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Material selection for supercritical CO2 transport

TWI Bulletin, March - April 2011

Understanding materials' behaviour and assessing their integrity when in contact with supercritical CO2 is crucial to the success and sustainable implementation of carbon capture and sequestration plans.

Shiladitya Paul
Shiladitya Paul
Shiladitya Paul joined TWI's Metallurgy, Corrosion and Surfacing Technology Group as a Project Leader in 2008. Prior to joining TWI, he obtained a PhD in Materials Science from the University of Cambridge. At TWI he is involved in many inter-disciplinary projects on corrosion mitigation of offshore structures using coatings and materials assessment for carbon capture and storage applications. He has published a number of papers in the field of coatings in peer-reviewed journals and is also an author of a book.

 



 

Paul Woollin
Paul Woollin
Paul Woollin is currently Research Director. His work at TWI has concentrated on the performance of welded advanced stainless steels.

 



 

Richard Shepherd
Richard Shepherd
Richard Shepherd joined TWI in 2007. For the 25 years prior to this he has worked for various R&D and engineering organisations, working with engineering applications for polymers; many in the oil and gas sector.

 



 

Amir Bahrami
Amir Bahrami
Amir Bahrami manages TWI's Oil, Gas and Chemical industry sector, and is currently based at TWI's office in Houston particularly related to upstream activities including all TWI JIPs. His work includes hydrogen induced stress cracking of subsea components, fatigue performance of riser girth welds under environmental degradation as well as testing and qualification of materials and complex structures such as flexible pipes.

 



Of critical importance for the successful and cost effective operation of existing and new-build,infrastructure components, is quantifying materials' integrity in representative high pressure and supercritical CO2 environments. This will enable confident materials selection, safe operation and accurate remaining life assessment to avoid the consequences of failure, as well as removal and replacement. One of the most critical technical issues is quantifying degradation of different transport components, including pipes, pumps and valves, in CO2 as a high pressure gas or as a supercritical fluid, particularly in the presence of impurities. As Shiladitya Paul, Paul Woollin, Richard Shepherd and Amir Bahrami report, although there is considerable experience of testing materials in lower pressure CO2, there are no standard test methods and few data for supercritical CO2. This work explores the state-of-the-art in this field and highlights the areas of technology gap.


Climate change is a major concern for most governments around the world. Evidence attributing this to anthropogenic activities in the last century or so has recently gained importance. Activities such as combustion of fossil fuels generate compounds, amongst others, carbon dioxide (CO2), a greenhouse gas (GHG) whose release into the atmosphere is widely acknowledged as the main cause of global warming. It is anticipated that fossil fuels will remain a major source of energy in the foreseeable future, both in the UK and internationally, with global demand for coal set to increase by about 70% by 2030. Finding a path that mitigates emissions while using fossil fuels to meet energy needs is indeed a challenge for government and industry alike.

Carbon dioxide capture and storage (CCS), a carbon sequestration method, is recognised as one means of using fossil fuels whilst minimising impact upon the environment. Primarily, this involves capturing the arising CO2 from industrial and energy-related sources, separating it from some other gases if needed, compressing it (leading to the formation of supercritical1 or dense phase CO2), and then transporting and injecting it into storage sites such as depleted oil and gas wells or saline aquifers to ensure long-term isolation from the atmosphere.

Although the CCS concept is based on a combination of known technologies, large scale adoption and integration of individual existing technologies poses challenges. These technological challenges range from corrosion and structural integrity of materials to safety inspection during operation. Understanding these issues, mitigating if necessary, and filling the technology gaps in full scale implementation of CCS is important for its wider adoption as a CO2 emission reduction tool.

Industrial experience in handling CO2

Handling of CO2 for industrial operations is not a new technology, but the volumes, pressures and distances involved in wider adoption of CCS pose challenges. CO2 as an industrial gas has been transported via tankers over short distances. This however becomes less economical for transportation of large volumes of dense phase CO2. In these cases pipeline transport becomes more attractive as has been used in enhanced oil recovery (EOR). Using CO2 in EOR projects has the advantage of adding a value to the CO2, eg oil producers in the USA are willing to pay between nine and 18US$/ton of 'end of pipe' delivered CO2.

