An innovative method for blending hydrogen into natural gas

The integration of Hydrogen (H 2 ) into existing Natural Gas (NG) infrastructure represents a critical step toward decarbonising energy systems. This study investigates the blending of H 2 with NG, focusing on the development and evaluation of a modular static mixing system suitable for varying H 2 concentrations. Through comprehensive computational fluid dynamics simulations, we analyse key performance metrics including pressure drop and mixture uniformity. Results demonstrate that the system maintains low pressure losses across a range of H 2 percentages, highlighting its potential for efficient and scalable deployment. The modular design enables the use of a single cartridge configuration for high H 2 blending ratios, although adjustments to internal components (cartridges) significantly improve the uniformity of the mixture. The study also addresses key challenges associated with H 2 blending, such as safety, operational reliability, and adaptability. A case implementation in a real-world H 2 hub underscores the practical viability of the approach, offering insights into the system’s role in supporting the transition to a low-carbon energy future. • Modular static mixer developed for hydrogen-natural gas blending applications. • CFD analysis performed to assess pressure loss and mixture uniformity. • Cartridge configuration adapted to blend ratio enhances mixture uniformity. • Design maintains low pressure drop across varying hydrogen concentrations. • Real-world case study confirms safe and scalable system implementation.