As the global energy industry pivots toward sustainability, carbon capture and hydrogen technologies are emerging as two of the most promising solutions for reducing industrial emissions and decarbonizing hard-to-abate sectors. While these technologies are still evolving, one thing is certain: success depends on specialized infrastructure, and that infrastructure requires highly precise, industrial-grade pipe fabrication.
At AI Energy Solutions, we bring decades of experience to complex pipe fabrication projects across power, chemical, and industrial sectors. Now, we are helping lead the way in fabrication for carbon capture and hydrogen systems by leveraging our material expertise, advanced shop capabilities, and quality-focused processes.
This article explores what makes fabrication for these energy transition technologies unique, the material and process requirements involved, and how fabricators can help accelerate project timelines while meeting strict safety and quality standards.
Why Carbon Capture and Hydrogen Matter
Carbon capture, utilization, and storage (CCUS) and hydrogen production are foundational to many climate and energy strategies around the world. According to the U.S. Department of Energy, CCUS could help reduce emissions from large industrial facilities such as cement, steel, and petrochemical plants. Simultaneously, hydrogen, especially green hydrogen produced from renewable energy, can power transportation, heating, and industrial processes with zero emissions at the point of use.
However, both systems require specialized fabrication due to:
- High pressures and temperatures
- Corrosive or cryogenic media
- Strict quality standards for safety and environmental protection
- Compatibility with evolving regulatory frameworks
These factors demand a level of fabrication expertise that many traditional shops cannot offer.
Fabrication Requirements for Carbon Capture Systems
1. High-Integrity Welded Piping
Carbon capture systems often operate under elevated pressures and require zero leakage tolerances. That means weld quality is critical. Fabricators must be certified to the appropriate ASME codes and capable of performing nondestructive testing (NDT) on all joints. Common NDT methods include radiographic testing (RT) and ultrasonic testing (UT), both of which help confirm weld soundness without compromising material integrity.
2. Corrosion-Resistant Materials
Captured CO₂ can form carbonic acid when mixed with water vapor, creating a corrosive environment. To counter this, fabrication often involves stainless steels or corrosion-resistant alloys like 316L, Inconel, or Hastelloy. These materials require specialized welding procedures, proper heat input control, and strict filler material selection to avoid premature failure.
3. Gas-Tight Systems and Custom Components
Fabricators must be capable of producing gas-tight systems and working closely with EPC contractors to accommodate unique system designs. In some cases, pipe spooling must be adjusted mid-project based on evolving data about CO₂ compression and flow characteristics.
Fabrication Considerations for Hydrogen Systems
1. Hydrogen Embrittlement Awareness
Hydrogen atoms can penetrate and weaken many common metals in a phenomenon known as hydrogen embrittlement. Fabricators must understand which materials are most vulnerable and use alloys designed to resist cracking or degradation under hydrogen exposure. Chromium-molybdenum steels, certain duplex stainless steels, and nickel-based alloys are commonly used for hydrogen systems.
2. Precision in Fabrication and Assembly
Leaks in hydrogen systems pose a significant safety hazard due to hydrogen’s low molecular weight and high flammability. Fabrication for hydrogen pipelines and vessels requires extremely tight tolerances, certified welders, and rigorous inspection procedures.
Post-weld heat treatment (PWHT) may also be required to relieve residual stresses and maintain mechanical properties. Shops must have the capacity to perform in-house PWHT or coordinate it as part of a managed workflow.
3. Cryogenic and High-Pressure Compatibility
Many hydrogen systems involve either cryogenic storage (for liquefied hydrogen) or ultra-high-pressure gas (for compression and transport). Both scenarios demand robust piping systems that can perform under thermal cycling and pressure spikes. Material selection, welding qualifications, and pipe fit-up procedures must be documented and thoroughly validated.
How Fabricators Can Support the Energy Transition
The success of carbon capture and hydrogen infrastructure will depend in large part on whether fabrication shops can keep pace with demand while delivering safe, high-quality assemblies. At AI Energy Solutions, we contribute by:
1. Investing in Specialized Welding and Testing Capabilities
Our fabrication teams are trained and certified to handle a wide range of materials and welding procedures. We use advanced QA/QC systems to track every weld, heat number, and inspection result. Weld logs and inspection reports are made available to clients in real time to support transparency and compliance.
2. Supporting Fast Turnarounds with Scalable Capacity
Emerging energy projects often operate on accelerated timelines, particularly when supported by government funding or tied to emissions compliance. Our ability to scale production and work with parallel teams on shop and field fabrication helps us meet project milestones without compromising quality.
3. Collaborating Early to Optimize Fabrication Plans
We work closely with project engineers, EPC contractors, and material suppliers during the design phase to review constructability, select appropriate materials, and sequence spools efficiently. This early engagement helps reduce rework, cut down on RFIs, and improve delivery speed.
Preparing for Industry-Wide Growth
According to the International Energy Agency, the number of commercial carbon capture facilities worldwide must grow from dozens today to thousands by 2050 to meet global net-zero goals. Similarly, hydrogen production and distribution infrastructure is expected to expand rapidly, especially across the U.S., Europe, and Asia.
Fabricators who understand the technical challenges of these systems and proactively invest in capacity, training, and documentation workflows will be the ones best positioned to grow alongside this opportunity.
Conclusion
Fabrication for carbon capture and hydrogen projects requires more than just experience with steel; it demands deep knowledge of material performance, high-integrity welding, and total quality management. As developers and owners look to expand cleaner energy infrastructure, they need fabrication partners who understand the stakes and can deliver safe, code-compliant systems with no margin for error.
At AI Energy Solutions, we are proud to be part of this transition. From advanced alloy welding to precision spool delivery, our team supports the fabrication needs of tomorrow’s energy systems, today.
