Comparisons of corrosion behaviour for X65 and low Cr steels in high pressure CO2-saturated brine

doi:10.1016/j.jmst.2019.08.050

摘要/Abstract

Abstract:

Appropriate materials for injection pipelines and tubing for carbon dioxide geologic storage is fundamental to ensure asset integrity and save cost. This paper evaluates the corrosion behaviour of X65, 1Cr, 3Cr and 5Cr, which have the potential to be injection pipeline/tubing materials. The influence of steel Cr content on the general and localised corrosion behaviour was investigated at time periods from 6 to 192 h at 60 °C and 100 bar. The evolution, morphology and chemistry of corrosion products on the surface of each material were evaluated using a combination of scanning electron microscopy, energy dispersive X-ray spectroscopy and X-ray diffraction and related to their overall corrosion protection. Results indicate that prior to the formation of protective films on the steel surfaces, the resistance of the materials to corrosion increase with increasing Cr content (Corrosion resistance: X65 < 1Cr<3Cr<5Cr). However, as corrosion products evolve, the protection afforded to the different steels significantly varies and decreases with increasing Cr content. × 65 becomes the material with the lowest general corrosion rate by the end of the 192 h experiments and 5Cr exhibits the highest corrosion rate (ranking of corrosion resistance: X65 > 1Cr>3Cr>5Cr). In terms of the corrosion products on X65, both inner amorphous and outer crystalline corrosion layers consist of FeCO₃. For the Cr-containing steels, the outer layer also comprises FeCO₃, but the inner layer is enriched with Cr, and is predominantly amorphous Cr(OH)₃. The extent of localised corrosion (determined using surface profilometry) is noticeably less for X65 compared to the Cr-containing steels. The paper raises questions about the benefits that low Cr steels offer towards extending component design life compared to carbon steel under the test conditions considered here.

Key words: Carbon dioxide, Corrosion, X65, Low-Cr steels, Iron carbonate, Chromium hydroxide

. [J]. 材料科学与技术, 2020, 41(0): 21-32.

Yong Hua, Sikiru Mohammed, Richard Barker, Anne Neville. Comparisons of corrosion behaviour for X65 and low Cr steels in high pressure CO₂-saturated brine[J]. J. Mater. Sci. Technol., 2020, 41(0): 21-32.

图/表 14

Fig. 1. Optical microscope images of microstructures for (a) X65, (b) 1Cr, (c) 3Cr and (d) 5Cr. Note: A typical sample coupon is shown in the insert in (a).

Table 1 Elemental compositions of X65, 1Cr, 3Cr and 5Cr steels (wt.%).

Steel	C	Si	Mn	P	S	Cr	Fe
X65	0.12	0.18	1.27	0.008	0.002	0.11	Balance
1Cr	0.35	0.35	0.75	0.035	0.05	1.12	Balance
3Cr	0.24	0.21	0.53	0.005	0.0015	3.10	Balance
5Cr	0.35	0.85	0.4	0.012	0.002	5.00	Balance

Fig. 2. Schematic of autoclave setup.

Fig. 3. Plots depicting total mass loss (a) and general corrosion rates (b) for X65, 1Cr, 3Cr and 5Cr steel exposed to a CO2-saturated 1 wt.% NaCl solution at different immersion time at 60 °C and 100 bar.

Fig. 4. SEM images of surface morphology of corrosion products formed on X65 exposed to a CO2-saurated 1 wt.% NaCl solution at 60 °C and 100 bar for various immersion periods of 6 h (a), 24 h (b), 96 h (c) and 192 h (d). The corrosion products for 5Cr exposed to a CO2-saurated 1 wt.% NaCl solution at 60 °C and 100 bar for immersion periods of 6 h (e), 24 h (f), 96 h (g) and 192 h (h). The corresponding cross-sections are provided in Fig. 5, Fig. 6.

Fig. 5. Corresponding cross sections of corrosion products formed on X65 carbon steel exposed to a CO2-saturated 1 wt.% NaCl solution at 60 °C and 100 bar for various immersion periods of 6 h (a), 24 h (b), 96 h (c) and 192 h (d).

Fig. 6. SEM images of surface morphology and corresponding cross sections of corrosion products formed on 5Cr steel exposed to a CO2-saturated 1 wt.% NaCl solution at 60 °C and 100 bar for various immersion periods of (a) 6 h, (b) 24 h, (c) 96 h and (d) 192 h..

