Non-metallic materials for key Saudi sectors

Saudi Arabia

Wa’el Tashkandi, CEO of Novel Non-Metallic Solutions, talks to The Energy Year about the advantages of reinforced thermoplastic pipes (RTPs) over conventional pipes and developing non-metallic solutions for sectors outside oil and gas. Novel Non-Metallic Solutions is a joint venture between Aramco and Baker Hughes that conducts R&D on composite technology for industrial components.

What was the vision behind the establishment of Novel Non-Metallic Solutions?
Novel’s story started around 2018, when Aramco launched its non-metallic strategy to compensate for drops in demand due to the spread of renewable energies. The goal was to develop polymer-based applications for five main sectors: oil and gas, construction, renewable energy, packaging and automotive.
Around the same time, Baker Hughes had acquired a US company specialising in reinforced thermoplastic pipes (RTPs) for onshore applications, a non-metallic alternative to traditional steel pipes. Seeing alignment in their respective plans, Aramco and Baker Hughes formed Novel as a joint venture to develop non-metallic solutions for the energy industry and beyond.
The speed at which Novel came to life was remarkable. It took just one year from signing the NDA [non-disclosure agreement] to finalising the shareholder agreement – it was one of the fastest projects of its kind within Aramco. In November 2020, the ground-breaking ceremony took place at SPARK, and by May 2023, we had completed the first phase of our 100,000-square-metre facility to produce RTPs.

Can you share some specifics about the SPARK facility?
After commissioning the facility, we had to obtain all the necessary international certifications to begin operations. We started with ISO 9001 and continued with API Q1 and API 15s, which govern quality management systems and technical requirements. Once we secured them, we were able to start selling.
The facility has a blended production capacity of more than 1,000 kilometres per year of four-, six- and eight-inch-diameter pipes. The exact output depends on the size of the pipe; smaller pipes are faster to make, so we can make more in the same amount of time. If we focus on four-inch pipes, which are a more commoditised product, we can reach up to 1,600 kilometres per year.
One of our key differentiators is the eight-inch RTPs, which only a few companies can produce at a commercial scale. Most of the companies listed on the API website produce only four-inch or six-inch pipes.

What are the key advantages of non-metallic pipes compared to conventional ones?
Two key differentiators are the lifetime of the pipe and its fast deployment. Our pipes are manufactured and transported in reels. In the field, we can deploy a single, continuous one-kilometre section without connections or welding, which are usually considered weak points.
Then there is corrosion resistance. Unlike metal pipes, which require continuous chemical injections and mechanical cleaning to manage corrosion and scale buildup, our non-metallic pipes simply do not corrode. This eliminates a major operational expense.
Our pipes have an expected lifespan of 25 years, and Baker Hughes has a strong track record in onshore and offshore applications. By comparison, Aramco typically replaces metal pipes every 7-10 years due to erosion and internal corrosion from hydrocarbons. Perhaps they cost more up front, but our pipes deliver significant savings over time. That’s why, when we talk to customers, we focus on totex – total expenditure – rather than the initial investment.

Is installation speed also an advantage?
Yes. We can install kilometres of our pipe in a single day, compared to only 200 metres for a standard carbon steel pipe. In addition, there is no need for welding, which reduces manpower requirements.
Greater deployment speed is particularly valuable in remote locations or when operators need to start production quickly. It’s also very valuable when, as was the case in Libya, governments need to rapidly restore oil production and exports. In such cases, our ability to deploy pipelines quickly can make a real difference.

Can you comment on the carbon footprint of your product?
We conducted a study, funded by Baker Hughes, when presenting our case to Aramco. We share this study with clients upon request. The results, which were validated by a third party, show that our polymers and pipe-manufacturing processes generate 60% fewer carbon emissions than steel pipes. Steel mills require large amounts of energy, which leads to higher emissions of carbon dioxide and other gases.

We know that you place great emphasis on R&D. What projects are you currently working on?
When Novel was formed, 10% of the equity was allocated to R&D to create a regional growth platform for non-metallic manufacturing. Our current focus in oil and gas is to develop a downhole tubular pipe that can perform at the same level or better than carbon steel. We are at TRL [technology readiness level] 6 with a prototype, and we are preparing for field trials.
We aim to introduce the technology globally by 2027. It was presented at ADIPEC 2024 and at the SPE symposium “Accelerating Non-Metallics: Building Resilient Energy Infrastructures” in February 2025. Many operators have shown great interest, but we want to retain the IP [intellectual property] rights before considering joint ventures or licensing the technology.

What applications are you currently pursuing for non-metallics outside oil and gas?
In renewable energy, we are testing flexible solar panels in Saudi Arabia to ensure they can withstand high temperatures, dust and humidity. We have already eliminated some technologies that didn’t perform well under these conditions, but two are still showing promise. In construction, we are close to securing approval for a collaboration with a technology provider to build a second plant and bring their technology to the region, and we are also collaborating with a leading carbon fibre company to develop solutions for the automotive industry, specifically for trucks.

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