Hydraulic and Energy Optimization of the Al-Feel–Mellitah Undulating Crude Oil Pipeline Using Nano-Engineered Internal Coatings

Abstract

Crude oil pipeline transportation is a highly energy-intensive operation, particularly for long-distance pipelines traversing complex and undulating terrain. In such systems) Al-Feel-Mellitah oil pipeline(, pumping energy is primarily consumed in overcoming frictional losses, while elevation changes introduce additional hydraulic constraints that strongly influence local and overall pressure behavior. This study investigates the potential of nano-engineered internal pipe coatings as a passive and permanent solution for reducing energy consumption in a long crude oil pipeline characterized by variable diameters, multiple pressure-drop zones, and alternating uphill and downhill segments.

A real pipeline transporting crude oil from a high-elevation production field to a low-elevation coastal terminal is considered as a representative case. The pipeline operates at a constant flow rate of 40,000 barrels per day and is hydraulically segmented into five pressure-drop zones, each with distinct geometric and elevation characteristics. The undulating elevation profile provides significant net hydrostatic assistance to the system; however, local pressure losses remain governed by friction, valve losses, and diameter-dependent flow velocities.

The effect of nano-engineered internal coatings is modeled through a reduction in the Darcy friction factor while preserving the original pipeline geometry, operating conditions, and elevation profile. The study framework establishes a clear link between surface-induced friction reduction, zone-wise pressure losses, and overall pumping energy demand. The results demonstrate that nano-engineered coatings can significantly enhance the hydraulic and energy performance of undulating crude oil pipelines without requiring changes to throughput or infrastructure layout, offering a practical pathway toward more energy-efficient pipeline operation.