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Article history: The injection of green hydrogen into the natural gas grid is a way to decarbonize the gas
Received 13 December 2021 sector and build an economic transport route for the large-scale delivery of hydrogen. The
Received in revised form suitability of the natural gas infrastructure for this purpose depends on the impact that
3 February 2022 hydrogen may have on the correct operation of its components and understanding the new
Accepted 7 March 2022 flow conditions in the system is essential for this aim. Computational studies can antici-
Available online 6 April 2022 pate the expected environment in the pipe system, assessing the readiness of the system.
However, the experience on this topic is not extensive enough and deeper understanding is
Keywords: necessary. Here we show a CFD study to simulate the transport of H2/NG blends in a gas
Low-carbon hydrogen setup with the main characteristics of injection sites and gas pipelines representatives of
* Corresponding author.
E-mail address: jsanchez@hidrogenoaragon.org (J. Sa nchez-Laı́nez).
1
Both Teresa Villuendas and Javier Sa nchez-Laı́nez are first authors of this article.
https://doi.org/10.1016/j.ijhydene.2022.03.055
0360-3199/© 2022 Hydrogen Energy Publications LLC. Published by Elsevier Ltd. All rights reserved.
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 4 7 ( 2 0 2 2 ) 1 5 8 3 2 e1 5 8 4 4 15833
Natural gas grid retrofitting the transmission gas network. This setup considers a blending station, the pumping and
Grid decarbonization injection procedure, and different pipelines geometries to predict the behavior of various
Hydrogen injection mixtures of H2/NG. It can be seen how (1) a good mixing is achieved in the blending station
CFD study after a pipe length equivalent to 20e30 diameters is reached; (2) pumping gas by a piston
Transmission gas grid modelling type compressor shows pulsations in the flow regardless the composition of the blend that
can be damped implementing mitigation measurements; and (3) asymmetries in the flow
are found when the direction of the fluid changes after section reduction, but 20 diameters
downstream of the reduction the flow is fully developed.
© 2022 Hydrogen Energy Publications LLC. Published by Elsevier Ltd. All rights reserved.
concentrations over 2 %vol make the viscosity of the blend the literature. Most of them, however, are again focused on
decrease, while concentrations below this amount increase it the impact of H2/NG blends on combustion issues [28,29] or
[15]. explosion risks [14,30,31]. Predicting the flow pattern of H2/NG
The impact of adding hydrogen to natural gas or blends in pipes and its comparison with the transport of bare
exchanging natural gas by hydrogen has been studied in natural gas or hydrogen is also necessary so that the natural
several experimental works. Most studies, however, corre- gas grid retrofitting or repurposing can become a reality. With
spond to end-uses and are related to the combustion field, this regard, Liu et al. [32] investigated the decompression
checking the effect that the blend has on the performance of speed wave of H2/NG gas mixtures in high-pressure pipelines
burners and the combustion process itself. For example, some and Behbahani-Nejad et al. [33] investigated the behavior of
experimental studies have evaluated the power, efficiency high velocity natural gas flows in pipes during purging pro-
and emissions of natural gas engines, highlighting the need to cess, highlighting changes in friction factor. Finally, Elaoud
change the design parameters for a better performance with et al. [34] studied high-pressure transient flows of H2/NG
the new fuel [16e18]. Understanding the impact that hydrogen blends in rigid pipelines concluding that transient pressure
may have on the correct operation of components and oscillations for hydrogen and blends were higher compared to
equipment of natural gas grids is vital to decide if the infra- natural gas. Modelling tanks filling with hydrogen is also an
structure is ready for the delivery of this new gas, applying the important issue related to the topic since injection scenarios
necessary adaptations in consequence. The use of the existing need for pressurized storage buffers where hydrogen must be
compression and pressure-reduction stations, hydrogen stored at high pressure to feed the injection point. Some works
embrittlement issues and gas leakages are key aspects to be are focused on the temperature increase during this filling
considered when analyzing the suitability of the natural gas process, highlighting how the heat transfer to the solid
grid for hydrogen transport [19]. While piston compressors are structure of the tank plays an important role in the thermo-
basically not affected by the addition of hydrogen to natural dynamics of the process [35]. Modelling the injection of CO2 in
gas, centrifugal compressors require the compression of a oil and gas wells can also serve as reference studies to apply in
volume three times as large as when natural gas is used, hydrogen injection scenarios owing to their extensive back-
which can affect to the capacity of compressor stations. ground, especially for geological hydrogen storage. Some
Regarding regulation stations, reducing the pressure of natu- mathematical models have been developed to analyze the
ral gas causes its temperature to decrease 0.5 C/bar, whereas effect of injection parameters of CO2 on the performance of
the temperature rises 0.035 C/bar when the pressure of geothermal energy extraction [36e38]. The injection of
hydrogen is considered. This issue is related to the seawater or steam is also considered in some other works
JouleeThompson effect, with different impact for each gas. [39e41] and shale gas or oil transport through nanopores can
The change to hydrogen would result in a temperature rise, also be found in the literature [42,43]. The available informa-
avoiding or at least minimizing freezing problems in compo- tion regarding hydrogen injection is, however, limited and a
nents. The risk of hydrogen embrittlement depends on the deeper understanding of the relevant transport phenomena of
material of the pipeline, but also on the pipeline's history. The new gases in natural gas grids is still missing and therefore,
impact of hydrogen embrittlement on carbon steels with necessary to fill the existing gaps of knowledge.