Fig. 7. SEM cross-section images and EDX maps of X65 (a), 1Cr (b), 3Cr (c) and 5Cr (d) samples exposed to CO2-saturated solution at 100 bar and 60 °C for 192 h.

Fig. 8. XRD patterns of X65, 1Cr, 3Cr and 5Cr samples exposed to a CO2-saturated 1 wt.% NaCl solution at 100 bar and 60 °C for 192 h.

Fig. 9. Raman spectroscopy of corrosion products at particular positions from 5Cr steel exposed to a CO2-saturated 1 wt.% NaCl solution at 60 °C and 100 bar for 192 h.

Fig. 10. Example of profilometry images for X65 (a), 1Cr (b), 3Cr (c) and 5Cr (d) steel surfaces after removal of corrosion products after exposure to a CO2-saturated 1 wt.% NaCl solution at 100 bar and 60 °C for 192 h.

Fig. 11. Mass of corrosion products formed on sample surface and measured pit depth for X65 (a), 1Cr (b), 3Cr (c) and 5Cr (d) exposed to a CO2-saturated 1 wt.% NaCl solution at 60 °C and 100 bar at various immersion time.

Fig. 12. Corrosion rates for X65 and 5Cr after 192 h exposure to a CO2-saturated 1 wt.% NaCl solution at 60 °C and 100 bar. The graphs illustrate the effect of replenishing the test solution after 48 h.

Fig. 13. Schematic model for the corrosion product evolution of inner and outer layer on X65, 1Cr, 3Cr and 5Cr steels.

