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In the oil and gas industry, long-distance transportation of petroleum and related products is usually carried out in large-diameter carbon steel pipelines. Water present with the oil, along with corrosive species such as CO2, H2S and organic acids, causes severe corrosion of the inner pipe walls.1 An effective method of controlling corrosion is to continuously inject corrosion inhibitors into pipelines conveying oil-water mixtures. As corrosion occurs on water wetted metal surfaces, corrosion inhibitor (CI) molecules form protective films which retard electrochemical reaction rates at the water-metal interface,2 thereby protecting carbon steel pipes against CO2 ("sweet") corrosion and H2S ("sour") corrosion. Most commercial CIs are a complex mixture of several compounds that contain surfactant-type active ingredients, such as imidazoline, amine, phosphate ester, and quaternary ammonium derivatives.
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Pyrolysis processes of post-consumer plastics are a promising chemical recycling route and a good alternative to disposal. Nevertheless, these processes are challenging for metallic materials since chlorine containing materials or biological components inside the feedstock can yield HCl and H2S, respectively, during cracking. In combination with high temperatures of the reactor zone metallic construction materials can be attacked by high-temperature corrosion.
ECA technologies are not very well known in the oil and gas industry and are still undeservedly suffering from the bad reputation of traditional eddy current testing from twenty years ago. Eddy current techniques are often humorously compared to "black magic" in the sense that the results are difficult to understand, the probes are complicated to use, and only eddy current gurus can use it efficiently. However, ECA has evolved significantly over the past 15 years and is now much easier and more intuitive to use.
Chromate conversion coatings are relied upon to ensure the long-term corrosion performance and surface electrical properties of aluminum alloys, as well as to improve the bond strength and adhesive properties of organic coatings and adhesives. Chromate based chemistries have been all but eliminated in Europe, and it is believed the Environmental Protection Agency (EPA) will stage their elimination in the USA within the next 5 to 10 years. The development of chemistries to replace chromate has been a hot area of research for over 30 years, and now a series of commercial alternatives have become available. These new coatings differ in their chemistry and performance characteristics, as well as their functional limitations, from chromate.
Supercritical CO2 storage has been gaining more attention due to its wider application. It is one of the desirable solutions for reducing CO2 emission, which is an important contributor to the global climate crisis. In other cases, some of the early applications were focused on the oil and gas industry, by using supercritical CO2 to sequence the mature wells for better production [1],[2]. In those environments, C1018 carbon steel was extensively used, due to its good balance of toughness, strength, and ductility as well as its excellent weldability.
Several industrial applications including the chemical industry and oilfield technology involve frequently halide-containing streams at elevated temperatures, that challenge the pitting corrosion resistance of metallic materials. Pitting susceptibility becomes not only a reject criterion for materials selection during the design stages of engineering components used in these applications. It also constitutes a significant limiting factor to the service life of these components once in service. Therefore, the characterization of the pitting corrosion resistance of metallic materials including the influence that operational factors can have on material’s susceptibility is crucial.
High-pressure steel pipeline is a common, cost-effective method for transporting CO2 from its point of capture to storage sites1. In pipeline transport systems, CO2 is mostly transported in its liquid or supercritical phase, depending on the operating pressure2,3, which requires compression of CO2 gas to a pressure above 80 bar (Figure 1) and avoid a two-phase flow regime in the steel pipelines. In the USA, the longest CO2 pipelines, which transport more than 40 MtCO2 per year from production point to sites in Texas, where the CO2 is used for enhanced oil recovery (EOR), operate in the “dense phase” mode and at ambient temperature and high pressure.
Biomass-derived pyrolysis oils (bio-oils) are recognized as a renewable energy source that couldaid in the reduction of fossil fuel use. Bio-oils exhibit higher corrosivity to common ferrous alloys because the oils contain organic acids and water. A series of corrosion studies were previously performed to determine the corrosion rates of ferrous alloys exposed in bio-oils for a quantitative evaluation of the material compatibility. The key information from these previous studies is that ferrous alloys with more Cr, Ni, and Mo are needed for compatibility with bio-oils.
Additive manufacturing (AM) has allowed for the rapid prototyping of parts and the ability to control the structure of a material and, to a lesser extent, the microstructure. AM as applied to metals, as stainless steel is especially promising as it provides the ability to produce complex shaped components rapidly. Laser-powder bed fusion (L-PBF) is one such technique in which the part is formed from the base up by fusing successive layers of powder. As each layer is fused, the print plate moves down and a new layer of metallic powder is swept over the top. A laser then welds this layer to the top of the existing piece and the process repeats.1 However, AM can result in non-equilibrium microstructures, porosity, and residual stresses that could affect the longevity of the material and performance in corrosive conditions.
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
A Saudi Aramco facility continues to serve a vital rule in the processing and export of crude oil. This facility is one of the few facilities worldwide that is considered to be fully sufficient with different processes within its boundaries. While processing hydrocarbon throughout the day, this facility also processes utilities to serve the nearby community as well as its own oper ation. The raw water that feeds the utility process arrives from a nearby fields through the 24” supply lines. These lines provide n. the subject RO plant within the utility process with the sufficient amount of water to sustain the huge magnitude of operation.
Aerospace assets are subjected to routine maintenance cycles to prevent, monitor, and repair corrosion damage. Currently, the maintenance cycles are determined according to its model and following its respective requirements document (eg: NA(1) 01-1A-5091 or USAF(2) Technical Order 1-1-691).2 A new paradigm of condition-based maintenance (CBM) is highly desired, as a given asset will require different prevention, monitoring, and repair maintenance cycles depending on where it is deployed. As corrosion is the degradation of a material in response to its environment, CBM takes into consideration the variability of the environment (the conditions to which an asset is exposed) when determining appropriate maintenance intervals and what should be done at each interval.