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Carbon steels such as API 5L X65 are widely used oil and gas exploration, production and transportation service. However, these steels tend to corrode in the presence of wet CO2 and corrosion is more pronounced in the presence of dissolved salts and acids. Other metals, alloys and polymers also degrade in the presence of high pressure gaseous and supercritical CO2. The corrosion rate of carbon steels in some aqueous environments have been reported to be more than a few millimeters per year.9-10 The situation could be further exacerbated by H2S where cracking can be an issue for high strength steels.
Welded 13% Cr steel specimens were tested at 80°C in de-aerated NaCl solution (1000mg/L) for 30 days purged with (i) ~10MPa CO2 and (ii) a mixture of ~9.999MPa CO2 and ~0.001MPa H2S. One set of specimens was submerged in the solution and the other was suspended above it. Two sets of specimens were prepared: (i) for corrosion test with no applied stress, and (ii) for stress corrosion cracking (SCC) test using a four-point method by applying 100% of 0.2% proof stress. For four-point testing, specimens were extracted transverse to the weld and were tested with the weld root in tension. Post-test examination of the specimens revealed evidence of corrosion. The strained specimens tested in H2S/CO2 showed very fine features. These sub-micron features were narrow in the vapor space, but wider features were observed in the region close to the fusion line in the specimen tested in the aqueous phase.
High-pressure steel pipeline is a common, cost-effective method for transporting CO2 from its point of capture to storage sites1. In pipeline transport systems, CO2 is mostly transported in its liquid or supercritical phase, depending on the operating pressure2,3, which requires compression of CO2 gas to a pressure above 80 bar (Figure 1) and avoid a two-phase flow regime in the steel pipelines. In the USA, the longest CO2 pipelines, which transport more than 40 MtCO2 per year from production point to sites in Texas, where the CO2 is used for enhanced oil recovery (EOR), operate in the “dense phase” mode and at ambient temperature and high pressure.
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High flow velocity can have negative impact on the integrity of the oil and gas production equipment. This negative impact can manifest by the reduction of Corrosion Inhibitor (CI) efficiency: the higher the flow velocity, the lower the CI efficiency. The negative impact can also manifest by the occurrence of liquid erosion corrosion phenomena.
Structural steel, which is a critical component of many infrastructures, can suffer from deterioration of steel by reaction with air and its pollutants known as atmospheric corrosion when exposed to theenvironment. The risks associated with corrosion of newly-built and ageing infrastructure are high and their consequences costly. The recent International Measures of Prevention, Application, andEconomics of Corrosion Technologies (IMPACT) study led by NACE International (now renamed asAMPP) has shown for Canada the estimated annual corrosion cost to be $51.9 billion, which is 2.9% of Canada’s GDP.