation of UHS. This study investigated the efficacy of various disinfection and sterilization methods including ultraviolet irradiation autoclaving oven heating ethanol treatments and gamma irradiation in removing the microorganisms from silica sand. Additionally the consideration of their effects on mineral properties are reviewed. A total of 567 vials each filled with 9 mL of acid-producing bacteria (APB) media were used to test killing efficacy of the cleaning methods. We conducted serial dilutions up to 10−8 and repeated them three times to determine whether any deviation occurred. Our findings revealed that gamma irradiation and autoclaving were the most effective techniques for eradicating microbial contaminants achieving sterilization without significantly altering the mineral characteristics. These findings underscore the necessity of robust cleaning protocols in hydrogeochemical research to ensure reliable reproducible data particularly in future studies where microbial contamination could induce artifacts in laboratory research.

Hydrogen (H2) has the potential to become a cleaner fuel alternative to increase energy mix versatility as part of a low-carbon economy. Geological H2 storage represents a key component of the emerging H2 value chain since large-scale energy generation linked to energy generation and large-scale industrial applications will require significant upscaling of geological storage. Geological H2 storage can take place in both salt domes and bedded salt formations. Bedded salt formations offer a significant advantage for H2 storage over salt domes because of their widespread availability. This research focuses on evaluating the H2 storage potential of the Salado Formation a bedded salt deposit in the Permian Basin of West Texas in the United States. Using data from 3268 well logs this study analyzes an area of 136100 km2 to identify suitable depth and net halite thickness for H2 storage in salt caverns. In addition this work applies a novel geostatistical workflow to quantify the uncertainty in the formation’s storage potential. The H2 working gas potential of the Salado Formation ranges from 0.62 to 17.53 Tsm3 (1.75–49.68 PWh of stored energy) across low-risk to high-risk scenarios with a median potential of 1.19 Tsm3 (3.37 PWh). The counties with the largest storage potential are: Lea in New Mexico and Gaines and Andrews in Texas. These three counties account for more than 75 % of the formation’s total storage potential. This is the first study to quantify uncertainty in H2 storage estimates for a bedded salt formation while providing a detailed breakdown of results by county and 1 km2 grid sections. The findings of this work offer critical insights for developing H2 infrastructure in the Permian Basin. The Permian Basin of West Texas has the potential to become an important hub for H2 production from both natural gas and/or renewable energy. Estimating H2 storage potential is an important contribution to assess the feasibility of the entire H2 value chain in Texas. An interactive map accompanies this work allowing the readers to explore the results visually.

The erosion behavior and the service life of a hydrogen transmission tube with high velocity suitable for a hydrogen fuel aviation engine are not clear which is the bottleneck for its application. In this study a coupled model considering the fluid flow field of hydrogen and discrete motion of particles was established. The effects of the geometry parameters and erosion parameters on the hydrogen erosion behavior were investigated. The maximum erosion rate increased exponentially with the increased hydrogen velocity and increased linearly with the increased erosion time. The large bend radius and inner diameter of the bend tube contributed to the decreased erosion rate. There was an optimized window of the bend angle for a small erosion rate. The relationship between the accumulated thickness loss and maximum erosion rate was established. The prediction model of the service life was established using fourth strength theory. The service life of the tube was sensitive to the hydrogen velocity and erosion time. The experiments were conducted and the variations in thickness and hardness were measured. The simulated models agreed with the experiments and could provide guidance for the parameter selection and prediction of the service life of a bend tube.

This study examines the pricing and assesses resilience methods in hydrogen supply chains by thoroughly analyzing two main disruption scenarios. The model examines a scenario in which a hydrogen production company depends on a Renewable Power plant (RP) for its electricity supply. Ensuring a steady and efficient hydrogen supply chain is crucial but outages at renewable power sources provide substantial obstacles to sustainability and operational continuity. Therefore in the event of disruptions at the RP the company has two options for maintaining resilience: either sourcing electricity from a Fossil fuel Power plant (FP) through a grid network to continue hydrogen production or purchasing hydrogen directly from another company and utilizing third-party transportation for delivery. Using a game theoretic approach we examine how different methods affect demand satisfaction cost implications and environmental sustainability. The study employs sensitivity analysis to evaluate the impact of different disruption probabilities on each scenario. In addition a unique sensitivity analysis is performed to examine the resilience of transmission security to withstand disruptions. This study evaluates how investments in security measures affect the strength and stability of the supply chain in various scenarios of disruption. Our research suggests that the first scenario offers greater reliability and cost-effectiveness along with a higher resilience rate compared to the second scenario. Furthermore the examination of the environmental impact shows that the first scenario has a smaller amount of CO2 emissions per kg of hydrogen. This study offers important insights for supply chain managers to optimize resilience measures hence improving reliability reducing costs and minimizing environmental effects.

