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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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Carbon Dioxide (CO2) corrosion of carbon steel (sweet gas corrosion) poses a serious problem in oil and gas production, since most used materials are low alloyed carbon steels, which are not corrosion resistant. Basically, the main aspects of CO2 corrosion are well known today, and the parameters are temperature, CO2 partial pressure, pH value, and flow velocity [1-2]. CO2 dissolves in brine to form an acidic solution that corrodes carbon steel equipment.
In China, some underground gas storages (UGS) would be built to reserve the gaseous coal gas (CO, H2, CO2, H2O, etc.). Gaseous hydrogen induced hydrogen embrittlement (HE) and CO2 corrosion could possess great threat to the safety of OCTG in UGS. Fitness-for-purpose research of OCTG materials is urgently expected to screen out the suitable material for tubing application in UGS.HE resistance and CO2 corrosion of OCTG materials (C110, 3Cr-90S, 13Cr-110 and 13Cr-110S) were investigated by slow strain rate testing and weight loss tests in UGS environments containing CO2 and H2. SSRT results show that both elongation ratio and reduction in area ratio of C110, 13Cr-110 and 13Cr-110S were more than 80%, except for 3Cr-90S. In addition, 3Cr-90S and 13Cr-110 tested in H2/CO2 environments possessed embrittled regions and secondary cracks, respectively. Weight loss test results show that C110 and 3Cr-90S exhibited high corrosion rates, which were classified as severe corrosion followed by qualitative categorization of corrosion rates for oil production systems in NACE RP0775. For stainless steels (13Cr-110 and 13Cr-110S), the corrosion rates were very low (low corrosion). Combined with the above results, 13Cr-110S could be the suitable OCTG material for UGS containing gaseous coal gas.
The aim of this work is to identify an approach to materials selection and corrosion control that can address the specific requirements of a Carbon Capture and Storage (CCS) project. This work is largely based on the accumulated knowledge and expertise that has been published. Besides the direct guidance from this document, specific topics may require more detail that can be found in the references.
Laboratory testing of corrosion inhibitors under high temperature high pressure (HTHP) conditions is challenging. HTHP testing has been traditionally performed in closed systems with fixed liquid/gas volume and testing results are usually influenced/compromised by the accumulation of ferrous ions and corrosion products. The aim of the work is to optimize corrosion inhibitor testing conditions at HTHP to generate results of better reliability. The corrosion of carbon steel by CO2 at HTHP was assessed using small working electrodes of large liquid volume-to-sample surface area in autoclaves. The effect of CO2 partial pressure was also investigated. The blank and inhibited corrosion rates were monitored by linear polarization resistance (LPR) and the morphology of coupon surface was measured by vertical scanning interferometry (VSI). The testing results were deemed to be more representative of the field service environment when the amount of ferrous ions and corrosion products was reduced due to the usage of small working electrodes.
A dense phase or supercritical CO2 pipeline is a crucial state in the oil and gas sector, particularly when it comes to enhanced oil recovery (EOR) and carbon capture and storage (CCS)1. The process of CCS involves three stages: capture from sources (e.g., cement factories and power plants), transportation process, and storage. Generally, these pipelines carry CO2 from different industrial facilities to geological formations.
Corrosion resistant alloys (CRAs) are used for many pipeline and wellhead components associated with oil and gas production environments but may be considered too costly for longer crude oil and natural gas production lines. Mitigation of internal corrosion for these types of pipelines is normally carried out by batch treatment or continuous injection of corrosion inhibitors, especially the surfactant type of organic inhibitors, which are more economical than using a CRA.
CO2 captured from different sources for carbon capture and storage (CCS) will contain impurities. Although it is technologically possible to treat CO2 to near 100% purity in the gas conditioning process, it is preferable to have fewer rigid specifications to reduce both operational and capital costs. From a corrosion point of view, SOx, NOx, H2S, and O2 are considered to be the most aggressive impurities.
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.
Over the past decade, there has been increasing interest in the corrosion behavior of carbon steels in supercritical CO2 conditions. Unlike the case of carbon capture and storage (CCS) where small amounts of water are present, the exploitation of fields with high pressures of CO2 needs to consider the presence of formation water, which presents strong corrosivity. It has been reported that the aqueous corrosion rate of carbon steel at high CO2 pressures (liquid and supercritical CO2) without protective FeCO3 corrosion product layers is very high (>20 mm/y) due to the high concentrations of corrosive species such as H+ and H2CO3.1-5 Steels with low Cr contents (i.e., 1% Cr and 3% Cr) have shown no beneficial effect in terms of reducing the corrosion rate to admissible values.6 Therefore, controlling corrosion in these cases usually involves the use of corrosion resistant alloys (CRAs) or corrosion inhibitors (CI). Adequate protection of carbon steel was achieved by applying CI in high pressure CO2 environments.6