EOR has been an industrial practice in the oil and gas sector for over 35 years, mostly in the United States. Over this time, the oil and gas industry has developed many technologies and operating practices for efficient functioning of over 13,000 wells, over 3,900 miles of high pressure CO2 pipelines and injected over 600 × 106 tonnes of CO2 (Table 1).

Table 1. Some existing long distance CO2 pipelines

Pipeline Location Operator CO2 capacity
Mt/y
Length, km Year finished Origin of CO2
Cortez USA Kinder Morgan 19.3 808 1984 McElmo Dome
Bravo USA BP 7.3 351 1984 Bravo Dome
Sheep Mountain USA BP/Occidental Permian 9.5 657 - Sheep Mountain/Bravo Dome
Canyon Reef Carriers USA Kinder Morgan 5.2 225 1972 Gasification Plants
West Texas and Lano Lateral USA Trinity Pipeline 1.9 290 - -
Val Verde USA Petrosource 2.5 130 1998 Val Verde Gas Plants
Bati Raman Turkey Turkish Petroleum 1.1 90 1983 Dodan Field
Weyburn USA and Canada North Dakota Glassification Co 5 328 2000 Gasification Plant

As a result, the USA produces over 245,000 barrels of oil per day via EOR [Parker et al, 2009]. Many of the technologies and practices that have been developed for, and the experience gained in, CO2 EOR are invaluable for CCS.

In 1972, the first CO2 injection project for EOR was initiated in the SACROC unit (Scurry Area Canyon Reef Operators Committee). The project used various corrosion resistant materials to avoid corrosion problems in injection operations (Table 2).

Table 2. Typical construction materials for CO2 injection wells [Parker et al, 2009].

Component Materials
Upstream metering and piping runs 316SS, Fibreglass
Christmas tree 316SS, Ni, Monel
Valve packing and seals Teflon, Nylon
Wellhead
Tubing Hanger
Tubing
316SS, Ni, Monel
316SS, Incoloy
GRE lined carbon steel, IPC carbon steel, CRA
Tubing joint seals
ON/OFF tool, profile nipple
Seal ring (GRE), coated threads and collars (IPC)
Ni-plated parts, 316SS
Packers Internall coated hardened rubber of 80-90 durometer strength (Buna N), Ni-plated parts
Cements and cement additives API cements and/or acid resistant speciality cements and additives

In any wetted region, Type 316 austenitic stainless steel was used for valve trim, metal piping, etc. In selected cases, operators use fibreglass piping in upstream metering/piping runs.

Currently, glass reinforced epoxy (GRE) lined tubing, comprising an internal fibreglass liner, or sleeve, bonded to the inside of a steel pipe, is used. Some CO2 pipelines are also constructed from epoxy-coated and polyethylene-lined carbon steel. Internally plastic coated (IPC) tubing consisting of a sprayed coating (phenolics, epoxies, urethanes or novolacs) to the inside of a steel pipe is also used.

Seal rings are commonly used for making up GRE lined tubing joints. For seals and joints elastomers are used. These include Buna-N and Nitrile rubbers with an 80-90 durometer hardness reading. For packers Teflon and Nylon are used for seals, whilst nickel plating is often used on all wetted parts and internally coated hardened rubber elastomers of 80-90 durometer hardness are used to circumvent CO2 permeation [Parker et al, 2009]. Viton valve seats and flexitallic gaskets are typically specified in the USA for CO2 pipeline seals.

However, pipelines suffer from pressure drops due to drag along the transportation route, which can result in two phase flows, and operational and material problems (eg cavitation) in components such as booster stations and pumps.

From the foregoing therefore, it would seem that the oil and gas industry in the US has used CO2 without much concern. However, to avoid problems with CO2 transport its quality, ie allowable impurity levels, has been specified (Table 3).

