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Article history: A systematic study was performed to investigate the effect of pressure and water content on the general
Received 8 February 2016 corrosion and localized attack of carbon steels during the transport of CO2 for the CCS industry. Corrosion
Received in revised form 2 June 2016 experiments were conducted on X60, X65, X70, and X80 carbon steels in water-unsaturated supercritical
Accepted 6 June 2016
CO2 with SO2 and O2 in conditions of 50 ◦ C and 8–12 MPa. The general corrosion rates increased with water
Available online 20 June 2016
content and ranged from 0.02 mm/year to 0.31 mm/year at 8 MPa and from 0.01 mm/year to 0.94 mm/year
at 10 MPa. Localized corrosion was determined by measuring the penetration rate and pitting factor.
Keywords:
The penetration rates ranged from 0.2 mm/year to 3.25 mm/year at 8 MPa and from 0.04 mm/year to
Supercritical CO2 transport
Pressure
6.02 mm/year at 10 MPa. Meanwhile, the pitting factors ranged from 4 to 70 at 8 MPa and from 3 to 43 at
Water content 10 MPa, with water contents varying from 1600 ppm to 3000 ppm. The degrees of general corrosion and
Localized corrosion localized attack were higher at 8 MPa than those at 10 MPa, with water contents ranging from 1600 ppm
Carbon steel to 2600 ppm, but lower at a water content of 3000 ppm.
© 2016 Elsevier Ltd. All rights reserved.
1. Introduction urated with CO2 , creating carbonic acid (H2 CO3 ), hence posing a
corrosive threat to pipeline steel. Other contaminants present in
Carbon capture and storage (CCS) has been recently identified the CO2 stream, such as O2 , H2 O, SOx , NOx , Ar, and N2 , also influ-
as a possible means to reduce global carbon emissions. In the CCS ence and potentially accelerate the corrosion process. For example,
process, CO2 is captured from power plants or other industrial acidic impurities, such as SOx , may dissolve in water to become sul-
factories, transmitted to the storage site, and deposited within furous acid and sulfuric acid, which cause a considerable threat to
a geological reservoir (Zhang et al., 2006). Considering the large the durability of pipelines (Xiang et al., 2011, 2013b). The species
quantities of CO2 transmitted over long distances, carbon steel and contents of impurities in transported CO2 vary depending on
pipeline transport is recognized as the most reasonable and cost- the application of different combustion and flue gas cleaning tech-
effective option. CO2 transported through pipelines is typically nologies (de Visser et al., 2008).
compressed into a supercritical state (greater than 7.38 MPa and CO2 transportation is a vital aspect of the CCS cycle, but the study
31.1 ◦ C) to prevent pressure drops and two-phase flow regime (Gale of transportation process safety has been somewhat overlooked
and Davison, 2004). before (Hua et al., 2015a; Xiang et al., 2013c). Fortunately, more
Since CO2 transportation is the critical connecting link between researchers have recently focused on the internal pipeline corro-
the capture and storage processes, this process should be eco- sion issue during CO2 transportation process (Hua et al., 2014a,
nomical, effective, and environmentally safe. However, pipeline 2014b, 2015b, 2015c, 2015d; Sim et al., 2013a, 2013b; Xiang et al.,
networks implemented to transport supercritical CO2 are likely to 2012a, 2012b, 2013a; Zhang et al., 2012). A summary of recent stud-
suffer significant levels of internal pipeline corrosion when free ies is provided in Table 1. Several researchers investigated the effect
water exists within the system (Choi et al., 2010). The aqueous of impurities on the corrosion behavior of carbon steel pipelines
phase forming on the surface of the internal pipeline will be sat- (Hua et al., 2015a; Sim et al., 2013a; Xiang et al., 2011, 2012a),
whereas other researchers concentrated on the effects of opera-
tion conditions, such as temperature and pressure (Choi et al., 2013;
∗ Corresponding author.
Hua et al., 2014a; Xiang et al., 2012a, 2012b, 2013a). However, no
E-mail addresses: zhewang@tsinghua.edu.cn, wangzhe988@gmail.com
general consensus on the actual water contents and operation con-
(Z. Wang).
http://dx.doi.org/10.1016/j.ijggc.2016.06.002
1750-5836/© 2016 Elsevier Ltd. All rights reserved.
358 M. Xu et al. / International Journal of Greenhouse Gas Control 51 (2016) 357–368
Table 1
Summary of literature relating to corrosion behavior in pressurized CO2 in recent years.a
Fig. 1. Microstructure of X60, X65, X70 and X80 steel. (a) X60 steel; (b) X65 steel; (c) X70 steel; (d) X80 steel.