qualities up to API 5L X80 has been studied in the literature to The work developed in this manuscript proposes several
identify the relationship between hydrogen concentration CFD model studies to simulate the flow of H2/CH4/H2S/N2/CO2
and failure loading with conclusion highly dependent on the blends through a piping system, consisting in an injection site
testing conditions [20,21]. and a gas pipeline, aiming to anticipate the flow behavior that
In order to assess that the hydrogen transport through is expected when new gas conditions occur in high-pressure
natural gas pipelines can be achieved with successful opera- pipelines. The geometries studied recreate real components
tion of the natural gas infrastructure, it is necessary to identify to analyze the behavior of materials and equipment repre-
in advance the behavior of the new flow conditions that will sentative of transmission gas network. Thus, the results ob-
be present in the system. In this scenario, Computational tained are directly applicable to the existing infrastructure
Fluid Dynamics (CFD) are really useful tools. The high costs and its elements (scraper traps, changes of direction and
and time consumption associated with experimentation, section, etc.).
coupled with recent achievements in the development of
numerical solutions for the Navier-Stokes equations and the
enhancement of computing power and efficiency, have Experimental section
boosted the application of CFD as a viable alternative in in-
dustry [22]. This way, a CFD analysis can provide an accurate Definition of whole system and case of study
prediction of the gas behavior in the system, anticipating the
necessary changes before gas operators have to invest too The gas setup modeled in this work is depicted in the scheme
many resources in empirical tests [23]. of Fig. 1.
CFD techniques have been widely applied to support the It is a hypothetical setup which considers a simplified
design of equipment to manage hydrogen flows, such as tanks version of a hydrogen injection system and part of a natural
[24,25], ejectors [26] or injectors [27]. The CFD techniques have gas pipeline. The former starts with a blending station, con-
been proved as an efficient way to assess the equipment sisting in individual lines of pure gases (H2, CH4, CO2 and H2S)
performance, avoiding the traditional trial-and-error task [24]. that merge for blending, and the resulting mixture is stored in
Regarding H2/NG blends, there are many studies available in a buffer. Afterwards, the blend generated is pumped and
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 4 7 ( 2 0 2 2 ) 1 5 8 3 2 e1 5 8 4 4 15835
injected into a natural gas pipeline. The latter consists in equation, ii) momentum equation and conservation of species
several natural gas pipelines of different sections, from DN 80 equation (chemical reaction is not considered). These equa-
to DN 250, in series. The system considers not only the tions are shown in detail in the section 5 of the Supporting
expansion/contraction of the flow owing to the change in the Information. The density of gaseous species is obtained ac-
pipe section, but also changes in the direction of the flow. cording to the ideal gas equation.
Natural gas is simplified in this study as a mixture of CH4 with One of the main uncertainties in these simulations has
traces of CO2, N2 and H2S as impurities. In some cases, only been the choice of the appropriate turbulence model, since in
the H2/CH4 blend is considered when the other gases do not the cases analyzed the Reynolds number indicates that the
add to much value to the flow simulated. flow is in a transition zone between laminar and turbulent
Specifically, five cases of study are addressed in this work: flow. Therefore, a sensitivity analysis has been performed
comparing the results obtained with several turbulence
i) The quality of the blend after merging lines in the models (LES, k-ε, k-ε low-Re, k-u low-Re) and, in addition,
blending station of the injection system. considering the flow as laminar.
ii) The pumping procedure to storage blends in the buffer. The geometric model (computational mesh) developed to
iii) The change of fluid direction in the gas pipeline after represent the experimental circuit can be seen in Fig. 2a. The
expansion from DN 80 to DN 250 computational mesh consists of approximately 5 million cells,
iv) The flow pattern after expansion of the gas pipeline combining polyhedral and hexahedral cells. This mesh is
from DN 80 to DN 150 refined in the areas adjacent to the pipe walls to capture as
v) The pumping of H2 and CH4 by a compressor and its accurately as possible the effects of the boundary layer on the
injection in the gas pipeline. gas flow circulation in the pipe.