Table 3. CO2 quality restrictions for EOR, and recommencations for CCS [De Visser et al, 2008]

Constituent/parameter Limiting value Reason for concern
CO2 >95% >95.5% Minimum miscible pressure for EOR
N2 <4% <4% Minimum miscible pressure for EOR
Hydrocarbons <5% <4% Minimum miscible pressure for EOR
H2O <650ppm <500ppm Corrosion
O2 <10ppm - Corrosion/reaction with odorants
H2S <10-200ppm <200ppm Corrosion/Health & Safety
Total sulphur <1500ppm - Safety
Glycol <4 x 10-2ml/m3 - Operations
Temperature <48.9°C - Materials operating limit

These limiting values ensure that corrosion is minimised while maintaining operational safety. For transport of CO2 from power plants for CCS applications, these specifications will probably need to be changed to accommodate the presence of impurities as purification will incur cost penalties. A compromise will probably be reached to minimise cost of purification while still using cheap pipeline materials (eg X-60, X-65 carbon steels) for transport.

A number of pilot plants and some commercial CO2 storage projects are already underway (Table 4). Most of the working projects are associated with gas processing such as Sleipner (Statoil), Snohvit (Statoil) and In Salah (BP, Sonatrach, Statoil). The first commercial CO2 storage project started in 1996 at Sleipner Vest, Norway. At Sleipner, wet CO2 is injected into the Utsira formation using 13%Cr steel casing joints to minimise corrosion. In order to optimise life, solution annealed 25%Cr duplex stainless steel has been chosen for the tubulars used in injection. 22%Cr duplex stainless steel has also been used in topside equipment. Due to the presence of approximately 150ppm H2S in this field, sulphide stress corrosion cracking was also considered. For machined components alloy 625 is used. This project, being a CO2 injection system to an offshore field, proved that CCS is a technically feasible method for climate change mitigation. It further demonstrated that storage is both safe and has low environmental impact. More than 10Mt of CO2 extracted from gas processing has been injected into the deep sub-sea Utsira saline formation. Monitoring the injected CO2 in the geological reservoir using seismic surveying indicates that most of the CO2 collects in a stack of accumulations under thin layers of clay within the sand. With time the natural trapping mechanism will change from structural and stratigraphic, through to solubility and finally to mineral trapping; which is considered the most permanent and secure form of geological storage. At In-Salah (Algeria), BP, Sonatrach and Statoil inject ~1.2Mt/y CO2 obtained from gas processing into a saline aquifer north of the gas reservoir. It is estimated that ~17Mt of CO2 will be injected over the life of the project.

Table 4. Selection of current and planned CO2 capture and storage projects

Project name Location Leader/Coordinator CO2 source CO2 sink Approx storage rate,
Mt/y
Start year
Sleipner Norway Statoil Gas processing Offshore saline formation 1 1996
Weyburn Canada Pan Canadian Coal gasification Onshore EOR 1 2000
In Salah Algeria BP Gas processing Depleted gas reservoir/deep saline formation 1.2 2004
Snohvit Norway Statoil LNG processing Depleted gas reservoir 0.7 2008
Schwarze pumpe Germany Vattenfall Coal combustion Depleted gas field - 2008
CO2SINK Germany German Research Centre for Geosciences (GFZ) Hydrogen production Sandstone reservoir 0.03 2008-2009
Gorgon Australia Chevron Texaco Gas processing Offshore saline formation/deep water sandstone - 2009
Total Lacq France Total Oil combustion Onshore depleted natural gas field 0.08 2010 (Europe's first full chain CCS demonstration project)
AEP mountaineer USA American electric power Coal combustion Deep saline formation 0.1 2009-2011
Scottish & Southern UK Scottish and Southern Coal combustion Depleted gas fields 1.7 2011 (Small scale demonstration started in 2009)
ZeroGen Australia Stanwell corporation Coal combustion Deep saline aquifer 0.4 2012
UK CCS UK - Coal combustion Offshore storage - 2014
GreenGen China China Datang group Coal combustion Sequestration/EOR - 2015-2020
E. On
Benelux
The Netherlands E. On Coal combustion Depleted offshore gas field - Undecided

Clearly there exists a degree of experience in storage of CO2 in geological formations in full scale applications. This experience will form an essential part in the CCS chain.

