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

doi:10.1016/j.jmst.2019.08.050

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

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: 21-32.

Figures/Tables 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.

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

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