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This study was conducted to determine the root cause of aggressive corrosion due to wet NH4Cl salt deposition in reactor effluent streams in hydroprocessing units. In addition corrosion resistance and behavior of carbon steel and alloys in high-concentration NH4Cl solutions were investigated.
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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.
CO2 stream in CCS system usually contains impurities, such as water, O2, SO2, NO2, H2S, and other trace substances, which could pose a threat to internal corrosion and integrity of CO2 transportation pipelines. The general and localized corrosion behavior of API 5L X65 mild steel were evaluated using an autoclave both in water-saturated CO2 and CO2-saturated water environments in the presence of varying concentrations of O2. Experiments were performed at 25 °C and 35 °C, 8 MPa and 35 °C, 4 MPa to simulate the conditions encountered during dense, supercritical and gaseous CO2 transport. General corrosion rates were obtained by weight-loss method. The surface morphology of the coupons was examined by scanning electron microscopy (SEM). Results indicated that general corrosion rates at each O2 concentration in CO2-saturated water environment were much higher than those in water-saturated CO2 environment. The corrosion rates did not increase with increasing O2 concentration from 0 to 2000 ppm; instead the corrosion rate reached a maximum with 1000 ppm O2 at 25 °C, 8 MPa and 50 ppm O2 at 35 °C, 8 MPa in water-saturated CO2 environment and 50 ppm at 25 °C, 8 MPa and 100 ppm at 35 °C, 8 MPa in CO2-saturated water environment. However, the change trend of general corrosion rate with O2 content at 35 °C, 4 MPa was different from that in 25 °C and 35 °C, 8 MPa both in water-saturated CO2 and CO2-saturated water environments. Localized corrosion or general corrosion rate of over 0.1 mm/y was identified at each test condition both in a water-saturated CO2 and CO2-saturated water environments. When O2 was added, coupon surfaces were covered by a more porous corrosion product scale. A final series of tests conducted with the addition of 100 ppm and 2000 ppm O2 in CO2 environment with 60% relative humidity (RH) and 80% RH revealed that no localized corrosion was observed and the general corrosion rates were lower than 0.1 mm/y at 25 °C and 35 °C, 8
The recent development of ASTM D8370-22 provides a field-applicable technique for measuring impedance on protective coatings. The test method expands the use of electrochemical impedance spectroscopy (EIS) beyond the laboratory and standardizes the approach for various applications to polymeric coatings on conductive substrates, e.g., barrier coatings on steel structures. Example applications include condition assessments and quality control testing.
Epoxy coatings are a mainstay of the protective and marine coatings markets. Used as intermediate coats over inorganic and organic zinc rich primers or used as direct-to-metal primers in coating systems, epoxy coatings are widely recognized for their versatility and the excellent corrosion resistance they provide. One drawback to current epoxy coating technology is that it requires separate packaging for the epoxy resins and the amide or amine hardeners because the chemical reaction between these materials causing the applied film to cure to a dry state would also cause the bulk material to gel if packaged together (pot life).