参考文献

[1]	A. Ikeda, M. Ueda, S. Mukai, Adv. CO2 Corros. 1(1984) 39-51.
[2]	J. Crolet, N. Thevenot, S. Nesic, Corrosion 54 (3) (1998) 194-203.
[3]	S. Nesic, L. Lunde, Corrosion 50 (9) (1994) 717-727.
[4]	E.P. DeGarmo, J.T. Black, R.A. Kohser, B.E. Klamecki, Materials and Process in Manufacturing, Prentice Hall, 1997.
[5]	L.N. Xu, S.Q. Guo, W. Chang, T.H. Chen, L.H. Hu, M.X. Lu, Appl. Surf. Sci. 270(2013) 395-404.
[6]	L. Xu, B. Wang, J. Zhu, W. Li, Z. Zheng, Appl. Surf. Sci. 379(2016) 39-46.
[7]	J. Sun, C. Sun, Y. Wang, Int. J. Electrochem. Sci. 11(2016) 8599-8611.
[8]	C. Chen, M. Lu, D. Sun, Z. Zhang, W. Chang, Corrosion 61 (6) (2005) 594-601.
[9]	M.B. Kermani, A. Morshed, Corrosion 59 (8) (2003) 659-683.
[10]	S.Q. Guo, L.N. Xu, L. Zhang, W. Chang, M.X. Lu, Corros. Sci. 63(2012) 246-258.
[11]	Y. Hua, S.S. Xu, Y. Wang, W. Taleb, J. Sun, L. Zhang, R. Barker, A. Neville, The formation of FeCO3 and Fe3O4 on carbon steel and their protective capabilities against CO2 corrosion at elevated temperature and pressure, Corrosion Science 392-405(2019) 157.
[12]	J.B. Sun, W. Liu, W. Chang, Z.H. Zhang, Z.T. Li, T. Yu, M.X. Lu, Acta Metall. Sin. 45 (1) (2009) 84 (in Chinese).
[13]	J. Sun, C. Sun, X. Lin, X. Cheng, H. Liu, Materials 9 (3) (2016) 200.
[14]	K. Nose, H. Asahi, P.I. Nice, J.W. Martin, Corrosion properties of 3% Cr steels in oil and gas environments, in: Corrosion 2001, 11-16 March, Houston, Texas, 2001.
[15]	S. Hassani, T.N. Vu, N.R. Rosli, S.N. Esmaeely, Y.S. Choi, D. Young, S. Nesic, Int. J. Greenh. Gas Con. 23(2014) 30-43.
[16]	T. Muraki, T. Hara, H. Asahi, Effects of chromium content up to 5% and dissolved oxygen on CO2 corrosion, in: Corrosion 2002, 7-11 April, Denver, Colorado, 2002.
[17]	S.H. Zhang, L.F. Hou, Y.H. Wei, H. Du, H.Y. Wei, B.S. Liu, X.B. Chen, Mater. Corros. 70 (5) (2019) 888-896.
[18]	S. Zhang, L. Hou, H. Wei, Y. Wei, B. Liu, Mater. Corros. 69 (8) (2018) 1123-1130.
[19]	L. Hou, M. Raveggi, X.B. Chen, W. Xu, K.J. Laws, Y. Wei, M. Ferry, N. Birbilis, J. Electrochem. Soc. 163 (6) (2016) C324-C329.
[20]	B. Kermani, J.C. Gonzales, G.L. Turconi, T.E. Perez, C. Morales, In-field corrosion performance of 3% Cr steels in sweet and sour downhole production and water injection, in: Corrosion 2004, 28 March-1 April, New Orleans, Louisiana, 2004.
[21]	A. Dugstad, H. Hemmer, M. Seiersten, Corrosion 57 (4) (2001) 369-378.
[22]	B. Kermani, M. Dougan, J.C. Gonzalez, C. Linne, R. Cochrane, Development of low carbon Cr-Mo steels with exceptional corrosion resistance for oilfield applications, in: Corrosion 2001, 11th-16th March, Houston, Texas, USA, 2001.
[23]	A. Kumar, S.K. Desai, J.L. Pacheco, W. Sun, W. Huang, M. Asmann, Corrosion performance of L80-1Cr and L80-3Cr Oil Country Tubular Goods (OCTG) in high CO2 at elevated temperature, in: Corrosion 2013, 17-21 March, Orlando, Florida, 2013.
[24]	R. Elgaddafi, A. Naidu, R. Ahmed, S. Shah, S. Hassani, S.O. Osisanya, A. Saasen, J. Nat. Gas Sci. Eng. 27(2015) 1620-1629.
[25]	Y. Hua, A. Shamsa, R. Barker, A. Neville, App. Surf. Sci. 455(2018) 667-682.
[26]	M. Ueda, H. Takabe, The formation behavior of corrosion protective films of low Cr bearing steels in CO2 environments, in: Corrosion 2001, 11th-16th March, Houston, Texas, USA, 2001.
[27]	Y. Xiang, H. Huang, Z. Long, C. Li, W. Yan, Int. J. Greenh. Gas Con. 82(2019) 127-137.
[28]	A. Pfennig, R. Bäßler, Corros. Sci. 51 (4) (2009) 931-940.
[29]	E.3-01 ASTM, Standard practice for preparation of metallographic specimens, in: Annual Book of ASTM Standards, ASTM, 2002.
[30]	ASTM E 407-99, Standard Guide for Microetching Metals and Alloys.American Society for Testing Materials.
[31]	Y. Hua, R. Barker, A. Neville, J. Supercrit. Fluid. 97(2015) 224-237.
[32]	Y. Hua, R. Barker, A. Neville, Int. J. Greenh. Gas Con. 31(2014) 48-60.
[33]	Y. Hua, R. Barker, C. T, M. Ward, A. Neville, J. Supercrit. Fluid. 98(2014) 183-193.
[34]	MultiScale 7.1 is a commercial software package from Expro Group International Ltd, .
[35]	ASTM, Standard G1-03, Standard Practice for Preparing, Cleaning, and Evaluating Corrosion Test Specimens, ASTM International, West Conshohocken, PA, 2003.
[36]	ASTM, Standard G46-94, Standard Guide for Examination and Evaluation of Pitting Corrosion, ASTM International, West Conshohocken, PA, 2003.
[37]	M.H. Nazari, S. Allahkaram, M. Kermani, Mater. Des. 31 (7) (2010) 3559-3563.
[38]	A. Dugstad, Mechanism of protective film formation during CO2 corrosion of carbon steel, in: Corrosion 98, NACE International, Sand Diego, CA, NACE, 1998.
[39]	W. Sun, S. Nesic, Corrosion (2006) 06365.
[40]	A. Dugstad, Texas, 1992.

Comparisons of corrosion behaviour for X65 and low Cr steels in high pressure CO₂-saturated brine

RichHTML

PDF (PC)

可视化

摘要/Abstract

引用本文

使用本文

图/表 14

参考文献

相关文章 0

编辑推荐

Metrics

本文评价