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Corrosion testing of CRA in simulated CO2 injection well environments

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The number of CCS projects (planned and in operation) is increasing, and project developers need to provide firm evidence that the proposed material is suitable for these applications.
The petroleum industry has long experience with materials selection for wells, but the conditions for CO2 injection wells are somewhat different from “conventional” oil and gas wells. This is due to the high CO2 content and pressure (up to several hundred bar) which results in low pH condensed water (exact value depends on pressure and temperature, but approximately pH 3.0).

Product Number: 51323-18993-SG
Author: Gaute Svenningsen, Bjørn Helge Morland
Publication Date: 2023
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Despite the unprecedented growth in the number of carbon capture and storage (CCS) projects, this figure needs to increase to meet global climate objectives. For this to happen, there is a need for corrosion testing of materials to be used in the CO2 injection wells. The present work tested several common corrosion resistant alloys (CRA) for the Acorn CCS project.
The conditions of CO2 injection wells were simulated using two types of testing with dense phase CO2 and the Acorn CO2 specification. The first test type simulated exposure to the CO2/water interface during a shut-in event after CO2 injection, at 80°C and 180 bar. The second test type simulated exposure during a short-term transient shut-in condition where the temperature was reduced to -15°C.
The results showed that the CRAs generally had good corrosion resistance in the tested environments. No cracks were observed but crevice corrosion attacks were commonly observed on nearly all materials. Some CRAs had in addition localised corrosion attacks that were 20 – 50 μm deep.

Despite the unprecedented growth in the number of carbon capture and storage (CCS) projects, this figure needs to increase to meet global climate objectives. For this to happen, there is a need for corrosion testing of materials to be used in the CO2 injection wells. The present work tested several common corrosion resistant alloys (CRA) for the Acorn CCS project.
The conditions of CO2 injection wells were simulated using two types of testing with dense phase CO2 and the Acorn CO2 specification. The first test type simulated exposure to the CO2/water interface during a shut-in event after CO2 injection, at 80°C and 180 bar. The second test type simulated exposure during a short-term transient shut-in condition where the temperature was reduced to -15°C.
The results showed that the CRAs generally had good corrosion resistance in the tested environments. No cracks were observed but crevice corrosion attacks were commonly observed on nearly all materials. Some CRAs had in addition localised corrosion attacks that were 20 – 50 μm deep.

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In Upstream, CRAs (Corrosion Resistant Alloys) are widely selected to handle seawater and brines in piping, valves, pumps, heat exchangers, vessels, and seawater injection1-4. Also, disposal of produced water is commonly performed through injection into spent fields. Water from a variety of sources including produced water, seawater and surface/fresh water may also be injected to create pressure drive for existing fields. Usually dissolved oxygen (DO) is not fully controlled when there are multiple sources of injection water and sometimes even possibility of injection of fully oxygenated water exists. For oxygenated seawater, the PREN (Pitting Resistance Equivalent Number = %Cr + 3.3 *(%Mo + 0.5 %W) + 16 %N) shall be >40 and limits are applied to the temperature4. Other applications involve Solid CRA or cladded production pipelines which may get flooded with seawater during installation and precommissioning.
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