Replacing fossil fuels with non-carbon fuels is an important step towards reaching the ultimate goal of carbon neutrality. Instead of moving directly from the current natural gas energy systems to pure hydrogen, an incremental blending of hydrogen with natural gas could provide a seamless transition and minimize disruptions in power and heating source distribution to the public. Academic institutions, industry, and governments globally, are supporting research, development and deployment of hydrogen blending projects such as HyDeploy, GRHYD, THyGA, HyBlend, and others which are all seeking to develop efficient pathways to meet the carbon reduction goal in coming decades. There is an understanding that successful commercialization of hydrogen blending requires both scientific advances and favorable techno-economic analysis. Ongoing studies are focused on understanding how the properties of methane-hydrogen mixtures such as density, viscosity, phase interactions, and energy densities impact large-scale transportation via pipeline networks and end-use applications such as in modified engines, oven burners, boilers, stoves, and fuel cells. The advantages of hydrogen as a non-carbon energy carrier need to be balanced with safety concerns of blended gas during transport, such as overpressure and leakage in pipelines. While studies on the short-term hydrogen embrittlement effect have shown essentially no degradation in the metal tensile strength of pipelines, the long-term hydrogen embrittlement effect on pipelines is still the focus of research in other studies. Furthermore, pressure reduction is one of the drawbacks that hydrogen blending brings to the cost dynamics of blended gas transport. Hence, techno-economic models are also being developed to understand the energy transportation efficiency and to estimate the true cost of delivery of hydrogen blended natural gas as we move to decarbonize our energy systems. This review captures key large-scale efforts around the world that are designed to increase the confidence for a global transition to methane-hydrogen gas blends as a precursor to the adoption of a hydrogen economy by 2050.

The emphasis on climate change requires processes to be more efficient to minimize CO₂ emissions, and nanostructured materials as catalysts could play a crucial role due to their high surface area per unit volume. Herein, we report the synthesis of silica microspheres (450–600 nm) using a modified Stober process, on which iron oxide clusters were deposited by sonolysis of iron pentacarbonyl to yield a nanostructured iron material (Si-Fe). A suite of spectroscopic techniques was used to characterize the synthesized materials. The BET surface area of freshly prepared Stober silica was 8.00 m²/g, and the Si-Fe material was 24.0 m²/g. Iron is commercially used as a Fischer–Tropsch (F–T) catalyst due to its low cost. However, catalyst attrition causes catalyst loss and lower product quality. In this study, the synthesized Si-Fe materials were evaluated for F–T synthesis to address these challenges. For comparison, two commercial materials, UCI (silica-supported micron-sized iron oxide) and BASF (unsupported nanosized iron oxide), were also evaluated. All three materials were first activated by pretreatment with either CO or synthesis gas (a mixture of CO and H₂) for 24 h, then evaluated for quick screening in batch mode for F–T synthesis in a Parr batch reactor at three temperatures: 493 K, 513 K, and 533 K. The F–T data at 513 K showed that the CO-pretreated Si-Fe catalyst demonstrated lower CO₂ (<0.5%), lower CH4 (58%) C₈–C₂₀ selectivity (mol% C) to hydrocarbons, surpassing both reference catalysts. The temperature dependence data for Si-Fe: 17.4%, 58.3%, and 54.9% at 493 K, 513 K, and 533 K, respectively, showed that the hydrocarbon yield maximized at 513 K. The surface area increased to 27.9 m²/g for the CO-reduced Si-Fe catalyst after the F–T reaction at 513 K. The morphology and structural change of catalysts, before and after the F–T runs, were imaged. Of all the catalysts evaluated, the SEM–EDS data analysis showed the least carbon deposition on the CO-treated Si-Fe catalyst after the F–T reaction at 513 K and minimized CO₂, a greenhouse gas. This could pave the way for selecting nanomaterials as F–T catalysts that effectively operate at lower temperatures and produce negligible CO₂ by minimizing water-gas-shift (WGS) activity.

Natural gas distribution companies are developing ambitious plans to decarbonize the services that they provide in an affordable manner and are accelerating plans for the strategic integration of renewable natural gas and the blending of green hydrogen produced by electrolysis, powered with renewable electricity being developed from large new commitments by states such as New York and Massachusetts. The demonstration and deployment of hydrogen blending have been proposed broadly at 20% of hydrogen by volume. The safe distribution of hydrogen blends in existing networks requires hydrogen blends to exhibit similar behavior as current supplies, which are also mixtures of several hydrocarbons and inert gases. There has been limited research on the properties of blended hydrogen in low-pressure natural gas distribution systems. Current natural gas mixtures are known to be sufficiently stable in terms of a lack of chemical reaction between constituents and to remain homogeneous through compression and distribution. Homogeneous mixtures are required, both to ensure safe operation of customer-owned equipment and for safety operations, such as leak detection. To evaluate the stability of mixtures of hydrogen and natural gas, National Grid experimentally tested a simulated distribution natural gas pipeline with blends containing hydrogen at up to 50% by volume. The pipeline was outfitted with ports to extract samples from the top and bottom of the pipe at intervals of 20 feet. Samples were analyzed for composition, and the effectiveness of odorant was also evaluated. The new results conclusively demonstrate that hydrogen gas mixtures do not significantly separate or react under typical distribution pipeline conditions and gas velocity profiles. In addition, the odorant retained its integrity in the blended gas during the experiments and demonstrated that it remains an effective method of leak detection.

New York State (NYS) has set strict greenhouse gas (GHG) emission reduction targets across all sectors of its economy, including the heating sector. This study examines the financial value and environmental impacts of the residential space heating sector in NYS under different GHG abatement options by comparing the existing natural gas heating pathway with three potential GHG abatement pathways: renewable natural gas (RNG), hydrogen blended into RNG, and air-source heat pumps (ASHPs). These pathways are analyzed via a comparative net present value (NPV) framework from 2022 to 2042 with the emission reduction represented as a revenue stream that serves as a function of the social cost of GHGs. The investment timing of each of these pathways is also accounted for to reflect the pathways’ varying deployment timelines. The ASHP pathway with a 10% financial discount rate and a 2% social cost of the GHG discount rate achieves the lowest NPV. The RNG pathway achieves the highest NPV. A sensitivity analysis determines the impact of key factors on the NPV results. This study aims to inform policymakers, homeowners, and stakeholders of the potential benefits and costs of each of the four pathways to aid them in their decision-making process.