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In-Situ Synthesis Of Corrosion Product-Polymer Composites On Carbon Steel For Enhanced Erosion-Corrosion Protection In CO2 Corrosion Environments

Picture for In-Situ Synthesis Of Corrosion Product-Polymer Composites On Carbon Steel For Enhanced Erosion-Corrosion Protection In CO2 Corrosion Environments
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Hydrocarbons still remain as a fundamental contributor towards meeting the worldwide demand for energy, despite the growth of other alternative sources such as renewable and nuclear options. Due to low cost and availability, carbon steel, remains as the most commonly used material for pipelines in down and upstream activities within the oil and gas industry. However, carbon steel is not an exceptional metal alloy from the perspective of internal corrosion resistance. The economical cost for its degradation and related failures represent 10% to 30% of the maintenance budget in petroleum industry. It is therefore crucial that the corrosion of such a susceptible steel is managed and controlled accordingly.

Product Number: 51322-17717-SG
Author: Dilshad Shaikhah, Bruce Cowe, Wassim Taleb, Anne Neville, Maalek Mohamed-Said, Richard Barker
Publication Date: 2022
Industries: Corrosion Monitoring and Control , Coatings and Linings , Coatings
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$20.00

Iron carbonate (FeCO3) is a common corrosion product found on steel surfaces in carbon dioxide (CO2)-containing aqueous environments. The formation of this corrosion product on the internal walls of carbon steel pipelines can suppress material dissolution by over an order of magnitude, providing an effective form of corrosion inhibition. One significant limitation associated with relying upon solely FeCO3 to suppress material dissolution is its propensity to be locally removed by chemical or mechanical mechanisms. Here we report a novel strategy, implemented to generate a mineral-polymer nanocomposite layer in situ on an X65 steel surface in a CO2 corrosion environment. The formation of the layer is achieved through the intercalation of functionalized polystyrene nanospheres into the developing FeCO3 corrosion product. We demonstrate the feasibility of microsphere intercalation into the FeCO3 crystal layer through appropriate functionalization. Such intercalation produces a composite structure that affords excellent corrosion protection analogous to ‘natural’ FeCO3. Additionally, the composite FeCO3 layer offers unique, enhanced physical-mechanical properties compared with naturally formed FeCO3 layer. The process provides a potential means of improving the resistance of corrosion product layers to mechanical removal, and hence, the initiation of localized corrosion.

Iron carbonate (FeCO3) is a common corrosion product found on steel surfaces in carbon dioxide (CO2)-containing aqueous environments. The formation of this corrosion product on the internal walls of carbon steel pipelines can suppress material dissolution by over an order of magnitude, providing an effective form of corrosion inhibition. One significant limitation associated with relying upon solely FeCO3 to suppress material dissolution is its propensity to be locally removed by chemical or mechanical mechanisms. Here we report a novel strategy, implemented to generate a mineral-polymer nanocomposite layer in situ on an X65 steel surface in a CO2 corrosion environment. The formation of the layer is achieved through the intercalation of functionalized polystyrene nanospheres into the developing FeCO3 corrosion product. We demonstrate the feasibility of microsphere intercalation into the FeCO3 crystal layer through appropriate functionalization. Such intercalation produces a composite structure that affords excellent corrosion protection analogous to ‘natural’ FeCO3. Additionally, the composite FeCO3 layer offers unique, enhanced physical-mechanical properties compared with naturally formed FeCO3 layer. The process provides a potential means of improving the resistance of corrosion product layers to mechanical removal, and hence, the initiation of localized corrosion.

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Austenitic stainless steels are widely used in refineries and petrochemical industries due to their good combination of properties such as workability, mechanical strength and corrosion resistance. However, one of the most important problems they show, and which can lead to failures in service, is the susceptibility to intergranular corrosion and intergranular stress corrosion cracking (IGSCC). When these materials are subjected to temperatures in the range from 500 ºC to 800 °C, the precipitation of chromium-rich carbides occurs preferentially at grain boundaries (GB).
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