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51316-7669-Performance of Thermally Sprayed CRA Coatings on Carbon Steel in Supercritical CO2 Environments

Picture for Performance of Thermally Sprayed CRA Coatings on Carbon Steel in Supercritical CO2 Environments
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Product Number: 51316-7669-SG
ISBN: 7669 2016 CP
Author: Shiladitya Paul
Publication Date: 2016
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This paper reports the use of a thermal spray corrosion resistant alloy (CRA) coatings to mitigate corrosion of carbon steel in an environment containing high pressure supercritical CO2 and an aqueous phase. CRA coatings were sprayed using high velocity oxy-fuel (HVOF) onto carbon steel substrates holidays were drilled in one set of specimens to expose the steel substrate and tested in 3.5wt.% NaCl solution at 40°C and 80°C for 30days bubbled with 10MPa CO2. Microstructural characterization revealed that the undamaged coatings protected the steel substrate from CO2 corrosion. The bare steel formed a siderite scale while no such scale was seen in the case of CRA-coated steel. The CRA coatings with holidays showed corrosion of the carbon steel substrate. The substrate close to the coating showed accelerated corrosion due to galvanic effects.It can be concluded that thermally sprayed CRA coatings can provide a cost-effective corrosion mitigation method for infrastructure likely to be in contact with wet supercritical CO2. The same coatings can be used as inner lining of pipes for transport of impure CO2. However care must be taken to ensure that the thermally sprayed layer does not have any through porosity; else such coatings may accelerate corrosion of the underlying steel due to galvanic interactions.
This paper reports the use of a thermal spray corrosion resistant alloy (CRA) coatings to mitigate corrosion of carbon steel in an environment containing high pressure supercritical CO2 and an aqueous phase. CRA coatings were sprayed using high velocity oxy-fuel (HVOF) onto carbon steel substrates holidays were drilled in one set of specimens to expose the steel substrate and tested in 3.5wt.% NaCl solution at 40°C and 80°C for 30days bubbled with 10MPa CO2. Microstructural characterization revealed that the undamaged coatings protected the steel substrate from CO2 corrosion. The bare steel formed a siderite scale while no such scale was seen in the case of CRA-coated steel. The CRA coatings with holidays showed corrosion of the carbon steel substrate. The substrate close to the coating showed accelerated corrosion due to galvanic effects.It can be concluded that thermally sprayed CRA coatings can provide a cost-effective corrosion mitigation method for infrastructure likely to be in contact with wet supercritical CO2. The same coatings can be used as inner lining of pipes for transport of impure CO2. However care must be taken to ensure that the thermally sprayed layer does not have any through porosity; else such coatings may accelerate corrosion of the underlying steel due to galvanic interactions.
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