2.3. Methods
(EDS). A 3D measuring laser microscope (LEXT OLS4100, OLYMPUS) ples exposed to pressure of (a) 8 MPa; (b) 10 MPa. , X60 steel; , X65 steel;
was also employed to examine the sample surface and determine
, X70 steel; , X80 steel.
the extent of localized corrosion after cleaning the product scale.
3. Results and discussion rates, analyzing corroded surface morphology and product compo-
sition.
3.1. Effect of pressure on the general corrosion behavior of carbon
steels at pressures of 8–12 MPa with various water contents 3.1.1. Average corrosion rates of carbon steels at pressures of 8
and 10 MPa with various water contents
The dependence of the general corrosion behavior of X60, X65, Fig. 3 shows the average corrosion rates of X60, X65, X70, and
X70 and X80 carbon steels on pressure, water content and steel X80 carbon steels exposed to water-unsaturated dense phase CO2
type in condition of pressures of 8–12 MPa and water contents of at pressures of 8 and 10 MPa and a temperature of 50 ◦ C.
1600–3000 ppm is discussed in detail as follows. The general cor- Fig. 3a shows the average corrosion rates of carbon steels
rosion behavior is characterized by calculating average corrosion exposed to 8 MPa. The corrosion rates of X60, X65, X70, and
M. Xu et al. / International Journal of Greenhouse Gas Control 51 (2016) 357–368 361
X80 carbon steels collectively range between 0.02 mm/year and than that at 10 MPa, resulting from the lower water solubility in the
0.31 mm/year. At a water content of 1600 ppm, the corrosion rates CO2 mixtures at 8 MPa than that at 10 MPa.
of X60, X65, X70, and X80 carbon steels vary from 0.025 mm/year Moreover, the trend of the variation of the corrosion rates with
to 0.06 mm/year. The corrosion rates of X80 and X65 carbon steels the water contents at 8 and 10 MPa exhibits an evident difference.
exceed 0.1 mm/year at a water content of 2000 ppm or more. Mean- Generally, the corrosion rates at 8 MPa gradually increase with the
while, the corrosion rates of X60 and X70 carbon steels surpass water contents. By contrast, the corrosion rates at 10 MPa slowly
0.1 mm/year at a water content of 2600 ppm or more. In contrast to increase when the water content is less than 2600 ppm and signif-
the previous research conducted by Hua et al. (2014a), the authors icantly increase when the water content is greater than 2600 ppm.
illustrated that no corrosion was observed on the X65 steel at a At 10 MPa, the abrupt change of corrosion rate exists at the water
water content of 1600 ppm, whereas a corrosion rate of approx- content point of 2600 ppm, with the corrosion rate increasing sig-
imately 0.014 mm/year was detected on the X65 steel at a water nificantly above the said point. However, the corrosion rates at
content of 2650 ppm when exposed to pure supercritical CO2 at 8 MPa do not reveal the existence of transition, which is charac-
8 MPa and 50 ◦ C. Therefore, the existence of SO2 and O2 is con- terized by critical relative humidity by previous researchers (Xiang
firmed to decrease the endurance of water content for carbon steel et al., 2012a), in the water content point in the present study.
pipeline networks.
Fig. 3a shows that the corrosion rates of X60 and X65 steels 3.1.3. Effect of pressure on the corrosion behavior of carbon steels
monotonously increase with the water contents. However, the at a water content of 2000 ppm
corrosion rates of X70 steel slightly decrease from 0.04 mm/year Further investigation into the effect of pressure on the corrosion
to 0.02 mm/year with water contents varying from 1600 ppm to behavior of carbon steels at a water content of 2000 ppm is con-
2000 ppm and then gradually increase with water contents ranging ducted with another experiment exposed to the same CO2 mixtures
from 2000 ppm to 3000 ppm. Meanwhile, the corrosion rates of X80 at 12 MPa. The effect of pressure on the corrosion behavior of car-
steel generally increase with water contents less than 2600 ppm bon steels at a water content of 2000 ppm is presented in Fig. 5. The
and slightly decrease from 0.31 mm/year to 0.30 mm/year with average corrosion rates of X60, X65, and X80 steels are shown to be
water contents varying from 2600 ppm to 3000 ppm. In spite of the highest at 8 MPa, but the average corrosion rates are at 10 and
the special corrosion behavior of X70 steel at a water content of 12 MPa similar, partly because of the fact that the water solubility
2000 ppm and X80 steel at a water content of 3000 ppm, which in the CO2 mixtures is the lowest at 8 MPa, and the water solubility
may be partly due to contingency factors, such as measurement is similar at 10 and 12 MPa. These result in the highest degree of
errors, the general corrosion behavior of X60, X65, X70, and X80 moisture for the corrosive medium at 8 MPa and the similar degrees
carbon steels can be concluded to be typically enhanced by water of moisture at 10 and 12 MPa.
