Corrosion of carbon steel in presence of mixed deposits under stagnant seawater conditions

Electrochemical Study on the Macro-Cell Corrosion of Pipeline Steel Partially Covered by Different Kinds of Mineral Deposits

This study presents the impact of mineral deposits (SiO2, Al2O3, and CaCO3) on the corrosion behavior of X65 pipeline steel in CO2-containing brine solution with low pH. The study investigates the initiation and propagation of under deposit corrosion (UDC) using a wire beam electrode (WBE) partially covered by different mineral deposit layers, in conjunction with electrochemical measurements and surface characterization. The results indicate that the corrosion behavior varies, depending on the characteristics of the deposit. During the test period, the Al2O3-covered steel acted as the main anode with more negative potential, while the bare steel acted as the cathode. The SiO2-covered steel acted as the cathode with more positive potential and a localized FeCO3 layer formed beneath the silica mineral. The CaCO3-covered steel initially acted as an anode with a more negative potential but transformed into the cathode at the end of the test. Additionally, shallow and small pits were observed beneath the deposits with the depth in the sequence Al2O3 > SiO2 > CaCO3.

Erosion-Corrosion Behavior of Friction Stud Welded Joints of X65 Pipelines in Simulated Seawater under Different Flow Rates

In order to study the complex erosion-corrosion mechanism of friction stud welded joints in seawater, experiments were carried out in the mixed solution of 3 wt% sea sand and 3.5% NaCl at flow rates of 0 m/s, 0.2 m/s, 0.4 m/s, and 0.6 m/s. The effects of corrosion and erosion-corrosion at different flow rates on materials were compared. The corrosion resistance of X65 friction stud welded joint was studied by electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization (PDP) curves. The corrosion morphology was observed by a scanning electron microscope (SEM), and the corrosion products were analyzed by energy dispersive spectroscopy (EDS) and X-ray diffraction (XRD). The results showed that the corrosion current density decreased first and then increased with the increase in the simulated seawater flow rate, which indicated that the corrosion resistance of the friction stud welded joint increased first and then decreased. The corrosion products are FeOOH (α-FeOOH and γ-FeOOH), and Fe₃O₄. According to the experimental results, the erosion-corrosion mechanism of friction stud welded joints in seawater environment was predicted.

Sulfur-oxidizing bacteria (SOB) and sulfate-reducing bacteria (SRB) in oil reservoir and biological control of SRB: a review

Sulfur-oxidizing bacteria (SOB) and sulfate-reducing bacteria (SRB) inhabit oilfield production systems. Sulfur oxidation driven by SOB and dissimilatory sulfate reduction driven by SRB play important roles in sulfur cycle of oil reservoirs. More importantly, hydrogen sulfide produced by SRB is an acidic, flammable, and smelly toxic gas associated with reservoir souring, corrosion of oil-production facilities, and personnel safety. Effective control of SRB is urgently needed for the oil industry. This depends on an in-depth understanding of the microbial species that drive sulfur cycle and other related microorganisms in oil reservoir environments. Here, we identified SOB and SRB in produced brines of Qizhong block (Xinjiang Oilfield, China) from metagenome sequencing data based on reported SOB and SRB, reviewed metabolic pathways of sulfur oxidation and dissimilatory sulfate reduction, and ways for SRB control. The existing issues and future research of microbial sulfur cycle and SRB control are also discussed. Knowledge of the distribution of the microbial populations, their metabolic characteristics and interactions can help to develop an effective process to harness these microorganisms for oilfield production.

