Optimal design of reinforced thermoplastic pipelines for hydrogen transportation by Kriging Model and genetic algorithm

Hydrogen has a great potential for application as a green energy source. Composite hydrogen pipeline is an important way of hydrogen transportation, and its engineering demand prospects are also very broad. This paper uses the finite element simulation method in combination with the Tsai-Wu failure criterion to derive the burst pressure of hydrogen transport pipelines under internal pressure and bending conditions as 28.5 MPa and the minimum bending radius as 1591.6 mm. Through hydrostatic pressure testing, the internal pressure of the pipeline was determined to be 28.8 MPa, with an error of 1.04%, verifying the validity of the simulation. The reinforcement layer of the pipeline was optimized using a Kriging surrogate model combined with the NSGA-II genetic algorithm based on simulation results. Through normalized result processing, the optimized parameters of the reinforcement layer were obtained (layer angle 55°, number of layers 8, thickness of single layer 0.3 mm), and finite element simulation verification was conducted, yielding an internal pressure of 22.3 MPa and a minimum bending radius of 1439.6 mm for the pipeline. The optimization approach achieves improved lightweight and economic performance under engineering constraints, demonstrating its feasibility and application potential.