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The Middle East and North Africa's vast natural gas pipeline network – over 85,000 kilometers of infrastructure built across decades – now faces a fundamental transformation. Energy ministries across the region plan to repurpose this extensive network for hydrogen transport, but technical and financial hurdles complicate this seemingly straightforward solution.
Industry experts estimate the total retrofit cost will exceed $12 billion over the next decade, raising questions about the economic viability compared to purpose-built alternatives.
Technical Barriers to Pipeline Conversion
Converting existing natural gas pipelines to carry hydrogen involves more than simple policy decisions. The molecular properties of hydrogen create unique challenges that engineers must address before regional distribution becomes viable.
"Hydrogen molecules are significantly smaller than methane molecules," explains Dr. Fatima Al-Mansoori, materials science director at the UAE's Energy Future Lab. "This creates immediate issues with traditional pipeline materials, particularly around permeation, embrittlement, and leakage risks."
Tests conducted on Saudi Arabia's East-West pipeline segments revealed that standard pipeline steel (API X65) suffers up to 15% reduction in structural integrity when exposed to hydrogen at high pressures over extended periods. This hydrogen embrittlement phenomenon affects even modern pipelines constructed within the last decade.
Compression Challenges Demand New Infrastructure
The energy density challenge presents another significant hurdle. Hydrogen contains approximately one-third the energy by volume compared to natural gas, requiring compression rates three times higher to deliver equivalent energy.
"Most of our existing compressor stations simply cannot handle these requirements," notes Ibrahim Hadad, infrastructure planning director at Egypt's EGAS. "We need to replace or substantially modify around 85% of our compression infrastructure."
This compression challenge alone accounts for nearly $4.8 billion of the total retrofit costs across the region.
Phased Adaptation Strategies Emerge
Rather than attempting wholesale conversion, MENA countries now favor phased approaches that gradually increase hydrogen blending percentages while systematically addressing infrastructure limitations.
Algeria's Sonatrach leads the region with the most advanced implementation plan, dividing its 2,200km northern pipeline network into three distinct phases:
Phase 1 (2023-2025): Hydrogen blending up to 10% in select pipeline segments with minimal modifications
Phase 2 (2026-2028): Incremental increases to 25% blending while replacing critical components
Phase 3 (2029-2032): Dedicated 100% hydrogen pipelines in high-demand corridors
"This graduated approach allows us to begin hydrogen transport while spreading capital expenditure across a decade," explains Sonatrach's infrastructure director Karim Bellil. "It also gives domestic manufacturers time to develop specialized components rather than importing everything."
Material Innovations Reduce Retrofit Costs
Recent advancements in pipeline coatings and liner technologies offer potential cost savings. Qatar's North Field pipeline expansion now incorporates hydrogen-compatible glass-reinforced epoxy liners that can be retrofitted into existing pipes.
"We developed these liners specifically to address hydrogen permeation without full pipeline replacement," says Dr. Mohammed Al-Thani, head of Qatar's Gas Infrastructure Research Center. "Early testing suggests they can reduce retrofit costs by approximately 30% compared to traditional replacement strategies." These material innovations have prompted Saudi Aramco to revise its initial retrofit budget estimates downward from $3.2 billion to approximately $2.5 billion.
The New Build vs. Retrofit Economic Equation
The fundamental question remains: is retrofitting existing infrastructure more economical than building dedicated hydrogen pipelines? Current analysis suggests the answer varies significantly by region and pipeline characteristics. For newer pipelines (under 15 years old) with modern materials, retrofitting costs average $800,000-$1.2 million per kilometer – approximately 40% cheaper than new construction. However, older infrastructure with extensive compression requirements can exceed new build costs by 15-30%.
"The economic calculation isn't straightforward," explains Nadia Bouaziz, energy infrastructure analyst at Morocco's Economic Research Institute. "For coastal corridors with high expected hydrogen volumes, new dedicated pipelines often make more sense. For inland routes with moderate demand, retrofitting provides better economics despite the technical challenges."
Egypt's Hybrid Approach Sets Regional Precedent
Egypt has pioneered what many consider the region's most pragmatic solution – a hybrid approach focusing on retrofitting strategic pipeline segments while developing new hydrogen-specific corridors.
The Egyptian strategy designates its Mediterranean coastal pipeline network for hydrogen retrofitting, targeting export markets in Southern Europe. Meanwhile, new purpose-built hydrogen pipelines will connect green hydrogen production zones in the Western Desert with industrial users in Cairo and Alexandria.
"We analyzed each pipeline segment individually rather than pursuing a blanket approach," explains Ahmed Hassan, strategic planning director at Egypt's Hydrogen Development Authority. "This hybrid model optimizes both capital expenditure and time-to-market."
The Regional Integration Challenge
Beyond national boundaries, the region's most ambitious vision involves creating an integrated MENA Hydrogen Pipeline Network connecting production hubs with consumption centers and export terminals. This cross-border integration adds regulatory complexity to the technical challenges. Different countries have adopted varying technical standards, blending limits, and safety requirements.
"Regional standardization has become critical," notes Omar Al-Zaabi, chair of the recently formed MENA Hydrogen Infrastructure Committee. "Without harmonized specifications, we risk creating isolated national networks rather than an integrated regional system." The committee recently published its first standardization framework, which five countries have already adopted. Full regional alignment remains several years away, however.
As MENA positions itself as a potential global hydrogen export hub, the pipeline infrastructure question will largely determine the region's competitiveness against emerging alternatives like ammonia carriers and liquid hydrogen shipping. For now, the retrofit path – despite its challenges – offers the fastest route to market for the region's hydrogen ambitions.
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