In Situ Investigation of Under-Deposit Microbial Corrosion and its Inhibition Using a Multi-Electrode Array System

Carbon steel pipelines used in the oil and gas industry can be susceptible to the combined presence of deposits and microorganisms, which can result in a complex phenomenon, recently termed under-deposit microbial corrosion (UDMC). UDMC and its inhibition in CO₂ ambiance were investigated in real-time using a multi-electrode array (MEA) system and surface profilometry analysis. Maps from corrosion rates, galvanic currents, and corrosion potentials recorded at each microelectrode allowed the visualization of local corrosion events on the steel surface. A marine bacterium Enterobacter roggenkampii, an iron-oxidizing, nitrate-reducing microorganism, generated iron deposits on the surface that resulted in pitting corrosion under anaerobic conditions. Areas under deposits displayed anodic behavior, more negative potentials, higher corrosion rates, and pitting compared to areas outside deposits. In the presence of the organic film-forming corrosion inhibitor, 2-Mercaptopyrimidine, the marine bacterium induced local breakdown of the protective inhibitor film and subsequent pitting corrosion of carbon steel. The ability of the MEA system to locally measure self-corrosion processes, galvanic effects and, corrosion potentials across the surface demonstrated its suitability to detect, evaluate and monitor the UDMC process as well as the efficiency of corrosion inhibitors to prevent this corrosion phenomenon. This research highlights the importance of incorporating the microbial component to corrosion inhibitors evaluation to ensure chemical effectiveness in the likely scenario of deposit formation and microbial contamination in oil and gas production equipment.

Investigating the Properties of Electrodeposited of Ni-P-ZrC Nanocomposite Coatings

Superior corrosion resistance along with higher mechanical performance is becoming a primary requirement to decrease operational costs in the industries. Nickel-based phosphorus coatings have been reported to show better corrosion resistance properties but suffer from a lack of mechanical strength. Zirconium carbide nanoparticles (ZCNPs) are known for promising hardness and unreactive behavior among variously reported reinforcements. The present study focuses on the synthesis and characterization of novel Ni-P-ZrC nanocomposite coatings developed through the electrodeposition technique. Successful coelectrodeposition of ZCNPs without any observable defects was carried out utilizing a modified Watts bath and optimized conditions. For a clear comparison, structural, surface, mechanical, and electrochemical behaviors of Ni-P and Ni-P-ZrC nanocomposite coatings containing 0.75 g/L ZCNPs were thoroughly investigated. The addition of ZCNPs has a considerable impact on the properties of Ni-P coatings. Enhancement in the mechanical properties (microhardness, nanoindentation, wear, and erosion) is observed due to reinforcement of ZCNPs in the Ni-P matrix, which can be attributed to mainly the dispersion hardening effect. Furthermore, corrosion protection efficiency (PE%) of the Ni-P matrix was enhanced by the incorporation of ZCNPs from 71 to 85.4%. The Ni-P-ZrC nanocomposite coatings provide an exciting option for their utilization in the automotive, electronics, aerospace, oil, and gas industry.

Characterization of crude oil degrading bacterial communities and their impact on biofilm formation

In the present study, produced water sample collected from the Indian crude oil reservoir is used to enrich the bacterial communities. The impact of these enriched bacterial communities on the biodegradation of crude oil, biofilm formation, and biocorrosion process are elucidated. A crude oil degradation study is carried out with the minimal salt medium and 94% of crude oil was utilized by enriched bacterial communities. During the crude oil degradation many enzymes including alkane hydroxylase, alcohol dehydrogenase, and lipase are playing a key role in the biodegradation processes. The role of enriched bacterial biofilm on biocorrosion reactions are monitored by weight loss studies and electrochemical analysis. Weight loss study revealed that the biotic system has vigorous corrosion attacks compared to the abiotic system. Both AC-Impedance and Tafel analysis confirmed that the nature of the corrosion reaction take place in the biotic system. Very less charge transfer resistance and higher corrosion current are observed in the biotic system than in the abiotic system. Scanning electron microscope confirms that the dense biofilm formation favoured the pitting type of corrosion. X-ray diffraction analysis confirms that the metal oxides formed in the corrosion systems (biotic). From the metagenomic analysis of the V3-V4 region revealed that presence of diverse bacterial communities in the biofilm, and most of them are uncultured/unknown. Among the known genus, Bacillus, Halomonas, etc are dominant in the enriched bacterial biofilm sample. From this study, we conclude that the uncultured bacterial strains are found to be playing a key role in the pitting type of corrosion and they can utilize crude oil hydrocarbons, which make them succeeded in extreme oil reservoir environments.

