The shift to hydrogen blends: What it means for gas turbine operators

Right now, gas turbines generate a massive share of the world’s electricity – offering that all-important flexibility and reliability needed to balance the grid.

In fact, as of 2023, global gas power capacity had reached approximately 1.9 terawatts.

But now, gas turbines are being reimagined as part of the hydrogen economy. 

And what is this reimagined solution?

Hydrogen blending.

This is when you mix hydrogen with natural gas to cut emissions, all while being able to still use existing infrastructure.

In this article, we’ll discuss the role of hydrogen blending, how gas turbines fit into a hydrogen-powered future, what challenges may await, and what you should know before retrofitting your assets.

The role of gas turbines in a hydrogen-powered future

Gas turbines have always been the backbone of reliable power generation.

They’re adaptable, efficient, and ready to step up when the grid needs them most.

As renewables like wind and solar are more readily utilized, that reliability becomes even more crucial. When the sun isn’t shining or the wind isn’t blowing, gas turbines are still there to provide power.

But as the push for decarbonization accelerates, the pressure is on to make gas turbines cleaner – but how?

Hydrogen blends could well be the answer.

By blending hydrogen with natural gas, you can cut CO₂ emissions without having to change your existing infrastructure. It’s a practical, lower-risk way to transition toward greener energy without scrapping the assets you’ve already invested so much capital in.

Hydrogen blending ticks all three boxes of helping extend the life of gas turbines, keeping them relevant, and helping them stay a reliable, low-carbon power source for years to come. 

But as with any solution, it comes with its own set of challenges. 

How gas turbines are being adapted for hydrogen blends: The challenges and solutions

Unfortunately, switching gas turbines to hydrogen blends is not that simple, due to the unique chemistry of the Hydrogen element that stands apart from your “traditional” hydrocarbon molecules.

There are a host of reasons why this isn’t the case. For example, hydrogen burns hotter and ignites more easily. It’s also more difficult to store as it requires larger volumes and special technologies to control its volatility.

Therefore, in order for turbines to burn this fuel, they need some key upgrades to handle the transition safely.

Keeping things stable

The challenge: Flame stability

Keeping a hydrogen flame stable isn’t easy.

Because it’s such a reactive element, it burns much faster than natural gas. That speed makes the flame front harder to control, which can lead to:

●      Increased NOx emissions, which can offset the environmental benefits of hydrogen blending

●      Combustion instability, which can cause flame blowout or even dangerous pressure fluctuations in the turbine

The solution: Smarter combustion systems

To handle hydrogen’s unique burn characteristics and keep emissions in check, engineers are modifying combustion chambers and fine-tuning dry low NOx (DLN) systems to handle higher hydrogen concentrations – without compromising on efficiency.

This involves some key modifications, including:

●      Staged combustion to slow down the burn rate and reduce NOx formation

●      Advanced cooling strategies to control flame temperatures and prevent hotspots

●      Optimized fuel injection to improve mixing and allow for stable combustion

Structural Integrity

The challenge: Material compatibility

Hydrogen may be a small molecule, but it can do serious damage to turbine materials.

Over time, hydrogen molecules seep into metal components, weakening the structural integrity of the metal through a process known as hydrogen embrittlement, which, if left unchecked, can lead to:

●      Cracks and premature wear, shortening your turbine’s lifespan

●      Structural failures, which, in extreme cases, can lead to catastrophic turbine failure

The solution: Material and coating upgrades

To counter this hydrogen-related damage, turbine manufacturers are investing in stronger materials and advanced coatings that are designed to withstand hydrogen exposure and protect turbine components from degradation.

Before increasing hydrogen blend ratios, it’s important to assess:

●      Material durability: Can your turbine components withstand prolonged hydrogen exposure, or do they need strengthening?

●      Key reinforcements: Do your turbine’s critical parts need upgrades to prevent long-term wear?

Making these upgrades now helps turbines run safely, reliably, and efficiently for longer. 

Building a hydrogen-ready supply chain

The challenge: Infrastructure and fuel supply

Hydrogen isn’t just a different fuel, it needs a completely different approach to storage and distribution.

For example, hydrogen has a lower energy density than gas, meaning turbines need more of it to produce the same amount of power. 

The problem? Existing fuel lines, valves, and storage systems simply weren’t built for higher hydrogen volumes and pressures.

To make things even trickier, unlike natural gas, which has a well-established global infrastructure, hydrogen supply chains are still in early development and playing catch-up.

The solution: Scaling up storage and distribution

For hydrogen blending to be viable at scale, the industry needs to invest in storage, transport, and fuel supply solutions that provide a safe, stable, and cost-effective transition – which means:

●      Upgrading storage facilities with high-pressure tanks or liquid hydrogen systems

●      Retrofitting fuel pipelines and delivery systems to handle hydrogen safely

●      Investing in local hydrogen hubs where multiple facilities share infrastructure to improve supply reliability

●      Developing on-site hydrogen production capabilities, such as electrolysis or steam methane reforming with carbon capture, to reduce dependency on external suppliers

What you need to consider when retrofitting for hydrogen

Upgrading your turbines and making the switch to hydrogen is all about planning for the long term.

In fact, clean hydrogen demand is expected to increase by between 125-585 million tonnes per year by 2050.

But while this is considered a big part of the future of energy, you still need to be cautious about how you adapt. 

Here are a number of key factors to keep in mind before making the leap. 

Is your turbine ready for hydrogen?

Is your turbine ready for hydrogen?

Not every gas turbine can handle hydrogen blends straight away.

Before you commit, you’ll need to assess your fleet’s compatibility. That means looking at your:

●      Combustion system design: Can your turbines safely burn hydrogen without risking instability or excessive NOx emissions?

●      Material durability: Will your turbine components stand up to hydrogen exposure, or do they need reinforcements?

●      Operational history: How has your turbine performed so far, and what modifications might be needed to allow for a smooth transition?

Balancing the costs and benefits

Retrofitting your turbines, upgrading fuel storage, and securing a reliable hydrogen supply all require careful financial planning.

That’s where incremental blending can help.

Instead of jumping straight to high hydrogen concentrations, many companies start with 10-20% hydrogen blends and gradually increase the concentration over time. 

This spreads costs, allows for performance validation, and helps you fine-tune operations as you scale up.

Tap into industry expertise

Retrofitting for hydrogen isn’t a DIY job. It requires specialized knowledge in combustion science, materials engineering, and fuel system design.

That’s why partnering with the right experts – whether it’s OEMs or independent service providers (ISPs) like EthosEnergy – is always a smart move to make. 

These specialists can provide:

●      Fuel testing to allow for stable combustion and emissions compliance

●      Emissions modeling to help you meet regulatory standards

●      Lifecycle assessments to gauge long-term performance and return on investment. 

Turning potential into performance

Hydrogen blend is a viable alternative to pure natural gas, and its use marks an exciting future for an energy sector that is becoming less reliant on hydrocarbons.

Of course, challenges exist. But with the right expertise and strategic investments, as well as leaning on the experience and expertise of OEMs and ISPs, hydrogen can become a viable, scalable solution for cleaner power generation.

EthosEnergy stands ready to support operators in making informed decisions that balance sustainability, efficiency, and operational reliability.