Objective Against the backdrop of carbon peaking and carbon neutrality goals and the energy transition, methanol has become an important clean energy source and energy carrier. Large-scale methanol deployment calls for safe and efficient storage and transport systems. Batch transportation of methanol in existing product pipelines can make full use of existing pipeline assets and reduce the capital cost of building dedicated pipelines. However, because methanol differs from conventional refined products in physical properties and transport behavior, its process compatibility needs to be systematically validated through industrial trials.

Methods An industrial trial of batch methanol transportation was conducted on an in-service long-distance product pipeline. The evaluation covered pipeline hydraulic safety, evolution of the batch interface/mixing zone, terminal receiving control, impact on product quality, and compatibility of key equipment. Field monitoring, dynamic simulation, mixture sampling and testing, and equipment inspections were used to systematically study operational response patterns during batch transportation. The evolution of the methanol–gasoline mixing zone under different operating conditions and the corresponding process control requirements were analyzed, providing measured data for terminal receiving and cutting plans and for optimizing operating parameters.

Results The industrial trial covered a full batch cycle, high and low flow rates, and multiple start-up and shutdown conditions. The pipeline system operated stably. The existing process configuration met the requirements for batch methanol transportation, and methanol–gasoline mixing and terminal receiving were generally controllable. Key equipment, including transfer pumps, valves, and seals, operated normally and showed good compatibility with methanol service. No overpressure, low pressure, or leakage occurred, confirming system safety.

Conclusion Batch methanol transportation in existing product pipelines is technically feasible. This study provides technical support for transforming traditional oil pipeline networks into multi-energy transportation platforms. Future work should integrate long-term operating data, multi-product transport conditions, and intelligent monitoring technologies to improve methanol pipeline transport processes and control strategies. This will promote the efficient use of existing pipeline resources and support the upgrading of energy transport systems.