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Development Of High Velocity Oxygen Fuel (HVOF) Corrosion Resistant Coatings; A Comparison Between Novel High Entropy Alloy (HEA) And Conventional Cermet Coatings For Geothermal Applications

Picture for Development Of High Velocity Oxygen Fuel (HVOF) Corrosion Resistant Coatings; A Comparison Between Novel High Entropy Alloy (HEA) And Conventional Cermet Coatings For Geothermal Applications
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Several components in geothermal power plants need to be protected from the environment due to the corrosive nature of geothermal fluids used to generate the energy. Depending on the fluid properties for any location, the type of protection varies. In geothermal power plants, wear, erosion, corrosion, and scaling are all known problems1. These issues can lead to a variety of outcomes, ranging from decreased plant efficiency to upstream component failure. Failure of a component is thus a significant challenge in the geothermal industry, where materials need to operate in high temperature and high pressure environments. A major cost factor is also linked to the drilling of geothermal wells, where cost rises due to increased depth/distance of drilling, increased trip times, higher high temperature and high-pressure conditions which can lead to increased wear and corrosion of the materials. To address the issue, coatings can be considered to be a potential solution to extend the service life of downhole equipment.

Product Number: 51322-17675-SG
Author: Gifty Oppong Boakye, Baldur Geir Gunnarsson, Erlend Oddvin Straume, Feifei Zhang, Arna María Ormsdóttir, Sigrún Nanna Karlsdóttir
Publication Date: 2022
Industries: Corrosion Monitoring and Control , Coatings and Linings , Coatings
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Corrosion damage of materials operating in the harsh geothermal environment with corrosive species, high temperatures and pressures necessitate the development of novel, cost-effective corrosion-resistant coatings to extend the service life of down-hole drilling equipment and power plant components. The thermal spraying process is a well-established and versatile method for producing thick coatings in terms of cost, wide range of powder selection, and high deposition efficiency. High Velocity Oxygen Fuel (HVOF) thermal spraying process has proven to be one of the most effective techniques for deposition of conventional cermet-carbide composite coatings improving their high-temperature oxidation corrosion, erosion, and wear resistance. The objective of this work focuses on testing the corrosion resistance of a CoCrFeNiMo0.85 high entropy alloy (HEA) coating fabricated by HVOF technique. Here we report the comparative analysis of corrosion resistance for the developed CoCrFeNiMo0.85 and CrC–NiCr, WC–Co carbide systems. The HEA and Cermets were immersed for 14 days in a simulated alkaline geothermal drilling environment at 120 °C and 50 bar. In addition, an electrochemical-accelerated corrosion test in a 3.5wt% NaCl was carried out at ambient temperature to investigate the behavior of the coatings in the presence of Cl-ions. The compositional effect of the microstructure on corrosion performance of the tested samples is discussed by analyzing corrosion damages and products using SEM/EDS analytical methods. The findings are essential to determine the suitability of HVOF as a fabrication method for CoCrFeNiMo0.85 HEA coatings and the candidacy of the resulting coating for corrosion protection of components used in geothermal energy production.

Corrosion damage of materials operating in the harsh geothermal environment with corrosive species, high temperatures and pressures necessitate the development of novel, cost-effective corrosion-resistant coatings to extend the service life of down-hole drilling equipment and power plant components. The thermal spraying process is a well-established and versatile method for producing thick coatings in terms of cost, wide range of powder selection, and high deposition efficiency. High Velocity Oxygen Fuel (HVOF) thermal spraying process has proven to be one of the most effective techniques for deposition of conventional cermet-carbide composite coatings improving their high-temperature oxidation corrosion, erosion, and wear resistance. The objective of this work focuses on testing the corrosion resistance of a CoCrFeNiMo0.85 high entropy alloy (HEA) coating fabricated by HVOF technique. Here we report the comparative analysis of corrosion resistance for the developed CoCrFeNiMo0.85 and CrC–NiCr, WC–Co carbide systems. The HEA and Cermets were immersed for 14 days in a simulated alkaline geothermal drilling environment at 120 °C and 50 bar. In addition, an electrochemical-accelerated corrosion test in a 3.5wt% NaCl was carried out at ambient temperature to investigate the behavior of the coatings in the presence of Cl-ions. The compositional effect of the microstructure on corrosion performance of the tested samples is discussed by analyzing corrosion damages and products using SEM/EDS analytical methods. The findings are essential to determine the suitability of HVOF as a fabrication method for CoCrFeNiMo0.85 HEA coatings and the candidacy of the resulting coating for corrosion protection of components used in geothermal energy production.

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Development Of Fes Scale Control Technology Using Polymeric Dispersants In Sour Environment

Product Number: 51322-17630-SG
Author: Saebom Ko, Zhaoyi Dai, Xin Wang, Amy T. Kan, Wei Lee, Mason B. Tomson
Publication Date: 2022
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Mineral scales frequently occur in tanks, pipelines, cooling and heating system, production wells of
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Development Of A F22 Compatible Scale Inhibitor

Product Number: 51322-17610-SG
Author: Ya Liu, Benton Hutchinson, Rose Lehman, Jeffrey Russek, James Outlaw
Publication Date: 2022
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F22 is a low alloy steel that typically contains 12% Carbon, 2.25% Chromium, and 1.0% Molybdenum1. This steel has been widely used in oil production systems, especially in well head design and construction. As a low alloy steel, F22 can be corroded by oilfield chemicals under certain circumstances. For example, it was observed in the Gulf of Mexico that typical scale inhibitor chemistries caused severe corrosion on F22.
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Design Of Sour Service Material: Combining Metallurgical Design, Laboratory And Full Scale Testing Towards A Novel High Strength Sour Service Material

Product Number: 51322-17615-SG
Author: Michel PIETTE, Florian THEBAULT, John FORTAILLIER, Livia-Raquel CUPERTINO-MALHEIROS
Publication Date: 2022
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During the last decades, low alloyed steels with improved resistance to Sulfide Stress Cracking (SSC) have been developed for covering specific applications as heavy wall casings1 or expandable tubings2 or for reaching higher mechanical properties, such as 125 ksi Specified Minimum Yield Strength (SMYS) materials.3-6 For the latter, relevant sour environments for developed grades are mild, meaning that all sour applications cannot be covered while a strong interest exists for O&G operators to use high strength materials when designing wells. Consequently, there is an incentive to push the limits of use of high strength sour service steels by enhancing their resistance to SSC. Several recommendations were already published when designing high strength sour service grades: hardness level shall be limited as much as possible and be preferentially below 22 HRC7, microstructure shall present a minimum required amount of martensite8 which is well known to be ideal for combining high mechanical properties and high resistance to hydrogen. Besides, many authors highlighted some other influencing parameters related to the material or the process.
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