Magnesium Sacrificial Anode Case Study 200km Underground Gas Pipeline Cathodic Protection Middle East Project
June 17, 2026
Case Study: Magnesium Sacrificial Anode Cathodic Protection for 200km Underground Gas Pipeline in the Middle East
Executive Summary
This case study documents the successful deployment of High Broad's high potential magnesium sacrificial anodes for a 200-kilometer underground natural gas transmission pipeline project in the Middle East. The project required a reliable, long-term cathodic protection (CP) solution capable of withstanding high-resistivity desert soil conditions while maintaining a service life of over 15 years.
Client Background
The client is a state-owned oil and gas transmission company operating a major pipeline network across the Middle East. With over 2,000 kilometers of buried steel pipelines under management, the company sought to expand its network with a new 200km trunk line connecting gas fields to a central processing facility. Corrosion protection was identified as a top priority due to the aggressive soil conditions and the high cost of pipeline repair and replacement.
Project Challenge
The project presented several technical challenges that required careful anode selection and CP system design:
- High Soil Resistivity: Desert soil at 5,000-15,000 Ω·cm required high driving voltage anodes for adequate protection current.
- Extended Service Life: Pipeline designed for 30-year operation needed anodes with 15+ years of reliable performance.
- Remote Installation: Remote desert terrain required prepackaged anode systems with no on-site backfill mixing.
- Environmental & Quality Compliance: All materials required RoHS/REACH compliance and ASTM G97/GB/T 17731-2015 certification with mill test certificates.
Solution: High Broad Magnesium Sacrificial Anode System
The client selected CHINA HUNAN HIGH BROAD NEW MATERIAL CO.,LTD as the primary anode supplier for 1,200 units of prepackaged high potential magnesium sacrificial anodes:
| Parameter | Specification |
|---|---|
| Anode Type | High Potential Prepackaged Magnesium Sacrificial Anode |
| Alloy Grade | M1C High Potential Magnesium Alloy |
| Open Circuit Potential | -1.70V to -1.75V (vs Cu/CuSO₄) |
| Current Efficiency | ≥ 50% (ASTM G97 certified) |
| Current Capacity | ~1,200 A·h/kg |
| Anode Weight | 14.5 kg (32 lb) per unit |
| Backfill Composition | 75% Gypsum + 20% Bentonite + 5% Sodium Sulfate |
| Cable Type | XLPE Insulated AWG Copper, 10mm² cross-section |
| Bag Material | Durable biodegradable cotton cloth |
| Packaging | Wooden case with waterproof inner layer, sea-worthy |
| Design Service Life | 15-25 years (soil resistivity dependent) |
| Standards | ASTM G97, GB/T 17731-2015, ISO 9001 |
Key Product Features Delivered
Prepackaged Backfill Installation
Each anode was supplied as a complete prepackaged unit with precisely formulated backfill (75% gypsum, 20% bentonite, 5% sodium sulfate) in a durable cotton cloth bag. This eliminated on-site backfill preparation, reducing installation time by 30% while ensuring consistent performance across all 1,200 points.
XLPE Cable for Harsh Environment
All anodes featured XLPE insulated AWG copper cables (10mm²), selected over standard PVC for superior resistance to desert heat, moisture, and abrasion. Low-resistance welded connections below 0.001Ω ensured reliable and consistent current delivery across all 1,200 units.
Certified Quality and Traceability
Every production batch underwent electrochemical testing, spectrometer analysis, and visual inspection. Mill test certificates covering open circuit potential, current efficiency, and alloy composition were provided for all 1,200 units, ensuring full traceability from raw ingot to finished anode.
Project Results
The cathodic protection system was commissioned in early 2024 following a 45-day installation period. Key performance indicators included:
| Performance Metric | Result |
|---|---|
| Pipe-to-Soil Potential | -0.95V to -1.05V (vs Cu/CuSO₄), exceeding NACE -0.85V criterion |
| Anode Current Output | Stable at 45-55 mA per anode, consistent with design predictions |
| Installation Efficiency | 30% faster than traditional on-site backfill methods |
| Anode Consumption Rate | Uniform consumption pattern confirmed at 6-month inspection |
| Field Failure Rate | 0% — zero field failures across all 1,200 installed units |
| On-Time Delivery | 100% — all 1,200 units delivered ahead of schedule in 4 shipments |
Client Feedback
"High Broad's prepackaged magnesium anodes exceeded our expectations. The factory-assembled backfill saved significant installation time in remote locations, and their technical team provided excellent support throughout the CP design phase. We have since placed two additional orders for expansion projects."
— Senior Corrosion Engineer, Middle East Gas Transmission Company
About the Supplier
- 17+ Years Experience: Established in 2006, specialized in magnesium sacrificial anode manufacturing with ISO 9001 certified production and ASTM G97 compliance.
- Integrated Production: Full chain from raw magnesium ingot to finished anode, ensuring quality traceability and competitive factory-direct pricing.
- Global Export: 80-90% of production exported to Middle East, Europe, Southeast Asia, and North America with annual sales of USD 15-20 million.
- OEM & Engineering: Custom anode dimensions, cable specs, backfill formulations, private labeling, and free CP system design consultation available.
Conclusion
This 200km gas pipeline project demonstrates the reliability of High Broad's prepackaged magnesium sacrificial anodes in demanding desert environments. The M1C alloy, optimized backfill, and XLPE cable combination delivered exceptional CP performance with zero field failures. The client continues to specify High Broad anodes for ongoing expansion projects. Contact our engineering team for a customized cathodic protection proposal for your project.