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Keywords: Corrosion by CO2/H2S, corrosion products, API 5L X70 steel, polarization resistance
Abstract
Corrosion caused by the mixture CO2/H2S in the transport of hydrocarbons is one of the most
important research areas in the energy industry due to the severe problems it produces during the
wear and tear of the pipes. Based in previous studies, in the present investigation the corrosion of API
5L X-70 steel in media with CO2 and H2S is studied as well as mixtures of both media, by means of a
rotating cylindrical electrode due to the need to know the behavior of corrosion products in metals.
The corrosion rate is evaluated at different pressures of H2S and CO2 and at 30 and 60 °C using the
potentiodynamic polarization resistance measurements. From the results, it is observed that steel at
the conditions of 0.8 bar H2S+0.2 bar CO2 at 30 °C, yielded the lowest corrosion rate. This behavior
is attributed to the fact that when H2S predominates it allows the formation of a greater number of
protective layers comprised by a mixture of oxides, sulfides, sulfates and carbonates as corrosion
products.
1. Introduction
The corrosion study specifically in hydrocarbons transport is great interesting because any metal lost means a
reduction in the physical integrity and useful life of the pipelines, consequently the risk of failure of these
increases. The pipes internal corrosion is caused by the interaction between the wall and the transported
products. However, factors such as pressure, temperature, water-hydrocarbon ratio, pH, presence of corrosion
products and flow rate are variables that affect the corrosion process [1]. The flow rate effect is considered as one
of the most significant parameters in corrosion that occurs in the petrochemical industry, causing the Flow
Accelerated Corrosion (FAC), this corrosion type occurs when there is an speed increase between the corrosive
solution and the metal surface [2], increasing the mass transport [1] harming the pipeline inner surface. It has
been observed that a high speed, there is a removal of the protective oxide film or the formation of these films is
prevented, leading to a non-protected surface [3]. Also, the presence of polluting gases such as CO2 and H2S
dissolved in water pipelines, increases significantly the corrosion problem. Corrosion proceeds rapidly by
electrochemical means and the corrosion rate accelerates as the velocity of the fluid increases. Dissolution of
protective magnetite oxide layer into flowing stream of water causes wall thinning (metal loss) of carbon steel [4].
Flow accelerated corrosion (FAC) of the carbon steel is one of the most important subjects in the coolant systems
of the power plants. FAC normally occurs in the turbulent flow region in the feed water systems [5].
The CO2 presence, originates the sweet corrosion inside the oil pipelines, because when CO2 is dissolved in
water, it is hydrates and generates a weak acid, H2CO3, decreasing the pH in the solution and increasing the
corrosion rate [6]. This corrosion type has been observed in carbon steel, forming FeCO3 that precipitate on the
metal surface below 60 °C as a impermeable corrosion product, but above this temperature, becomes permeable
[7], thus yielding a plateau-localized corrosion increasing when the medium is in motion. The H2S originates the
sour corrosion that is less corrosive than sweet corrosion, but nevertheless, the H2S is three times more soluble in
water than CO2, dissociating in H + and HS−, which in combination capturing the iron dissolved in the anode
and form FeS in a colloidal form that is semi-protective but unstable, leaving the metal exposed to the action of
corrosive agents producing pitting corrosion generally [8]. The presence of CO2 and H2S originate a highly
corrosive mixture that can generate pitting corrosion, hydrogen damage and other corrosion localized types. In
presence of CO2 and H2S has been observed that the carbonates are deposited on corroded metal and the
primary layer due to the carbonate recrystallization [9]. The FeS, is located preferentially in the pearlite regions
presenting a deterioration in the ferritic zone and that according Uhlig and Revie [10], the cementite acts as a
cathode respect to ferrite in acid solution resulting a galvanic couple and forming a corrosion cell where the
anodic reaction or dissolution of iron, occurs mainly in the ferrite, however, the formation of FeCO3 (siderite)
[7], constitutes a protective layer that decreases the corrosion rate. The corrosion type observed in systems where
CO2 and H2S are present, will depend on the existing CO2/H2S ratio [11]. It has been observed that at high
CO2/H2S ratios, the corrosion tends to be generalized but when the concentration of H2S increases, the
corrosion is localized due the carbonate and sulphide films are semi protective, they have a poor adhesion and
low protection, originating the pittings formation. The pitting occurs in areas where the protective FeS does not
fully cover the steel surface. This corrosion type propagates due to a depletion the ferrous ion in the pit, which
reacts with the H2S to form FeS, but this product does not reach the external surface of the pit, while the rest of
FeS in the metal surface precipitates away from the localized attack. At low pH values, it is difficult that a stable
sulfide layer is formed, but pH increasing, the FeS is most porous and can act as a great cathode surface,
producing localized corrosion. Due to the above, the interaction of these two compounds in the steel corrosive
process is influenced by pH, for example, at low pH, the FeCO3 solubility decreases, forming a protective film. In
alkaline solutions, the FeS formation it is be favoreced for the solid sulphur solubility, decreasing and for the H2
redución reaction, easily forming the corrosion products that will provide protection to steel, decreasing the
corrosion rate. The temperature is an other important factor that has influence on these processes; it is known
that at high temperature, there is an increase in the corrosion rate due to the acceleration of anodic and cathodic
reactions [12], however, at high temperatures, precipitation rates are increased and the protective films
formation is easier also acelerates the moisture evaporation process on the metal decreasing the oxygen and
other gases concentration dissolved in it, changing the corrosion products properties [13], reducing the
corrosion rate. Ramanarayan [14], affirms that CO2 dominated systems with small amounts of H2S
(PCO2/H2S>200), produce mackinawite at temperatures below 120 °C and the system where H2S prevails
(PCO2/H2S<200), a carbonate layer is preferentially formed that protects the metal between 60 and 240 °C.