Bacterial community analysis of biofilm on API 5LX carbon steel in an oil reservoir environment

This study aimed to characterize the biofilm microbial community that causes corrosion of API 5LX carbon steel. API 5LX carbon steel coupons were incubated with raw produced water collected from two oil reservoir stations or filter-sterilized produced water. Biofilm 16S rRNA amplicon sequencing revealed that the bacterial community present in the biofilm was dominated by Proteobacteria, including Marinobacter hydrocarbonoclaustics and Marinobacter alkaliphilus. Electrochemical analysis such as impedance and polarization results indicated that Proteobacteria biofilm accelerated corrosion by ~ twofold (2.1 ± 0.61 mm/years) or ~ fourfold (~ 3.7 ± 0.42 mm/years) when compared to the control treatment (0.95 ± 0.1 mm/years). Scanning electron and atomic force microscopy revealed the presence of a thick biofilm and pitting corrosion. X-ray diffraction revealed higher amounts of the corrosion products Fe₂O₃, γ-FeOOH, and α-FeOOH, and confirmed that the microbial biofilm strongly oxidized the iron and contributed to the acceleration of corrosion of carbon metal API 5LX.

Investigation of Laser Power Output and Its Effect on Raman Spectrum for Marine Metal Corrosion Cleaning

The relationship between the laser power output and its effect on Raman spectrum is investigated for a laser cleaning application of marine metal corrosion processing. First, an image feature based on a corrosion degree evaluation is implemented before cleaning. The image features include texture coarseness, texture entropy, texture intensity, texture contrast, the texture’s cluster degree, and texture homogeneity. To decrease the image feature dimension for a convenient application, the Analytic Hierarchy Process (AHP) method is used to estimate the weight of each feature. Then the linear weighted sum of image features can be computed to get only one evaluation result. Second, a series of laser power outputs are implemented for the cleaning application under a typical corrosion degree. Then the analysis results of Raman spectrum can be obtained. The analyzed spectrum results include the corrosion components and their contents. Lastly, the relationship between laser power output and Raman spectrum under a typical initial corrosion degree can be constructed. This research study can build the prediction result of the cleaning effect map for the workpiece and guide the secondary processing of metal surface cleaning.

Electrochemical Comparison of SAN/PANI/FLG and ZnO/GO Coated Cast Iron Subject to Corrosive Environments

ZnO/GO (Graphene Oxide) and SAN (Styrene Acrylonitrile)/PANI (Polyaniline)/FLG (Few Layers Graphene) nanocomposite coatings were produced by solution casting and sol-gel methods, respectively, to enhance corrosion resistance of ferrous based materials. Corrosive seawater and ‘produced crude oil water’ environments were selected as electrolytes for this study. Impedance and coating capacitance values obtained from Electrochemical Impedance Spectroscopy (EIS) Alternating Current (AC technique) showed enhanced corrosion resistance of nanocomposites coatings in the corrosive environments. Tafel scan Direct Current (DC technique) was used to find the corrosion rate of nanocomposite coating. SAN/PANI/FLG coating reduced the corrosion of bare metal up to 90% in seawater whereas ZnO/GO suppressed the corrosion up to 75% having the impedance value of 100 Ω. In produced water of crude oil, SAN/PANI/FLG reduced the corrosion up to 95% while ZnO/GO suppressed the corrosion up to 10%. Hybrid composites of SAN/PANI/FLG coatings have demonstrated better performances compared to ZnO/GO in the corrosive environments under investigation. This study provides fabrication of state-of-the-art novel anti corrosive nanocomposite coatings for a wide range of industrial applications. Reduced corrosion will result in increased service lifetime, durability and reliability of components and system and will in turn lead to significant cost savings.