contents. Such water feature, which accelerates the average corro- In contrast to the study of Zhang et al. (2012), the average cor-
sion rates, is also revealed by previous studies (Hua et al., 2014a; rosion rate of X65 steel under a pure supercritical CO2 condition
Sim et al., 2013b; Xiang et al., 2012a). (9.5 MPa) was determined to be higher than that at a low CO2 par-
Fig. 3b shows that the average corrosion rates of carbon steels tial pressure (1 MPa) in a CO2 -saturated water solution, because
at 10 MPa collectively range from 0.01 mm/year to 0.94 mm/year the CO2 solubility in water is much higher under a supercritical CO2
with the water contents. At water contents of 1600–2600 ppm, condition, which consequently enhances the concentrations of car-
the corrosion rates of X60, X65, X70, and X80 steels are all bonic species (H2 CO3 , HCO3 − , and CO3 2− ) in the solution. However,
less than 0.1 mm/year. However, the corrosion rates of carbon such feature of pressure that enhances the corrosion rates does not
steels vary from 0.81 mm/year to 0.94 mm/year at a water con- apply to the water-unsaturated CO2 condition in the present study,
tent of 3000 ppm. For all carbon steels, the corrosion rates show because the dependence of corrosion rates on pressure seems to be
a monotonous increasing trend with the water contents, which more determined by the relative humidity as well as the degree of
strongly agrees with previous research (Xiang et al., 2012a). moisture instead of the solubility of CO2 in water phase.
Fig. 4. Comparison of general corrosion behavior of carbon steels exposed to pressure of , 8 MPa; and , 10 MPa. (a) X60 steel; (b) X65 steel; (c) X70 steel; (d) X80 steel.
a product film, whereas the surfaces with metallic luster need to are all in a supercritical CO2 phase at 8 and 10 MPa. The macro mor-
be detected by a microscope to determine whether the products phology difference at water contents less than 2600 ppm between
exist on the surfaces. Nevertheless, the dark-colored surfaces are 8 MPa and 10 MPa are speculated to originate from the difference
assumed to contribute more in promoting the degradation of the in water condensation behavior. Water condensed non-uniformly
entire surface than the surfaces with metallic luster. Meanwhile, onto the steel surfaces at 8 MPa. By contrast, water condensed uni-
the area of dark-colored surfaces on the samples increases with formly onto the steel surfaces at 10 MPa at water contents less than
water contents at 8 MPa, which is consistent with the gradually 2600 ppm.
increasing trend of the corrosion rate with the water contents.
The phenomenon wherein the corroded surfaces are composed
of dark-colored and discolored sections was also observed by Hua
et al. (2015d). Corrosion tests were conducted for the X65 steel 3.1.5. Analysis of corrosion product morphology and composition
samples exposed to the water-saturated CO2 phase at 35 ◦ C and Fig. 7 shows the SEM images of the corroded surface exposed to
8 MPa. Hua et al. (2015d) reported that a distinct difference lies in varying water contents and pressures. The labels “A–I” represent
the morphology, size, and distribution of FeCO3 crystals on the steel the area where EDS tests are conducted to analyze the chemical
surface in both regions, thus resulting in two contrasting mecha- composition of the product. The EDS tests results are presented in
nisms of corrosion attack and product formation behavior. They Table 4. The product composition mainly consisted of the elements
argued that one way of explaining the difference in FeCO3 crys- Fe, S, C, and Mn and was enriched with the element O. The ele-
tals can be related to the extent of water, which condensed onto ment of C might indicate the existence of Fe3 C and FeCO3 , and the
the steel in each location. In a dark-colored region, a significant element of Mn came from the steel substrate. The surfaces of sam-
amount of water condensed onto the surface, whereas relatively ples exposed to 10 MPa at water contents of 1600 and 2000 ppm
smaller water droplets have condensed onto the steel and left the shown in Fig. 7a and b are covered by a flat and smooth product
surface discolored in the region with dim metallic luster. layer, although the surfaces are with dim metallic luster. Similar
Comparing the corrosion behavior and product formation of the to the photographic investigation of the corroded samples exposed
surfaces for the samples exposed to 8 and 10 MPa in the present to 8 MPa, the surface morphology exhibits at least two patterns in
study, not only the dependence of the average corrosion rates on the Fig. 6c and d. The surface morphology shown in Fig. 7c consists of a
water contents differs, but also the behavior of product formation thick and dense product layer, a thin and sparse product layer, and
on the surfaces, although the test conditions in the present study a stacking pattern of the product, whereas the surface morphology
shown in Fig. 7d consists of a thick layer and a thin layer. The thin
M. Xu et al. / International Journal of Greenhouse Gas Control 51 (2016) 357–368 363
Table 4 lar boundary. Upon exposure to a water content of 3000 ppm, the
Elemental composition (mol.%) of products in region A–I labeled in Fig. 7.a
surfaces are covered by a larger amount of product and an irregu-
Region Fe S C O Mn lar pattern of product at 10 MPa, as shown in Fig. 7f. By contrast,
A 9.80 17.17 9.51 63.35 – the surfaces of the samples exposed to 8 MPa exhibited a small
B 41.09 3.06 33.12 22.73 – patch pattern of product and a thick product layer with porous
C 12.71 6.00 15.57 66.02 – appearance, as shown in Fig. 7h.