The geometries for all these cases are detailed bellow in the Case 2: pumping blends in a buffer
following subsections.
This geometry is intended to study the filling of a buffer with
Case 1: quality of the blend in the blending station H2/NG mixtures, being stored under pressure for subsequent
injection into the gas pipeline. The storage buffer is formed by
The geometry and operational conditions for this specific case four bottles and its characteristics are described in Fig. S2.
of study is shown in Fig. S1. The geometry shows the The goal of this task is analyzing the operation of the
convergence of four individual gas lines formed by A316 storage tank from the point of view of the homogeneity of the
stainless steel pipes of 10.2 mm internal diameter. Each gas is hydrogen-methane mixture. Two different aspects have been
fed at a constant pressure of 15 bar and 25 C and all merge to studied: a) the possible segregation of a homogeneous
generate the mixture. The purpose of the study is to see at methane-hydrogen mixture in the tank and b) the homoge-
what point a homogeneous mixture is achieved, or the need to nization of methane and hydrogen when pure hydrogen is
incorporate a static mixer otherwise. The quality of the injected in the tank.
blending has been studied with different cases, in which the The segregation of a homogeneous methane-hydrogen
proportions of gas fluxes vary. The specific volume flows mixture (first case of study) has been performed in two
considered for each gas stream are described in Table S1. steps. 1) the simulation of the filling of one of the bottles to
These quantities correspond to mixing percentages between observe if any phenomenon occurs in this process that leads
15 and 70% H2 in CH4, thus covering a wide spectrum of pro- to the segregation of the mixture, and 2) the estimation of the
portions with low and high concentrations. separation of the mixture, once the filling process is ended,
To represent the phenomena taking place in the simulated due to the different density of hydrogen and methane. Three
pipes, the following equations (Navier-Stokes) are solved, simulations have been carried out on the filling of the tank. It
considering steady state and laminar flow: i) continuity is considered that both the tank and the injected mixture have
Fig. 1 e Scheme with an overall view of the gas setup aim of study in this work.
15836 i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 4 7 ( 2 0 2 2 ) 1 5 8 3 2 e1 5 8 4 4
continuity equation, ii) momentum equation and iii) conser- same model for all cases (for the purpose of comparing re-
vation of species equation (chemical reaction is not sults), the LES turbulence model has been employed, the only
considered). one applicable in all regimes found. The Supporting Infor-
The density of gaseous species was obtained according to mation shows in detail the equations solved in these simu-
the ideal gas equation. One of the main uncertainties in these lations, corresponding to the implementation of the LES
simulations has been the choice of the appropriate turbulence turbulence model.
model, since depending on the composition of the gas mixture
in the cases analyzed, the Reynolds number ranges from 2500 Case 5: pumping H2 and CH4 by a piston type compressor
(case A1) to 16000 (case A5), so different turbulence regimes and its injection gas pipelines
(laminar, transition and turbulent) must be considered. After
the analysis of the different turbulence models previously The aim of this study is to analyze the flow downstream of a
performed, and given the complex geometry of the speci- piston type compressor and, in particular, the pulsating na-
mens, 2-equation turbulence models (RANS) have been cho- ture of this flow. By applying simulation techniques, the goal
sen: k-u SST Low-Re model for the A1 case (practically laminar is to observe the behavior of this flow and to determine
regime) and k-ε in the rest of the cases. The option of using an corrective measures if necessary. The compressor under
LES turbulence model has been discarded given the complex study consists of two coupled pistons, 180 desynchronized
geometry of the instrumentation elements, which would (see Fig. S5). This compressor increases the pressure of the
require a much more refined computational mesh than the gas from 60 bar to 80 bar. The flow exits the two pistons
one built. The section 5 of the Supporting Information shows through two DN 10 pipes, where the blue and orange lines
in detail the equations applied in these simulations. indicate the flow circulation after exiting the pistons. Both
pipes join in another DN 10 pipe, shown in green in Fig. S5.
Case 4: flow pattern after expansion of the gas pipeline from This pipe connects then to another DN 80 pipe (purple arrow).
