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Carbon steels such as API 5L X65 are widely used oil and gas exploration, production and transportation service. However, these steels tend to corrode in the presence of wet CO2 and corrosion is more pronounced in the presence of dissolved salts and acids. Other metals, alloys and polymers also degrade in the presence of high pressure gaseous and supercritical CO2. The corrosion rate of carbon steels in some aqueous environments have been reported to be more than a few millimeters per year.9-10 The situation could be further exacerbated by H2S where cracking can be an issue for high strength steels.
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In recent years the oil and gas industry has made significant commitments to carbon reduction.1 Aligned with the goal of decreasing carbon emissions the authors have developed a corrosion inhibitor (CI-1) that is intended to protect scCO2 systems that are wet or water contaminated (1000 ppm).2 The development and composition of this corrosion inhibitor (CI) for dry scCO2 is reported elsewhere.2,3 While chemical companies have been treating high water cut, production enhanced, CO2 floods (i.e. enhanced oil recovery [EOR]) for several decades there were no inhibitors designed specifically for CO2 disposal systems or wet scCO2 systems producing CO2 for sale.4
Over the past decade, there has been increasing interest in the corrosion behavior of carbon steels in supercritical CO2 conditions. Unlike the case of carbon capture and storage (CCS) where small amounts of water are present, the exploitation of fields with high pressures of CO2 needs to consider the presence of formation water, which presents strong corrosivity. It has been reported that the aqueous corrosion rate of carbon steel at high CO2 pressures (liquid and supercritical CO2) without protective FeCO3 corrosion product layers is very high (>20 mm/y) due to the high concentrations of corrosive species such as H+ and H2CO3.1-5 Steels with low Cr contents (i.e., 1% Cr and 3% Cr) have shown no beneficial effect in terms of reducing the corrosion rate to admissible values.6 Therefore, controlling corrosion in these cases usually involves the use of corrosion resistant alloys (CRAs) or corrosion inhibitors (CI). Adequate protection of carbon steel was achieved by applying CI in high pressure CO2 environments.6
Carbon steels and low alloy steels are the workhorse of several industries where properties such as strength, fracture toughness and weldability play a key role. In addition to these properties, carbon steels are also the most cost effective materials is several applications. Of particular interest is the API 5L X65 which is widely used in oil and gas exploration, production and transportation service.
This paper reports the performance of HVOF-sprayed corrosion resistant alloy (CRA) coatings in an aqueous solution bubbled with 50MPa supercritical CO2.