D 19.48 16.70 – 63.82 – XRD is utilized to determine the composition and crystallogra-
E 7.99 9.77 10.02 72.77 –
phy of the corrosion product. Fig. 8 shows the XRD results of the
F 10.33 11.27 9.57 68.63 0.20
G 28.69 6.57 9.16 55.17 0.41 product layers on X65 steel surfaces of samples exposed to varying
H 34.60 6.85 – 58.55 – water contents and pressures. Apparently, hydrated ferrous sul-
I 6.24 14.97 26.39 52.40 – fates (FeSO4 ·xH2 O) are the main components of the product films.
a
The regions ‘A–I’ labeled in Fig. 7 represent the area where the EDS tests are However, as the XRD was done using Cu-source for the X-ray and
conducted to analyze the chemical composition (mol.%) of the product. Bragg-Brentano geometry instead of low angle technique, the full
phase information (for example, FeCO3 , Fe3 C phase) in thin layers
might be missing.
Fig. 6. Photographic images of corroded X65 steel samples exposed to varying water contents at pressure of 8 MPa and 10 MPa. (a) 8 MPa; (b) 10 MPa.
364 M. Xu et al. / International Journal of Greenhouse Gas Control 51 (2016) 357–368
Fig. 7. SEM images of corroded carbon samples exposed to varying water contents. The labels ‘A–I’ represent the area where the EDS tests are conducted to analyze the
chemical composition of the product and the EDS tests results are presented in Table 4. (a) X70 steel at water content of 1600 ppm exposed to 10 MPa; (b) X80 steel at water
content of 2000 ppm exposed to 10 MPa; (c) X70 steel at water content of 1600 ppm exposed to 8 MPa; (d) X80 steel at water content of 2000 ppm exposed to 8 MPa; (e) X60
steel at water content of 2600 ppm exposed to 10 MPa; (f) X65 steel at water content of 3000 ppm exposed to 10 MPa; (g) X60 steel at water content of 2600 ppm exposed
to 8 MPa; (h) X65 steel at water content of 3000 ppm exposed to 8 MPa.
of X60 steel increases with the water contents, exhibiting a trend contents varying from 2600 ppm to 3000 ppm. In contrast, the pen-
similar to the average corrosion rate variation. By contrast, the pen- etration rate of X70 steel initially decreases with water contents
etration rate of X65 steel generally increases with water contents ranging from 1600 ppm to 2000 ppm and then increases with water
greater than 2000 ppm. For X80 steel, the penetration rate varia- contents from 2000 ppm to 2600 ppm, followed by a stable value
tion with the water contents presents a similar trend comparable with water contents from 2600 ppm to 3000 ppm. Overall, the X80
to the average corrosion rate variation with the water contents. In steel suffers the most severe mass loss degradation (as shown in
other words, the penetration rate for X80 steel initially increases Fig. 3), whereas the X60 steel endures the harshest localized attack
with water contents up to 2600 ppm and then decreases with water
M. Xu et al. / International Journal of Greenhouse Gas Control 51 (2016) 357–368 365
(as shown in Fig. 9a) in spite of its relatively low average corrosion
rate (as shown in Fig. 3).
In addition, the increment of water is concluded to not only
enhance the average corrosion behavior, but also promote the local-
ized attack. Mass loss is also attributed to the localized corrosion,
as the penetration rate variation exhibits a high similarity to the
average corrosion rate variation for almost all carbon steels.