Materials issues in transport of CO2

Corrosion of Steel Pipelines in CO2-containing environments

General remarks

On the transport and storage side, the materials degradation issues arise from corrosion in wet CO2 environments. On the capture side, there are a few issues regarding the materials used in technologies such as chemical absorption using amines. In addition to corrosion, thermal and mechanical stability and lifetime of the components used for CCS are also important.

Choice of materials is critical for the success of CCS. Low alloy carbon steel pipelines have been used for transportation of high pressure CO2 without significant corrosion issues, but in these cases, CO2 was dried to <100ppm water to eliminate corrosion risks [Seiersten and Kongshaug, 2005]. CO2 in the presence of water, however, will form highly corrosive carbonic acid. The studies related to the impact of wet CO2 on corrosion of steels have mostly been limited to up to 20bar in support of oil and gas production requirements with extensive publications and predictive models generated (Table 5). At higher pressures experimental data are sparse.

Table 5. Existing prediction models for corrosion in high pressure CO2 environments [Seiersten and Kongshaug, 2005]

Model Developers(s) Temperature, °C Pressure, bar pCO2 pH
Min Max Max Min Max Min Max
de Waard-Milliams de Waard and Milliams,
1975/Shell, IFE
0 140 -   10    
HYDROCOR Shell 0 150 200   20    
Cassandra 98 BP     -   10    
NORSOK Statoil, Saga, IFE 20 150 1000   10 3.5 6.5
CORMED Elf   120 -        
LIPUCOR Total 20 150 250   50    
KSC IFE (Joint Industry Project) 5 150 200 0.1 20 3.5 7
Tulsa University of Tulsa 38 116 -   17    
PREDICT InterCorr International 20 200 -   100 2.5 7
Ohio Ohio University 10 110 20        
SweetCor Shell 5 121 - 0.2 170    

Dry supercritical CO2 (pressure 98-158bar) resulted in limited corrosion (approximately 1.3µ m/yr) of type 304 stainless steel at temperatures between 149-238°C for up to 380 days [Propp et al, 1996]. Similarly for AISI 1080 C-Mn steel, low corrosion values ~10 µm/yr have been measured at 90-120bar and 160-180°C during 200 days. Tests conducted at lower temperatures (3-22°C) at 140bar CO2, <1000ppm H2O and with 600-800ppm H2S gave corrosion rates <0.5 µm/yr for X-60 carbon steel [Seiersten, 2001].

Quantitative measurements of corrosion in wet CO2 at high pressure are sparse. Some investigations concluded that the corrosion rate is sensitive to the pH of the system and that at pH of approximately 3.5 the corrosion rate can be as high as 13mm/y at 50bar CO2 pressure. At 80bar CO2 pressure, X65 C-Mn steel corroded at a rate of 4.6mm/y at 50°C in aqueous solutions [Seiersten and Kongshaug, 2005]. A study conducted in an autoclave filled with 1M NaCl solution at 80°C and CO2 pressure up to 50bar suggested that pH changes of the test solution caused by the corrosion process affects the corrosion rates at high CO2 pressures.

The corrosion rate at approximately pH 3.5 was about 10mm/y at 5bar and 15mm/y at 50bar. Under floating pH conditions corrosion rates at 5 and 50bar CO2 were similar [Seiersten and Kongshaug, 2005]. Generally it is accepted that the corrosion rates decrease with increasing pH. This is due to the formation of a protective carbonate scale. The experimental values often contradict the models available for CO2 corrosion in oil and gas production. This limitation exists as these models have been developed to cover a pressure range relevant to oil and gas transportation, ie up to 20bar CO2 pressures. These models, summarised in Table 5, with two exceptions, are restricted to <50bar, with most being only valid up to 20bar.

Factors influencing CO2 corrosion

Corrosion of materials in contact with CO2-containing fluid is dependent on various factors. These include: (i) water chemistry, (ii) operating conditions, and (iii) material type.

