egeplast develops innovative Green Gas Pipes with an additional permeation barrier layer to reduce hydrogen and methane emissions.
With its extensive natural gas network and connected gas storage facilities, Germany possesses an infrastructure that can partially be used for hydrogen. However, additional pipelines are required to reliably transport the hydrogen quantities needed in the future to locations where fossil fuels are to be replaced. For this reason, a large-scale hydrogen network is currently being established in Germany – the so-called hydrogen core network. It is intended to serve as a central transport infrastructure, connecting production sites, storage facilities, industrial centers, and consumption regions. A total of around 9,000 km of pipeline is planned to link key regions across the country. Around 60% of the lines will be created by converting existing natural gas pipelines, while the remainder will be newly built.
Due to high pressure, the large main pipelines are made of steel. In contrast, flexible plastic pipes will be used for branching and fine distribution within the network. These offer several advantages: they can be installed in very long lengths without joints and are also corrosion-resistant. They are also economically attractive, as they can be installed particularly efficiently using modern, trenchless installation methods such as plowing or milling – with installation rates of over 1,000 m per day. At the same time, these methods protect the environment, as the impact on nature and soil is significantly lower.
However, hydrogen places special demands on materials. There is ongoing discussion at German and European levels regarding the permeability of plastics for hydrogen – specifically, how much hydrogen can escape through the pipe walls via permeation. Modern multi-layer plastic pipes offer a solution, featuring a special barrier layer that almost entirely prevents gas leakage.
As part of a DVGW research project conducted in collaboration with leading gas utilities, an optimized pipe design with an integrated internal barrier layer was comprehensively tested regarding its permeation properties, and extensive practical application tests were carried out: squeeze-off tests in accordance with DVGW G 452 prove that the new gas pipes with an additional internal layer withstand this extreme mechanical stress. This makes squeezing-off a viable operational measure.
The welding tests performed also demonstrate that the investigated pipes with an integrated barrier layer can be joined safely and reliably using butt welding. Naturally, the use of all electrofusion fittings available on the market and approved for gas is also possible without restriction.
These pipes can almost completely prevent methane loss and can also reduce hydrogen loss by half compared to simple pipes. Permeation measurements with the integrated barrier layer show a significant reduction in CO2 equivalents; for methane, the barrier layer is virtually permeation-resistant.
The summary of the research project concludes as follows:
Our PE pipes with an integrated permeation barrier layer combine proven practical suitability with sustainable emission protection and thus deserve the name “Green Gas Pipes.”
Since current requirements for the construction of hydrogen networks in the plastic pipe sector are initially focused on dimensions DN 100 and DN 150, we are starting in the first step with pipe dimensions from 90 to 160 mm. The following pipe systems will be available with an optional permeation barrier layer in the future:
- egeplast SLM® 3.0 (for operating pressures up to 10 bar)
- HexelOne® high-pressure pipes (for operating pressures up to 16 bar)
With the new egeplast “Green Gas Pipes,” emissions can be significantly reduced – a decisive contribution to the safe, sustainable, and environmentally friendly expansion of modern hydrogen networks.
For the safe expansion of modern hydrogen networks:
3R and gwf Gas + Energie also report in issue 01-02/2026 on “Emission-reducing plastic pipes with an additional permeation barrier layer” with a technical article by Dr.-Ing. Thorsten Späth.