In summary, it is important to carry out studies that consider the the corrosion speed analysis as a function of
the fluid flow velocity, the CO2/H2S ratio, the temperature and the pH, so the investigation objective is
determine the corrosion rates for API 5L X-70 steel exposed to a corrosive medium containing brine-kerosene to
at one bar of CO2 and an H2S bar independently, as well as in a mixture of brine-CO2/H2S in different
proportions, by using the rotating cylinder electrode (RCE) in a range of 0 to 6500 rpm and a temperature from
30 to 60 °C characterizing corrosion products by Scanning electron microscopy (SEM) and X-ray
Diffraction (XRD).
2. Experimental section
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(a) Sweet medium (CO2) with the addition of 15.396 g of CaCO3 and 10.992 ml of HCl (reactive grade) and
1382.7 ppm (equivalent to 1 bar of CO2 pressure).
(b) Sour medium (H2S) adding 2916 g of Na2S.9H2O and 1392 ml of CH3COOH (equivalent to 1 bar pressure
H2S).
(c) Medium with 0.8 bar H2S and 0.2 bar CO2, with the addition of 2.335 g of Na2S.9H2O, 1.124 ml of
CH3COOH, 3.072 g of CaCO3 and 2.197 ml of HCl, 1106.16 ppm of H2S and 4413.87 ppm of CO2
(equivalent to 1 bar of H2S and CO2 pressure).
(d) Medium with 0.2 bar H2S and 0.8 bar CO2, with the addition of 0.583 g of Na2S.9H2O, 0.281 ml of
CH3COOH, 12.289 g of CaCO3 and 8.789 ml of HCl, 276.54 ppm of H2S and 17657.62 ppm of CO2
(equivalent to 1 bar of H2S and CO2 pressure).
The pH of solution was adjusted directly between 4 and 6, using a pH meter. The temperatures of the
chemical means were 30 and 60 °C and the pressure of 1 bar in all cases.
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%Weight
Figure 1. Corrosion rate of API 5L X70 steel in the presence of 1 bar of H2S at 30 and 60 °C.
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Mater. Res. Express 6 (2019) 066550 B F Pérez-Ramírez et al
Figure 2. Corrosion rate of API 5L X70 steel in the presence of 1 bar of CO2 at 30 and 60 °C.
Figure 3. Corrosion rate of API 5L X70 steel in the presence of 0.8 bar of H2S+0.2 bar of CO2 at 30 and 60 °C.
rate, decrease to values close to zero, which indicates that the combination mainly of oxides like the cubic
magemite, the orthorhombic cementite as carbure and the rhombohedral siderite as a carbonate, form a more
stable and adherent film, protecting the steel.
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Figure 4. Corrosion rate of API 5L X70 steel in the presence of 0.2 bar of H2S+0.8 bar of CO2 at 30 and 60 °C.
Figure 5. Corrosion rate of API 5L X70 steel in the presence of 0.2 bar of H2S+0.8 bar of CO2 and 0.8 bar of H2S+0.2 bar of CO2 at
30 °C.
the low pressure of H2S was not sufficient to form sulfides and sulfates which have shown that in combination
with carbonates and carbides, form a stable, adherent and protective film [24–27].