Effect of water chemistry

As studies indicate that an aqueous phase is required for corrosion in the presence of CO2 in oilfield environments, understanding the aqueous chemistry becomes important. The formation of a protective, stable carbonate scale has been linked to reduced corrosion rates in CO2-containing solutions. Supersaturation plays an important role in the formation of a protective carbonate layer in steel. The stability of this layer is dependent on the solution chemistry such as the presence of dissolved salts, compounds affecting the pH, corrosion inhibitors etc.

The pH has a direct effect on the CO2 corrosion rate. It influences both the electrochemical reactions that lead to dissolution of iron and the precipitation of protective, corrosion inhibiting, carbonate scales.

However, the indirect effects of pH that relate to scaling conditions are equally important. High pH results in decreased solubility, increased precipitation and higher scaling tendency of iron carbonate. For example, an increase in the pH from four to five causes a five-fold reduction in the solubility of iron carbonate; for an increase in pH from 5 to 6, this reduction is around 100 times. A high pH does not always mean a reduction in corrosion rate. Supersaturation plays an important role in scale formation and its stability. For example, a low supersaturation at pH 6 may result in very little alteration of corrosion rates as relatively poor, unprotective carbonate scales form. At pH>6.6, higher supersaturation results in lower corrosion rates, due to faster precipitation, and formation of more protective scales. There are other indirect effects of such as the formation of non-siderite scale. If acetic acid (HAc, where Ac=CH3COO) is present in the aqueous media, increase in pH stabilises the acetate ions (Ac-).

The presence of organic acids is reported to increase the oxidising power of H+ by raising the limiting diffusion current for cathodic reduction. The quantity of such organic acids in the produced water may vary from 500-3000ppm of which acetic acid (or ethanoic acid) is often the major constituent. Although top-of-line corrosion is the most widely studied CO2 corrosion in connection with HAc, bottom-of-line corrosion of pipelines containing multiphase fluids is also known. Increase in un-dissociated HAc increases the corrosion rate of carbon steel as it provides a reservoir of H+ ions over and above that determined by the solution. Further work in the field also suggested that HAc is particularly harmful in its un-dissociated state. At low PCO2 the presence of such acetic acid also tends to form more soluble iron acetate (as opposed to iron carbonate), thus increasing corrosion rates.

Corrosion inhibition can occur either by: (i) addition of inhibitors during oil exploration or (ii) in-situ inhibition by components present in the crude oil. While the former is externally controlled by addition of inhibitors to achieve corrosion protection by surface coverage, the control over the latter is difficult as it is dependent on the crude oil composition and hydrodynamic conditions.

Glycols and methanols are often added (sometimes >50wt%) to prevent hydrate formation. The mechanisms that control CO2 corrosion in the presence of such inhibitors are not entirely understood. However, it has been assumed that the main inhibitive effect of such additions come from decreased activity of water due to dilution. Corrosion rates of nearly 0.03µm/y were reported for type 304 stainless steel when 1wt% water in the CO2-containing corrosive environment was replaced with 10wt% methanol at approximately 190°C and 150bar. In the presence of 1wt% water in similar conditions a corrosion rate >10times was observed. Glycols and amines, often used in CO2 capture plant, have an effect on the hydrate formation and corrosion rate. At lower CO2 pressures, a 50/50 blend of water/glycol resulted in 50% reduction in corrosion rate of ordinary carbon steel when compared to a system devoid of glycol.

A recent report on low temperature experiments (at circa 31°C) in a high pressure CO2 environment (approximately 79.3bar) suggested a similar outcome [Thodla et al, 2009]. A reduction of two orders of magnitude in corrosion rate, from 1-3mm/y to 0.01-0.02mm/y, was reported when a mixture of 100ppm water and 100ppm monoethanol amine (MEA) was used instead of 100ppm water only.

Crude oil often acts as an inhibitor by affecting the wettability of steel to produced water. The presence of crude oil prevents water from wetting the steel surface thereby reducing corrosion rates. It is also speculated that certain components present in crude oil get adsorbed on the steel surface and affect corrosion rates. The nature of such interactions is largely unknown, but the concentration of aromatics, resins, alkanes, asphaltenes, nitrogen, sulphur, oxygen and fatty acids have an effect on the degree of inhibition.