DN 80 to DN 150 This conduit describes a circuit that ends at a pressure
regulation valve. The pressure drop in this final part of the
The goal of this case of study is determining the fluid flow circuit and the regulation valve raises up to approximately
behavior for different compositions (H2, CH4) at changes of 20 bar. Thus, the gas flow returns to the piston pump with a
section in the pipeline, especially the flow recovery after pressure of 60 bar.
passing through the pipe widening and the study of the forces The ducts from the piston outlet to the DN 80 pipe were
on the walls and welding rings. modeled considering the real geometry. Regarding the rest of
The geometry of this case of study is depicted in Fig. S4. the circuit, its most relevant effect on the possible pulsating
The pipe widens from DN 80 to DN 150. The length of the DN character of the flow is due to its volume, since it dampens
150 pipe is 2.4 m and it is divided by welding rings into 8 equal such pulsating behavior. Therefore, the rest of the circuit is
sections of 0.3 m length. Finally, after this section with a larger represented as an only duct equivalent to its volume, which
diameter, the pipe recovers its original diameter (DN 80). has been called “Virtual Buffer” in Fig. S5. Eventually, the final
The geometric model (computational mesh) developed to part of the circuit is modeled as a DN 80 duct (artificially
represent the experimental pipeline can be seen in Fig. 2d. In considered as a porous medium) in which a pressure loss of
order to reduce the computational cost without reducing the approximately 20 bar is introduced, representing the effect of
accuracy of the calculation, symmetry of revolution was a pressure regulation valve. The computational mesh used
considered in this geometry. This way, only ¼ of the pipeline is consists of 180,000 hybrid cells (see Fig. 2e).
solved. The computational mesh applied to this domain con- To set up boundary conditions, the following characteris-
sists of approximately 2.3 million cells (9.2 million cells in the tics and assumptions of the piston operation were considered:
whole domain), where polyhedral and hexahedral cells are i) the mass flow rate of the gas introduced in one cycle is 56
combined. The mesh is refined in the areas adjacent to the Nm3/h, ii) operation of 15 cycles per minute (i.e. 4 s per cycle),
pipe walls to capture as accurately as possible the effects of of which 2s correspond to the compression phase, iii) until
the boundary layer on the gas flow circulation in the pipe. The 80 bar is reached, no flow comes out of the piston, iv) in the
conditions simulated are those defined in Table S2 at 25 C and compression phase, 0.5 s are considered until 80 bar is
80 bar absolute pressure. reached; 0.2 s of linear increase of the flow rate with time, 1.1 s
To represent the phenomena occurring in the pipes, the of constant flow rate (86 Nm3/h), and, finally, 0.2 s of linear
following equations (Navier-Stokes) are solved, considering decrease of the flow rate with time until 0 Nm3/h is reached
the LES turbulence model i) continuity equation, ii) mo- and v) the pistons operate 180 out of phase.
mentum equation and iii) conservation of species equation The flow is assumed to be isothermal, with a constant
(no chemical reaction is considered). The density of gaseous temperature of 25 C. This assumption is based on the Joule-
species is obtained according to the ideal gas equation. One of Thomson coefficients and the pressure increase. Thus, a) for
the main uncertainties in these simulations has been the methane, the value of this coefficient is 0.45 K/bar; therefore,
choice of the appropriate turbulence model, since, depending an increase of 20 bar means a temperature increase of 9 K and
on the composition of the gas mixture in the cases analyzed, b) in the case of hydrogen, the value of this coefficient is
the Reynolds number ranges from 2500 to 16000 (see table S2), 0.029 K/bar; therefore, an increase of 20 bar means a
so it is in different turbulence regimes (laminar, transition and decrease in temperature of 0.6 K. Given such low tempera-
turbulent). Therefore, after the analysis of the different tur- ture variations, the isothermal flow hypothesis is considered
bulence models previously carried out, and in order to use the reasonable.
