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The formation of mineral scale is an undesirable phenomenon which is as a result of the disturbances in thermodynamics and chemical equilibria of the water system. CaCO3 scale is one of the major flow challenges in the oil industry and the crystallization process starts from thermodynamically unstable hydrated form to anhydrous polymorphic stable forms1,2 The transformation involves a series of ordering, dehydration, and crystallization processes, each lowering the enthalpy of the system where the crystallization of the dehydrated amorphous material lowers the enthalpy the most. There are two theories regarding the polymorphic transformation of a solid structure. The first suggests the transformation occurs through a direct solid transition in which the metastable phase exhibits a rearrangement of its molecules or atoms to a more stable form3. The second is valid in the presence of a solvent which allows the dissolution and the re-nucleation and growth of the stable phase4.
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EIS is one of the techniques which is frequently used for studying electrochemical reactions on a metal surface in an aqueous environment. However, one of the main challenges in using EIS is the interpretation of results. Various interpretation methods and their associated uncertainties lead to ambiguous outcomes and often end up with a biased analysis One of the methods frequently used is the so-called “equivalent electrical circuit” method which models the response of and electrochemical system by matching it to that of a combination of “analogous” electrical circuit components, such as resistors, inductors, capacitors, etc.
Many industrial processes contain H2, CO, CO2, and H2O gas mixtures, such as syngas production and processing in hydrogen, ammonia, and methanol plants. These process environments have high carbon activity, i.e. ac > 1, and low oxygen partial pressure at their elevated operating temperatures, such as in the temperature range of 400-800 °C (752-1472 °F). The high carbon activity could result in a catastrophic material degradation, i.e. metal dusting. The resulting corrosion products consist of carbon or graphite and metal particles, along with possible carbides and oxides, and cause material disintegration.
Corrosion is a common and critical issue in the oil and natural gas industry and it adversely affects the component functionality and structural integrity of infrastructure for exploration, production, transportation, processing, and CO2 sequestration. The natural gas delivery system includes 528,000 km (328,000 miles) of transmission and gathering pipelines in U.S. According to the Pipeline and Hazardous Materials Safety Administration (PHMSA) database, corrosion has caused ~25% of the natural gas transmission and gathering pipeline incidents over the last 30 years in the U.S., and 61% out of corrosion-caused incidents were due to internal corrosion.
Bridge Owners are always on the lookout for a coating system for steel bridges that will perform for the longest time, and at a reasonable price. Metallizing has long been considered one of the best coating systems but the lack of qualified applicators simply has not made it available as an economical option. The success of early metallizing encouraged the investment in metallizing for Owners and bridge fabricators, and spurred on its significant growth over the past decade.
The incidence and proliferation of microbial population in oil and gas production facilities can have undesirable consequences on upstream, midstream and downstream production systems. Microbes thrive in the anaerobic conditions encountered in these systems and are supported by nutrients and metabolites found in produced water. Although the majority of process and water injection systems are susceptible to microbial fouling, the development of microbial activity is exacerbated by specific conditions such as stagnant fluids or the presence of deposits.1 Threats of microbiologically influenced corrosion (MIC) and other challenges associated with microorganisms have become valid as more cases are reported. While MIC, biofouling (BF), and reservoir souring are three of the most common problems associated with microbes, many other production issues can be attributable to microbial activity including: employee infections, filter plugging, loss of injectivity, and metal sulfide deposits.2
This paper presents the findings of an investigation that was carried out to determine the root cause of the premature failure of Ni-coated carbon steel fittings on the water injection composite piping system installed at an oil production facility in Western Canada. The facility had been in operation since 2011 without major corrosion issues. Many of the Ni-coated fittings, which are expected to have a service life of 20 years, started to fail (developed leaks) unexpectedly after about 4 years. The core structure of composite pipe is a high-density polyethylene (HDPE) inner pipe, a middle layer of high-strength dry fiberglass, and a protective thermoplastic outer jacket. The interconnecting fittings are made of carbon steel coated with a thin, ~40 micron (1.5 mil) layer of Nickel.
In the Netherlands, a large drinking water distribution system exists which composes of a complex network of underground pipes owned by several water companies. Part of the drinking water distributions pipes consist of cast iron pipes of which some have been installed more than 80 years ago.1 To prevent leaks, it is desirable to have insight into the condition of these pipes and the risk of leakages or even pipe bursts. During local replacements and maintenance work, corrosion is regularly found in the pipes and previous research7 has indicated that Microbiologically Influenced Corrosion (MIC) may be involved in this corrosion that is found in the pipes.
MIC is a major threat to oil pipelines because it reduces the service life of pipelines and can potentially leads to catatrophes. Microbial communities commonly associated with pipeline corrosion include sulfate reducing bacteria (SRB), acid producing bacteria (APB), acetogenic bacteria and methanogens. In a field environment, SRB, APB and other microbes often live in a synergistic biofilm consortium. Sessile SRB are often the main culprit of MIC. They can utilize sulfate as the terminal electron acceptor and various carbon sources and elemental iron as electron donors. Corrosive APB biofilms are also a contributing factor in an acidic environment because they release H+ which is an oxidant.
Common materials employed in catalytic reforming unit tubes are typically resistant to carburization due to protective chromium oxide films, but under low excess oxygen conditions can become compromised and allow carbon penetration and carbide formation at the exposed surface. Embrittlement and material wastage as a result of these mechanisms causes premature failures, with production loss, in addition to shutdown maintenance and replacement costs. Carburization in this environment is simulated in this paper through a pack carburizing method designed to create an environment optimal for diffusing carbon in an ASTM 335 9Cr-1Mo tube material.
Scale is an adherent deposit of inorganic compounds precipitated from water onto surfaces. Most oilfield waters contain certain amounts of dissolved calcium, barium or strontium salts. The mineral scale can be formed by chemical reactions in the formation water itself, by mixing of formation water with injected seawater, or by mixing of the well streams of two incompatible oilfield waters. In carbonate reservoirs, when calcium is deposited as calcium sulfate or calcium carbonate scale, a loss of production and increased maintenance expenses can result. Therefore, effective mitigation of scaling potential is of importance to the oil producers.
Hydrofluoric acid (HF) is used as a catalyst in the alkylation process to react isobutane with olefin feeds to manufacture a high octane alkylate product used in gasoline blending. The HF catalyst is added in its anhydrous liquid form (< 400 ppmw H2O) but as it circulates in the reaction system, residual water in the Paper No. 17520 liquid hydrocarbon feed is absorbed by the acid such that the circulating reaction acid builds up a small percentage (0.5 to 2.0 mass%) of water. This water/HF mixture is also referred to as rich HF (RHF). In addition, the alkylation reactions also will generate fluorocarbons and acid soluble oils (ASOs).