The Future of Multi-Product Pipelines: Innovation and Sustainability in Energy Transportation

Introduction

Multi-product pipelines are important infrastructures for the transportation of petroleum products such as gasoline, diesel, and other liquid or gaseous fuels. These pipeline systems enable the efficient distribution of different products through a single network, reducing costs and increasing transportation capacity on a large scale.

As the world moves toward a more sustainable energy future and faces the challenges of climate change, the infrastructure of these systems is at a crossroads. To remain relevant, the pipeline must adapt to technological innovations, improve its safety and efficiency, and reduce its environmental impact.

This article explores the future of multi-product pipelines, the technological innovations that are transforming them, and how they can be aligned with sustainability goals, such as the use of green hydrogen and biofuels.

Multi-product Pipelines Today: Global Overview

Today, these pipelines are a backbone in the transportation of refined products. In countries such as the United States, more than 60% of petroleum products are transported through a multi-product pipeline, highlighting their importance in the energy supply chain.

In the United States, for example, the network exceeds 3 million miles, making it one of the most extensive in the world. Globally, countries such as China are rapidly expanding their pipeline infrastructure to meet growing energy demand.

Despite their efficiency, these systems face challenges. In regions such as Mexico, fuel theft (known as “huachicol”) has caused large economic losses and damaged infrastructure. In addition, accidents and spills are persistent problems that increase pressure on the industry to improve safety and reduce its environmental impact.

Technological Innovation

Technological innovation is transforming the management of these systems. It is estimated that the use of artificial intelligence (AI) in pipeline prediction and maintenance could reduce operational costs by 20% in the next five years. In addition, drones and robotics are transforming the way pipelines are inspected and repaired, such as the SmartBall and PipeDiver robotic devices, which allow detailed inspections without operational interruptions, increasing efficiency and safety.

• Automation and Robotics in Construction: One of the main innovations is the use of advanced robotics for the installation of these pipelines. Automated installation robots can operate in difficult terrain, which optimizes accuracy and reduces human intervention, improving safety and reducing operational costs, enabling accurate pipe laying, minimizing errors and material waste, contributing to more sustainable projects.

• IoT Technology for Monitoring and Maintenance: The Internet of Things (IoT) has transformed the monitoring of these pipelines by integrating sensors that collect real-time data on pressure, temperature, and flow. These sensors enable rapid response to anomalies and optimize maintenance cycles through predictive algorithms. This technology improves the service life of infrastructure and reduces the risk of leaks, which is vital for safety.
• Use of Drones and Digital Mapping: These devices are increasingly used to inspect and monitor these systems from the air, providing high-resolution images that allow the condition of pipelines to be assessed without putting workers at risk. In addition, the use of digital mapping and GIS systems has transformed project planning and execution, providing accurate details on the ground and helping to mitigate environmental impacts.
• Innovations in Materials and Construction: Advanced materials, such as specialized polymers and corrosion-resistant alloys, are being used to extend the life of pipelines and minimize the risk of structural failure. In addition, 3D printing is emerging as an innovative tool for manufacturing specific components, enabling customization and precision in the construction process.
• Artificial Intelligence (AI) and Project Optimization: This innovative technology is revolutionizing project planning for these pipelines. Through these algorithms, large amounts of data, such as soil conditions and weather forecasts, can be used to optimize resources, reduce costs, and minimize construction times. Maintenance plans can also be created based on historical data and predictions, improving long-term operational efficiency.

Pipeline Sustainability: Challenges and Solutions

This is one of the main challenges in the future. Although this mode of transportation is more efficient and safer than other methods, such as overland, spills, and carbon emissions remain a major concern.

• Pump electrification: One of the key solutions is the electrification of pumping stations, which reduces greenhouse gas emissions. This aligns with global efforts to reduce dependence on fossil fuels.
• Adapting to green hydrogen: With the increasing adoption of hydrogen as a clean alternative, it is estimated that up to 30% of the existing infrastructure could be adapted for transportation with minimal modifications. Hydrogen offers an emission-free solution, as it only produces water as a by-product when used as a fuel.
• Biofuel transportation: A more sustainable alternative to fossil fuels, it is expected to increase in use by 25% by 2030. This growth is driven by global emissions’ reduction policies and increased production of cleaner fuels.

Future Challenges: The Role of Pipelines in the Energy Transition

The development of these new infrastructures represents a priority in key energy markets such as North America, the Middle East, and Asia. For example, in 2023, the United States maintained its leadership with major investments in gas pipelines, while countries such as Russia continue to push ahead with the expansion of their networks to meet growing energy demand in Europe.

However, challenges are faced, such as the age of many infrastructures, especially in regions such as North America and Europe, where a large part of the pipelines are more than 50 years old, which increases the risks of leaks and accidents, requiring significant investment in integrity management programs and advanced monitoring technologies.

These pipelines will have to adapt to new and increasingly stringent environmental and safety regulations. These regulations affect not only the construction of new systems but also the operation of existing ones. Companies will have to invest in advanced technology to meet these demands.

Another key challenge is financing, as adapting infrastructure for green hydrogen and biofuel transportation requires large investments. To achieve these goals, companies will need to seek public-private partnerships to support the necessary transformations.

Moreover, climate change poses additional risks, such as extreme weather events, which may compromise their integrity. To mitigate these risks, companies will need to develop adaptation and resilience-enhancing strategies.

Industry Views and Perspectives

Globally, experts agree that these systems will continue to be a fundamental part of the energy infrastructure for decades to come, but their success will depend on the industry’s ability to innovate and adapt to new demands.

• Technological innovation: The implementation of AI, robotics, and new materials will be key to ensure efficiency and safety in the future.
• Clean energy: Green hydrogen and biofuels are seen as the main energy sources for the future of pipelines. Despite the financial challenges, these energy resources offer a path to cleaner and more sustainable infrastructure.
• Design standards: Products transported through pipelines can be hazardous to the environment and people nearby, it is important to follow strict engineering standards and practices. These standards and design considerations are essential to the proper design, installation and operation of a multi-product pipeline. The ASME B31.4 code includes the key factors that must be considered in pipeline transportation systems for hydrocarbons and other liquids.

Based on the importance of design conditions in the manufacture of these pipes, here is a video courtesy of EPCLAND, regarding ASME Code 31.4: Multiple choice questions and answers for liquid transportation pipelines; so that you can enrich the content when discussing this topic among professionals.

Conclusions

The future of pipelines presents a combination of challenges and opportunities. The industry faces pressure to modernize to meet the demands of sustainability and decarbonization. However, the adoption of advanced technologies and the transition to green hydrogen and biofuels offer a promising future for these systems.

With adequate investment and regulatory support, these pipelines will continue to be an essential infrastructure in energy transportation, playing a key role in the transition to a more sustainable world. Technological innovations and sustainable solutions will be key to ensuring their relevance in the coming decades.

Discover how technology and sustainability are transforming multi-product pipelines. find out more now!

References

1. G McKinsey & Company: Global Energy Perspective 2023: Transition bottlenecks and unlocks
2. IEA: (Energy Technology Perspectives 2023)
3. Public Gas Journal: (Global Pipeline Construction Outlook 2023)
4. Fortune Business Insights: (PIPELINE TRANSPORTATION MARKET TRENDS)
5. ​Trellis Energy: (Pipelines of the Future: Innovations in Natural Gas Transportation)