The produced water in many oil and gas wells has high total dissolved solids (TDS) content (often TDS>10wt%). For example, water analysis from a Texas gas well showed TDS content of about 23wt%. At such high concentrations, theories related to ideal solutions are not valid and hence cannot be used. Instead, activity coefficients should be used in place of concentrations. Salts might precipitate to form scales which might adhere to the surface of steel affecting the corrosion rate. Field experience suggests that corrosion rates can be reduced in solutions with high TDS (ie high salt concentration). Increase in salt concentration changes the ionic strength of the solution which affects the solubility of CO2 and iron carbonate in the aqueous phase (also called kinetic electrolyte effect). As the solubility of these compounds in water governs the corrosion rate, the importance of salt concentration is thus recognised.

Effect of operating conditions

Operating conditions such as temperature, pressure and presence of other gases (other than CO2) and their partial pressures affect the steel corrosion rates. The presence of different gases and their partial pressures affect the corrosion rate by affecting the water chemistry.

Temperature has two opposing effects on the kinetics of CO2 corrosion. In general, increase in temperature accelerates diffusion-controlled mass transfer processes and facilitates CO2 corrosion. This is generally found to be the case at low pH. However, temperature rise has an opposing effect, particularly at higher pH when the solubility limit of iron carbonate is exceeded. Based on literature, [Sun et al, 2009] developed an expression relating iron carbonate solubility

b522a2-eq1.jpg
to temperature (T in K) and ionic strength (I in mol/l).

 

 

b522a2-eq2.jpg

According to their expression increased temperature should facilitate the formation of a carbonate film as its solubility decreases with temperature.

At room temperature, the process of precipitation is very slow and an un-protective scale is usually obtained even at very high supersaturation. On the other hand, at higher temperatures (>80°C), precipitation is likely to proceed rapidly; often forming dense and very protective scales even at low supersaturation thus decreasing corrosion rates. In the intermediate temperature range the corrosion rate progressively increases reaching a maximum between 70-80°C after which it decreases due to scaling.

The American Petroleum Institute (API), in the late 1950s, provided a rule-of-thumb criteria for corrosion of carbon steels. The rules of thumb suggest that at >2bar corrosion is likely, implying that corrosion rate may be >1mm/y; whereas at <0.5bar, corrosion was deemed unlikely (ie corrosion rate <0.1mm/y). These rules were based on field experience, primarily in the USA, but later endured several exceptions and proved qualitative at best. However, they can still be used as an aid to first-pass materials selection.

It is generally observed that in conditions where protective scales do not form, an increase in CO2 partial pressure (pCO2) typically leads to an increase in corrosion rate. The concentration of H2CO3 increases with an increase in pCO2 and thus more carbonic acid is available for proton-releasing cathodic reduction which ultimately increases the corrosion rate. In cases where scales can form (eg high pH), an increase in pCO2 leads to higher supersaturation, which accelerates precipitation and scale formation. This can lead to lower corrosion rates.

At very high total pressure, the gas phase-solution phase equilibria cannot be accounted for by Henry's law. To account for this non-ideal solution case, use of a fugacity coefficient is suggested. However, obtaining such coefficients is not trivial as it involves solving the equation of state for a gas mixture whose composition may not be known with certainty (eg in case of produced fluids).

Gas composition also significantly alters the corrosion mechanism which inevitably affects the corrosion rate. Presence of gases such as H2S, CO, H2, CH4 and O2 are known to affect CO2 corrosion. The effect of other gases, for example SOx, NOx etc, which are likely to evolve during fossil fuel combustion, is not extensively studied at high pressures. However, formation of acidic aqueous solutions when these gases are dissolved in water is known. This might have an impact on the corrosion rate as the sulphates and nitrates of Fe have different solubilities when compared to the corresponding carbonate.

