Objective Driven by the accelerated development of the new energy system and growing bottlenecks for green power accommodation, green hydrogen-based energy represents a critical technical solution to a series of systemic challenges. Hydrogen-based energy carriers feature distinct transport properties and impose different requirements on pipeline networks in terms of technical standards, operating parameters and safety specifications. However, the economic optimization of transport pathways remains insufficiently explored, calling for dedicated research.

Methods Based on the theoretical framework of the substance-energy network, this study establishes a life-cycle comprehensive cost model covering resource-side conversion, interregional transport, and demand-side conversion. Taking the Xinjiang-to-Yangtze River Delta route as the baseline scenario, we quantify the costs of 18 hydrogen-based energy transport pathways under four end-use cases: direct hydrogen consumption, methane consumption, methanol consumption, and synthetic ammonia consumption. A sensitivity analysis of key parameters is performed, and the cost components of each segment are quantitatively decomposed.

Results The results show that for end-use hydrogen applications, direct hydrogen transport delivers the best economic performance (CNY 2.06–2.93/kg), substantially outperforming all pathways relying on hydrogen carriers. For end-use methanol, synthetic ammonia and methane applications, the lowest overall cost is achieved when energy conversion is implemented at the resource side prior to transporting the corresponding media. Repurposing existing oil and gas pipelines can effectively reduce interregional transport costs and improve the system’s resilience against cost fluctuations.

Conclusion This study proposes strengthening the planning of strategic hydrogen transport corridors, advancing technological upgrades for storage, transport and conversion via innovation, promoting coordinated upstream–midstream–downstream industrial layout, and expanding full-chain “production–transportation–conversion–utilization” scenarios. The findings provide decision support for developing hydrogen transport systems under the new substance-energy network.