15838 i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 4 7 ( 2 0 2 2 ) 1 5 8 3 2 e1 5 8 4 4
When pure hydrogen was transported (see Fig. 5a), it could Case 4: flow pattern after expansion of the gas pipeline from
be observed that the flow, once the expansion and change of DN 80 to DN 150
direction has occurred, recovered uniformity before passing
through the DN 250 pipe. As depicted in Fig. S10a, this recov- The goal of this case of study is determining the fluid flow
ery caused the forces to which each of the objects is subjected behavior for different compositions of H2 and CH4, when a gas
to be practically symmetrical in the direction of flow for each pipeline widens from DN 80 to DN 150.
of them, producing greater forces in those areas closer to the The expansion of the gas flow is strongly dependent on the
entrance of the flow near the widening area. Reynolds number (see Fig. 6). When 100% hydrogen is trans-
When a 15 %vol CH4 blend in H2 was transported, Fig. 5b ported (Re ¼ 2576, as detailed in Table S2), the flow does not
depicts how the flow, after expansion and change of direction, expand over the entire length of the widening. In all other
has not regained uniformity before passing through the DN cases, the expansion of the flow occurs closer to the entrance
250 pipe. The flow impacted the wall opposite the inlet orifice to the change of the pipe section as the Reynolds number in-
and, although it expanded as it went downstream, the highest creases. It can be therefore stated that there is a strong
velocities were located adjacent to this wall. Therefore, the dependence of the flow behavior at the change of the pipe
flow was not uniform when it reached the objects. This section on the Reynolds number, and thus on the flow
resulted in an asymmetric distribution of the pressures and composition.
forces caused by the flow in the instrumentation objects (see The forces caused by the fluid on the duct walls and weld
Fig. S10b). rings are negligible, given the low velocities that occur (lower
If a 30 %vol CH4 blend in H2 was considered, the flow than 0.1 m/s, see Fig. 6a). This can be seen in Fig. 6b and 6c,
adhered to a greater extent to the wall opposite the inlet showing the contours of pressure and shear stresses caused
orifice (see Fig. 5c), causing an even more asymmetric pres- by the flow on the duct walls. It can be seen that the values of
sure distribution in the instrumentation elements than in the these variables are rather low. Therefore, the duct walls
previous cases (see Fig. S6c). This tendency gets more relevant should not support additional forces to those caused by the
for the next two conditions (40 %vol H2 in CH4 and pure pressure at which the system operates (80 bar), as already
methane), as depicted in Fig. 5d and 5e and Fig. S10d and S10e. happened in the study of case 4.
These asymmetries extend to about 0.5 m downstream of the
section reduction. However, about 20 diameters downstream Case 5: pumping H2 and CH4 by a piston type compressor
of the reduction, the flow is fully developed. and its injection gas pipelines
The effects observed in the different cases studied inten-
sify as the percentage of methane in the mixture gets higher, The aim of this case of study is to analyze the pulsating nature
since the Reynolds number increases. For all the cases of the flow downstream of a piston type compressor.
considered, the pressures/forces caused by this flow in the The model described in the experimental section has been
instrumentation elements are negligible compared to the applied to a 100% CH4 stream and a 100% H2 stream. Since the
pressure at which the system operates (80 bar) given the very results obtained are identical, the simulation of other
low velocities of the gas flow in the system. methane-hydrogen compositions was discarded. Fig. 7a
Fig. 5 e Velocity contours (m/s) and streamlines for the change in fluid direction in the gas pipeline after expansion from DN
80 to DN 250 when 100 %vol H2 (a), 85 %vol H2þ15 %vol CH4 (b), 70 %vol H2þ30 %vol CH4 (c), 40 %vol H2þ60 %vol CH4 (d) and
100 %vol CH4 (e) is transported in case of study 3.
i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 4 7 ( 2 0 2 2 ) 1 5 8 3 2 e1 5 8 4 4 15841
Fig. 6 e Velocity contours (m/s) (a), pressure contours (Pa) (b) and shear stress (Pa) (c) of the gases in the duct widening for
each of the simulated cases in case of study 4: 100 %vol H2 (A1), 85 %vol H2þ15 %vol CH4 (A2), 70 %vol H2þ30 %vol CH4 (A3),
40 %vol H2þ60 %vol CH4 (A4) and 100 %vol CH4 (A5).
shows the variation of the mass flow rate at the outlet of the oscillations are also observed at these points, corresponding
two pistons (seeFig. S5) according to the considerations indi- to the moments when sudden changes in the flow rate are
cated in the experimental section. These flow rate variations introduced in the system. However, the flow rate at the outlet,
are maintained at the junction of the two pipes exiting the plotted in Fig. 7b, remains constant throughout the cycle. This
pistons, and at the junction of the latter duct with the DN 80 indicates that the flow is homogenized before reaching the
pipe, as observed in Fig. 7b. In this figure, small flow outlet. Finally, the pressure change with time in the so-called
15842 i n t e r n a t i o n a l j o u r n a l o f h y d r o g e n e n e r g y 4 7 ( 2 0 2 2 ) 1 5 8 3 2 e1 5 8 4 4
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