The effect that even small amounts of H2S can have on the CO2 corrosion rate has been recognised for over 60 years. Still, the corrosion mechanisms under H2S/CO2 conditions are poorly understood, particularly in high pressure conditions most likely experienced in sour oil and gas wells. H2S is known to cause sulphide stress cracking (SCC), but apart from the cracking aspects associated with sour service, in the presence of CO2 its effect can be varied. Often, conflicting results are reported in the literature. For example, [Videm et al, 1998] and [Mishra et al, 1992] have reported two opposite effects concerning H2S. While [Videm et al, 1998] reported that very small amounts of H2S in CO2-containing aqueous media accelerated the corrosion rate; the latter argued that small amounts of H2S had some inhibitive effect on CO2 corrosion of steels. [Mishra et al, 1992] attributed this effect to the formation of iron sulphide film that apparently was more protective than iron carbonate. It is generally accepted that corrosion in a mixed sweet-sour system is CO2 dominated if pCO2/pH2S>500-1000.

A low concentration of H2S (<30ppm) in a CO2-saturated aqueous solution can accelerate the corrosion rate significantly in comparison to corrosion in a similar CO2 environment without H2S. At higher concentrations and temperatures (>80°C) this effect seems to vanish due to the formation of a protective film. The results at low temperatures were not explained in detail in their report. At lower temperatures (<<80°C) the possible involvement of H2S to catalyse the anodic dissolution of bare steel might lead to higher corrosion rates when a protective film of FeCO3 is not formed due to its greater solubility.

There are some data on the effect of very small H2S concentrations on CO2 corrosion at low pH, where precipitation of iron sulphides does not occur. Experiments for low H2S concentrations (<500ppm) in the gas phase and for pH<5, at various temperatures (20-80°C), pCO2 between 1-7bar and velocities (stagnant to 3m/s) in both single and multiphase strongly suggest that the presence of even very small amounts of H2S (10ppm in the gas phase) will lead to rapid and significant reduction in the CO2 corrosion rate. At higher H2S concentrations this trend is somewhat reversed. The effect seems to be universal and depends solely on the concentration, as all the data obtained at very different conditions follow the same trend.

CO2 corrosion of carbon steel increases by 1.5-2 times with increase of H2S content (<25%) in the mixture (pH2S<5bar; pCO2=15bar) in the temperature range 20-80°C. Further increase in H2S content (pH2S=5≥15bar; pCO2=15bar) weakens corrosion, especially in the temperature range 100-250°C, because of the influence of FeS and FeCO3.

FeCO3, which generally forms a passive film on the steel surface and retards CO2 corrosion, is unstable in the presence of oxygen. In field applications, if oxygen enters the production equipment due to water or inhibitors injection it will oxidise Fe2+ into Fe3+ ions and will form oxides and hydrated oxides of Fe instead of a carbonate scale. Thus the oxygen concentration should be kept under 40ppb (often <10ppb) in order to suppress this oxidation.

Recently some work has been reported on CO2 corrosion in the presence of impurities [Ayello et al, 2010]; [Choi and Nesic, 2010]. The corrosion rate of carbon steel is reported to increase from 2.3mm/y in the presence of 1000ppm H2O to 4.6mm/y when 100ppm SO2 was added to the system at 75.8bar CO2 at 40°C [Ayello et al, 2010]. When 100ppm SO2 was replaced by 100ppm NO2 the corrosion rate increased to 11.6mm/y.

[Choi and Nesic, 2010] performed similar experiments with X-65 carbon steel in circa 6000ppm H2O at 50°C and 80bar CO2 pressure. They observed that the addition of 1% SO2 in the gas phase dramatically increased the corrosion rate of carbon steel from 0.38 to 5.6mm/y. This then increased to more than 7mm/y with addition of 4% O2. The explanation for this enhanced rate of corrosion lies in the ability of SO2 to promote the formation of iron sulphate (FeSO4) on the steel surface which is less protective than iron carbonate (FeCO3). FeSO4 is further oxidized in the presence of O2 to become FeOOH and H2SO4. This further decreases the pH and accelerates the corrosion reaction.

Effect of material type

In the case of carbon steels, the microstructure seems to have a major effect, although the information available at the present time is controversial and consequently the selection of materials is not an easy task. It is strongly recommended to be aware of it, and whenever possible, to perform online tests in order to monitor the corrosion rate and the inhibitor's efficiency.