Underground hydrogen storage in aquifers is a promising solution to address the imbalance between energy supply and demand yet its practical implementation requires optimized strategies to ensure high efficiency and economic viability. To improve the storage and production efficiency of hydrogen it is essential to select the appropriate cushion gas and to study the influence of reservoir and process parameters. Based on the conceptual model of aquifer with single-well injection and production three potential cushion gas (carbon dioxide nitrogen and methane) were studied and the changes in hydrogen recovery for each cushion gas were compared. The effects of temperature initial pressure porosity horizontal permeability vertical to horizontal permeability ratio permeability gradient hydrogen injection rate and hydrogen production rate on the purity of recovered hydrogen were investigated. Additionally the impact of different well pattern on the purity of recovered hydrogen was studied. The results indicate that methane is the most effective cushion gas for improving hydrogen recovery in UHS. Different well patterns have significant impacts on the purity of recovered hydrogen. The mole fractions of methane in the produced gas for the single-well line-drive pattern and five-spot pattern were 16.8% 5% and 3.05% respectively. Considering the economic constraints the five-spot well pattern is most suitable for hydrogen storage in aquifers. Reverse rhythm reservoirs with smaller permeability differences should be chosen to achieve relatively high hydrogen recovery and purity of recovered hydrogen. An increase in hydrogen production rate leads to a significant decrease in the purity of the recovered hydrogen. In contrast hydrogen injection rate has only a minor effect. These findings provide actionable guidance for the selection of cushion gas site selection and operational design of aquifer-based hydrogen storage systems contributing to the large-scale seasonal storage of hydrogen and the balance of energy supply and demand.

The use of rare earth elements in hydrogen storage processes offers significant advantages in terms of increasing technological efficiency and ensuring system security. However this process also creates some serious problems in terms of environmental and economic sustainability. It is necessary to determine the most critical indicators affecting the sustainable use of these elements. Studies on this subject in the literature are quite limited and this may lead to wrong investment decisions. The main purpose of this study is to determine the most important indicators to increase the sustainable use of rare earth elements in hydrogen storage processes. An original decision-making model in which Siamese network logarithmic percentage-change driven objective weighting (LOPCOW) fractal fuzzy numbers and weighted influence super matrix with precedence (WISP) approaches are integrated in the study. This study provides an original contribution to the literature by identifying the most critical indicators affecting the sustainable use of rare earths in hydrogen storage processes by presenting an innovative model. Fractal structures such as Koch Snowflake Cantor Dust and Sierpinski Triangle can model complex uncertainties more successfully. Fractal structures are particularly effective in modeling linguistic fuzziness because their recursive nature closely mirrors the layered and imprecise way humans often express subjective judgments. Unlike linear fuzzy sets fractals can capture the patterns of ambiguity found in expert evaluations. Hydrogen storage capacity and government supports are determined as the most vital criteria affecting sustainability in rare earth use.

This paper provides authors’ perspective on the current advances and challenges in utilising polymers and composites in hydrogen economy. It has originated from ‘Polymers and Composites for Hydrogen Economy’ symposium organised in March 2025 at the University of Warwick. This paper presents views from the event and thus provides a perspective from academia and industry on the ongoing advances and challenges for those materials in hydrogen applications.

Hydrogen embrittlement (HE) threatens the structural integrity of industrial components exposed to hydrogenrich environments. This review critically explores hydrogen barrier coatings (HBCs) polymeric metallic ceramic and composite their application and assessment focusing on measured effectiveness in limiting hydrogen permeation and hydrogen embrittlement. Also coating application methods and permeation assessment techniques are evaluated. Recent advances in nanostructured and hybrid coatings are emphasized highlighting the pressing need for durable scalable and environmentally sustainable hydrogen barrier coatings to ensure the reliability of emerging hydrogen-based energy solutions. This comprehensive critical review further distinguishes itself by linking coating deposition methods to defect-driven transport behaviour critically assessing permeation test approaches. It also highlights the emerging role of polymeric and hybrid multilayer coatings with direct implications for advanced and reliable hydrogen production storage and transport infrastructure.