In order to investigate the extent of localized corrosion com-
prehensively, the pitting factor is shown in Fig. 9b for the samples
exposed to 8 MPa. Pitting factor is defined as the ratio of the pene-
tration rate to the average corrosion rate, shown in Eq. (2) (ASTM
Standard G46-94, 2005). Localized corrosion is reported to occur
if the pitting factor exceeds 5, shown in Inequality 3 (Singer et al.,
2013). The pit morphology is either deep and narrow, or hemispher-
ical and cup-shaped (Singer et al., 2013).
maximum penetration rate mm/year
pitting factor = (2)
general corrosion rate mm/year
Fig. 9. Evaluation of localized attack for carbon steel samples exposed to 8 MPa and
varying water contents. , X60 steel; , X65 steel; , X70 steel; , X80
steel. (a) The penetration rate for carbon steel samples exposed to 8 MPa and varying
water contents. (b) The pitting factor for steel samples exposed to 8 MPa and varying
Fig. 10. Evaluation of localized attack for steel samples exposed to 10 MPa and vary-
water contents.
ing water contents. , X60 steel; , X65 steel; , X70 steel; , X80 steel. (a)
The penetration rate for carbon steel samples exposed to 10 MPa and varying water
contents. (b) The pitting factor for steel samples exposed to 10 MPa and varying
water contents.
3.3. Additional discussion
3.3.1. The safe limit of water content for carbon steels exposed to (a) Dissolution of SO2 in thin condensed water on the steel sur-
the CO2 mixture at 50 ◦ C, 10 MPa face and ionization:
As stated, uniform corrosion is indicated to occur on carbon
SO2(g) ↔ SO2(aq) (4)
steels exposed to 10 MPa at a water content of 1600 ppm. Notably,
a corrosion rate of 0.1 mm/year is industrially acceptable in the SO2(aq) + H2 O(l) ↔ H2 SO3(aq) (5)
context of oil and gas production pipelines (Hua et al., 2014b).
+ −
The average corrosion rates and penetration rates for carbon steels H2 SO3(aq) ↔ H + HSO3 (6)
exposed to 10 MPa at a water content of 1600 ppm are less than
0.1 mm/year, which indicates that the safe limit of the water con- HSO3 − ↔ H+ + SO3 2− (7)
tent for carbon steels exposed to CO2 –SO2 –O2 mixture in present
H2 SO3 may be oxidized by oxygen to form H2 SO4 , which is more
study at 10 MPa, 50 ◦ C is 1600 ppm.
aggressive. The formation of sulfate is expressed as follows:
Meanwhile, localized corrosion occurred on the carbon steel
samples exposed to 8 MPa at water contents of 1600–3000 ppm, 2SO3 2− + O2 ↔ 2SO4 2− (8)
with the average corrosion rates and penetration rates surpassing
0.1 mm/year. Therefore, the safe limit of water content for carbon (b) Cathodic reaction can occur either by the direct reduction of
steels exposed to CO2 –SO2 –O2 mixture in present study at 8 MPa, hydrogen ions or the reduction of oxygen:
50 ◦ C must be less than 1600 ppm. However, the safe limit of water
contents for carbon steels exposed to different temperature, pres- 2H+ + 2e− → H2 (9)
sure and CO2 mixtures need to be further studied.
O2 + 4H+ + 4e− → 2H2 O (10)
4. Conclusions
The corrosion behavior of X60, X65, X70, and X80 carbon steels
exposed to water-unsaturated supercritical CO2 mixtures are sim-
ulated by using an autoclave with rotor. The effect of pressure and
water content on general corrosion and localized attack are investi-
gated. A systemic analysis method, which includes the weight loss
method, SEM, EDS, XRD, and 3D measuring laser microscope, is
employed to detect the extent of corrosion attack. Several conclu-
sions of this work are listed as follows:
Consequently, FeSO4 might be further oxidized to form FeOOH The research leading to these results has received funding from
through an acid regeneration cycle with sufficient O2 (Chio et al., the European Community’s Seventh Framework Programme (FP7-
2007; Nishimura et al., 2004): ENERGY-20121-1-2STAGE) under grant agreement N◦ 308809 (The
IMPACTS project). The authors acknowledge the project partners
4FeSO4 + 6H2 O + O2 → 4FeOOH + 4H2 SO4 (13) and the following funding partners for their contributions: Statoil
Meanwhile, another alternative reaction path for a direct reac- Petroleum AS, Lundin Norway AS, Gas Natural Fenosa, MAN Diesel
tion between the iron and H2 SO4 gas molecules to form FeSO4 was & Turbo SE and Vattenfall AB.
suggested by several researchers (Kranzmann et al., 2011; Ruhl
and Kranzmann, 2013). The possible reaction mechanisms are as
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