The formation of a stable oxide of chromium is beneficial for improved corrosion resistance in CO2-containing media. The presence of Cr in steel can offer significantly improved corrosion resistance. Some publications suggest the use of 13% Cr steel either in homogeneous ('solid') form or cladding on carbon steel for corrosion mitigation. If low chromium alloy steel is to be selected, it is worth noting that even though the influence of steel microstructure seems of less importance than for carbon steels, it is recommended not to have a ferritic-pearlitic microstructure. When inhibitors are required, it is important to assess the compatibility of inhibitors and the chromium-rich surface films grown on Cr-containing steels. As a general consideration, for any inhibitor selection, the chemical composition and the microstructure of the steel to be protected have to be taken into account.

In addition to the above, steels with high Cr content, especially stainless steels, are much more expensive than carbon steels. The price-optimal Cr level will vary with application, albeit a Cr level between 2-3wt% in conjunction with various microalloying constituents was considered essential to achieve satisfactory corrosion performance in one study.

References

Ayello F, Evans K, Thodla R and Sridhar N, 2010: 'Effect of impurities on corrosion of steel in supercritical CO2'. Corrosion 2010, paper no 10193 (Houston, TX: NACE, 2010).

Choi Y-S and Nesic S, 2010: 'Effect of impurities on the corrosion behaviour of carbon steel in supercritical CO2-water environments'. Corrosion 2010, paper no 10196 (Houston, TX: NACE, 2010).

De Visser E, Hendriks C, Barrio M, Molnvik M J, de Koeijer G, Liljemark S and le Gallo Y, 2008: 'Dynamics CO2 quality recommendations'. International Journal of Greenhouse Gas Control, vol.2, pp.478-484.

Mishra B, Olson D L, Al-Hassan S and Salama M M, 1992: 'Physical characteristics of iron carbonate scale formation in line pipe steels'. Corrosion 92, paper no 13 (Houston, TX: NACE, 1992).

Parker M E, Meyer J P and Meadows S R, 2009: Carbon dioxide enhanced oil recovery-injection operations technologies'. Energy Procedia, Vol1, pp3141-3148.

Propp W A, Carleson T E, Wai C M, Taylor P R, Daehling K W, Huang S and Abdel-Latif M, 1996: 'Corrosion in supercritical fluids'. US Department of Energy Report INEL-96/0180, Washington, USA.

Seiersten M and Kongshuag, 2005: 'Materials selection for capture, compression, transport and injection of CO2'. Carbon dioxide capture for storage in deep geological formations, Vol 2, Elsevier, UK. ISBN: 0 08 044570 5.

Seiersten M, 2001: 'Material selection for separation, transportation and disposal of CO2'. Corrosion 2001, NACE paper number 01042.

Sun W, Nesic S and Woollam R C, 2009: 'The effect of temperature and ionic strength on iron carbonate (FeCO3) solubility limit'. Corrosion Science, Vol 51, pp1273-1276.

Thodla R, Francois A and Sridhar N, 2009: 'Materials performance in supercritical CO2 environments'. Corrosion 2009, NACE paper number 09255.

Videm K, Kvarekvaal J, Perez T and Fitzsimons G, 1998: 'Surface effects on the electrochemistry of iron and carbon steel electrodes in aqueous CO2 solutions'. Corrosion 98, paper no 1 (Houston, TX: NACE, 1998).

End of part one.

Part two will be published in a subsequent issue of the Bulletin and will deal with the integrity of metallic and polymeric materials in contact with high pressure CO2.

1 Phase at a temperature and pressure above the critical temperature and pressure. The critical point beyond which CO2 exists in the supercritical phase is 31.1°C and 73.9bar. From the cost standpoint, supercritical transport allows for substantially higher throughput through a given pipe than transport as a lower pressure gas. At high pressure CO2 may exist as a liquid if the temperature is below the critical temperature. When CO2 exists as a liquid and/ or supercritical phase it is often collectively termed a 'dense phase' fluid.

2 Organic acids present in the oil and gas production fields have significant influence on CO2 corrosion. Acetic acid, an organic acid (and often the major constituent in produced organic acids), has long been used to mimic this in laboratory corrosion tests.