This study presents the development of a robust numerical model for simulating underground hydrogen storage (UHS) in salt caverns with a particular focus on the interactions between original gas-methane (CH4) and injected gas represented by hydrogen (H2). Using the Schlumberger Eclipse 300 compositional reservoir simulator the cavern was modelled as a highly permeable porous medium to accurately represent gas flow dynamics. Two principal mixing mechanisms were investigated: physical dispersion modelled by numerical dispersion and molecular diffusion. Multiple cavern configurations and a range of dispersion–diffusion coefficients were assessed. The results indicate that physical dispersion is the primary factor affecting hydrogen purity during storage cycles while molecular diffusion becomes more significant during long-term gas storage. Gas mixing was shown to directly impact the calorific value and quality of withdrawn hydrogen. This work demonstrates the effectiveness of commercial reservoir simulators for UHS analysis and proposes a methodological framework for evaluating hydrogen purity in salt cavern storage operations.

Liquid organic hydrogen carriers (LOHCs) are a promising class of hydrogen storage media in which hydrogen is reversibly bound to organic molecules. In this work we focus explicitly on cyclic LOHCs (both homocyclic and heterocyclic organic compounds) and their catalytic dehydrogenation. We clarify that other carriers (e.g. alcohols like methanol or carboxylic acids like formic acid) exist but are not the focus here; these alternatives are discussed only in comparative context. Cyclic LOHCs typically enable safe ambient-temperature hydrogen storage with hydrogen contents around 6–8 wt%. Key challenges include the high dehydrogenation temperatures (often 200–350 °C) catalyst costs and catalyst deactivation via coke formation. We introduce a comparative analysis table contrasting cyclic LOHCs with alternative carriers in terms of hydrogen density operating conditions catalyst types toxicity and cost. We also expand the catalyst discussion to highlight coke formation mechanisms and the use of mesoporous metal-oxide supports to mitigate deactivation. Finally a techno-economic analysis is provided to address system costs of LOHC storage and regeneration. Finally we underscore the viability and limitations of cyclic LOHCs including practical storage capacities catalyst life and projected costs.

Hydrogen embrittlement (HE) can degrade the mechanical integrity of steel pipes increasing failure risks in naval fuel systems. This study assesses HE effects on ASTM A131 and A36 steels through tensile testing and numerical modeling. Tests conducted with varying exposure times to hydrogen revealed that A131 outperformed A36 in terms of mechanical strength. However both materials experienced property degradation after six hours. After nine hours a transient increase in strength occurred due to temporary microstructural hardening though the overall trend remained a decline. The maximum reductions in ultimate tensile strength and toughness were 19% and 47% for A131 and 39% and 61% for A36 respectively. Additionally microstructural analysis revealed the presence of inclusions intergranular decohesion and micro-crack in specimens exposed for longer periods. Finally a combined GTN-PLNIH numerical model was implemented demonstrating its effectiveness in predicting the mechanical behavior of structures exposed to hydrogen.

This study presents a comparative techno-economic and environmental assessment of three leading stationary energy storage technologies: lithium-ion batteries lead-acid batteries and hydrogen systems (electrolyzer–tank–fuel cell). The analysis integrates Life Cycle Assessment (LCA) and Levelized Cost of Storage (LCOS) to provide a holistic evaluation. The LCA covers the full cradle-to-grave stages while LCOS accounts for capital and operational expenditures efficiency and cycling frequency. The results indicate that lithium-ion batteries achieve the lowest LCOS (120–180 EUR/MWh) and high round-trip efficiency (90–95%) making them optimal for short- and medium-duration storage. Lead-acid batteries though characterized by low capital expenditures (CAPEX) and high recyclability (>95%) show limited cycle life and lower efficiency (75–80%). Hydrogen systems remain costly (>250 EUR/MWh) and less efficient (30–40%) yet they demonstrate clear advantages for long-term and seasonal storage particularly under scenarios with “green” hydrogen production and reduced CAPEX. These findings provide practical guidance for policymakers investors and industry stakeholders in selecting appropriate storage solutions aligned with decarbonization and sustainability goals.