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Mater. Res. Express 6 (2019) 066550 B F Pérez-Ramírez et al
Figure 6. XRD patterns of corrosion products formed of API 5L X70 steel in the presence of 1 bar H2S at 30 and 60 °C.
Figure 7. XRD patterns of corrosion products formed of API 5L X70 steel in the presence of 1 bar CO2 at 30 and 60 °C.
Figure 9 shows the case of 0.2 bar H2S+0.8 bar CO2 at 30 °C, the predominant phase was identified as
mikasaite and at 60 °C, the presence of cementite and troilite was also observed. On the other hand, the effect of
the increase in temperature causes the corrosion products to be easily detached due to the effect of the flow due
to the fact that they become not very adherent.
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Figure 8. XRD patterns of corrosion products formed of API 5L X70 steel in the presence of 0.8 bar H2S+0.2 bar CO2 at 30 and
60 °C.
Figure 9. XRD patterns of corrosion products formed of API 5L X70 steel in the presence of 0.2 bar H2S+0.8 bar CO2 at 30 and
60 °C.
In figures 11(a) and (b) for the sour medium but at 60 °C, it is observed that the mackinawite does not form a
homogeneous film, besides few agglomerates corresponding to maghemite, magnetite and triolite. The small
amount of agglomerates, the instability, the rotational speed and the predominant cactus form, favour the direct
contact of the corrosive agent, steel being unprotected, so the corrosion rate is the highest observed in sweet and
sour media.
In the sweet medium (1 bar CO2), at 30 °C, in figures 12(a) and (b), the homogeneous formation of
agglomerates of magemite, siderite and cementite, of the cactus and dentate type are observed. This combination
cause stability and ahesion of the protective film [28].
At 60 °C (figures 13(a) and (b)), steel zones protected by the corrosion products are distributed more
uniformly, corresponding mainly to the magemite and siderite, whose combination has good adhesion, in
addition, the corrosion products correspond of rosebund shape forming chains, which allows a not uniform
flow of the medium, achieving the best protection for steel and lowest corrosion rate.
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Figure 10. Micrographs of corrosion products of the medium 1 bar H2S at 30 °C at 25X and 100X.
Figure 11. Micrographs of the products of corrosion of the medium 1 bar H2S at 60 °C to 25X and 100X.
Figure 12. Micrographs of the corrosion products of the medium 1 bar CO2 at 30 °C to 25X and 100X.
Figure 13. Micrographs of the corrosion products of the medium 1 bar CO2 at 60 °C at 25X and 100X.
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Figure 14. Micrographs of corrosion products of the medium 0.8 bar H2S+0.2 bar CO2 at 30 °C at 25X and 100X.
Figure 15. Micrographs of corrosion products of the medium 0.8 bar H2S+0.2 bar CO2 at 60 °C at 25X and 100X.
Figure 16. Micrographs of corrosion products of the medium 0.2 bar H2S+0.8 bar CO2 at 30 °C at 25X and 100X.
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Figure 17. Micrographs of corrosion products of the medium 0.2 bar H2S+0.8 bar CO2 at 60 °C at 25X and 100X.
temperatures analyzed. The main corrosion product corresponds to the mikasaite with an irregular morphology
of cactus, rosebud and dentate type.
For the medium 0.2 bar H2S+0.8 bar CO2 at 60 °C shown in figure 17, it is observed corrosion product
layer that correspond mainly to the siderite, cementite and troilite that is perceived to be cracked likely due to the
flow of the corrosive medium causing that the steel is in direct contact with this medium. The cactus and dentate
type morphology of the corrosion products at this temperature is more homogeneous and stable than at 30 °C.
4. Conclusions
In the mixture of CO2+H2S it is observed the presence of oxides, sulfides, sulfates and carbonates as corrosion
products.
The medium that offers the best protection to the steel studied is that 0.8 bar H2S+0.2 bar CO2 at 30 °C,
due to the dominant effect of the sour medium, that is, there is a greater presence of protective sulphides such as
mackinawite, troillite and pyrite.
The medium 0.2 bar H2S+0.8 bar CO2, at 30 °C shown the higher corrosion rates although form
carbonate (siderite) and iron carbides (Fe3C), but this corrosion products are not to be good protective steel.
This behavior is due to the small amount of H2S which is not sufficient to form sulfides which has been shown
that in combination with carbonates and carbides, form a stable, adherent and protective film.
Acknowledgments
The authors are also grateful for the financial support to CONACYT and SIP-IPN.
ORCID iDs
M Díaz-Cruz https://orcid.org/0000-0002-5942-3636
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