Hydrogen Infrastructure: Penspen Confirms Europe’s Gas Grids Can Handle 20% Blending

Ever wondered if Europe’s sprawling gas pipeline network could handle more than just methane? According to Penspen, the UK energy consultancy around since 1954, the answer is a resounding yes. Most of the continent’s distribution grid can safely carry up to 20% hydrogen. Thanks to decades of modernisation and a healthy dose of HDPE and MDPE piping, the shift to a lower-carbon blend might be closer than you think. After all, this network spans over two million kilometres and serves roughly 747 million people across the EU—so any tweak is a major undertaking.

Why 20% Matters

Blending hydrogen into natural gas isn’t just a fun engineering challenge—it’s a practical step toward industrial decarbonization and sustainable energy. Even at a modest 20% ratio, hydrogen can slash CO₂ emissions from home heating by up to 6%, while also cutting carbon monoxide and nitrogen oxides. Given that heating and power account for about a quarter of the EU’s greenhouse gas output, every percentage point really counts.

Of course, this only works if we’re talking green hydrogen. Most forecasts assume that by 2030, a significant share of that injected gas will come via hydrogen production powered by wind, solar, or hydropower—locking in the loop to decarbonised fuel generation.

Peter O’Sullivan, Penspen’s CEO, says the widespread switch to plastic pipes over the last few decades means most of today’s network already shrugs off hydrogen’s usual ghosts: brittleness and embrittlement. In other words, the groundwork’s been laid.

Plastic Pipes to the Rescue

Believe it or not, Europe’s grid dates back to when “town gas” sometimes had up to 50% hydrogen mixed in. As methane took over, pipelines evolved too. From the 1970s through the ’90s, regions gradually replaced cast iron and steel with flexible, durable HDPE and MDPE. These plastics aren’t fazed by hydrogen embrittlement—a common headache when hydrogen meets metal.

Sure, hydrogen molecules are tiny and permeate through plastic about five times faster than methane, but current studies suggest that with solid leak detection and maintenance regimes, the climate impact stays manageable. That said, experts agree we need more pan-European, peer-reviewed research to understand the long-term picture.

Pilot Projects Paving the Way

We’re not just speculating. Ireland’s HyEnd and HyTest projects, along with trials in Germany and the UK, have already fed mixed gas into live distribution lines serving homes, power plants, and factories. The verdict? Over 90% of domestic boilers and industrial furnaces ran smoothly on a 20% hydrogen blend—no surprise flameouts or major hardware swaps required.

For utilities and regulators, that’s a green light. It means you don’t have to rip out every pipeline. Instead, you can retrofit meters, tweak safety protocols, and roll out clear consumer communications to make the transition seamless.

A Boost for EU Climate Goals

Europe’s policy framework has been gearing up for this moment. The EU’s Hydrogen Strategy of 2020, the Fit for 55 package, and the 2024 “Hydrogen and Decarbonized Gas Market” rules all set the stage for at least 20% hydrogen blends by 2030. These rules essentially tell member states and operators to get their hydrogen infrastructure primed.

The European Network of Transmission System Operators for Gas (ENTSOG) has also published best-practice guidelines on safety, odorisation, and gas quality monitoring. The European Commission often cites these reports when drafting new legislation, highlighting how technical expertise and policy can work hand in glove.

Economic Shortcut

Picture your local gas grid as a highway built for diesel trucks that’s now also carrying electric vans. By blending at 20%, operators avoid the eye-watering costs of rebuilding every mile for pure hydrogen. Instead, they can funnel money into boosting renewable hydrogen production, building storage hubs, and rolling out market incentives—rather than massive civil works.

It’s a huge saving. A complete overhaul of Europe’s gas network could run into the hundreds of billions of euros. Blending, on the other hand, preserves existing assets and steers clear of stranded infrastructure nightmares.

Challenges on the Horizon

It’s not all smooth sailing. Some regions still rely on old metallic pipelines that are prone to embrittlement. Heavy industrial users with high-pressure systems may need expensive retrofits. Plus, across the EU’s 27 member states, safety standards and regulations can differ wildly—a potential bureaucratic tangle.

And let’s not overlook public perception. People often worry about hydrogen safety, so utilities will need to nail the messaging—and maybe even roll out real-time monitoring—to win trust. Training staff and aligning emergency response plans with local authorities will also be crucial.

Looking Ahead

So, what comes next? Policymakers must harmonise rules, fund upgrades in the most vulnerable regions, and sweeten the deal for hydrogen producers. Utilities will adjust maintenance routines, recalibrate pressure sensors, and pilot small-scale blends before committing to larger rollouts. For end users—from homeowners to factory managers—it might be as simple as a quick boiler tweak rather than a full system overhaul.

If all goes to plan, we could see Europe’s gas networks quietly humming along with a 20% hydrogen mix well before 2030. It’s a savvy shortcut on the road to zero-emission technology, proving that sometimes the best innovations are the ones that make the most of what you already have.

About Penspen
Founded in 1954, Penspen is a UK-based energy engineering and consultancy firm specialising in pipeline and infrastructure solutions for oil, gas, and hydrogen. Under the leadership of CEO Peter O’Sullivan, Penspen is at the forefront of hydrogen infrastructure research and safety feasibility studies, helping Europe’s gas networks transition towards a cleaner energy future.