First stages of siderite crystallisation during CO2 corrosion of steel evaluated using in situ synchrotron small- and wide-angle X-ray scattering

In Situ and Operando X-ray Scattering Methods in Electrochemistry and Electrocatalysis

Electrochemical and electrocatalytic processes are of key importance for the transition to a sustainable energy supply as well as for a wide variety of other technologically relevant fields. Further development of these processes requires in-depth understanding of the atomic, nano, and micro scale structure of the materials and interfaces in electrochemical devices under reaction conditions. We here provide a comprehensive review of in situ and operando studies by X-ray scattering methods, which are powerful and highly versatile tools to provide such understanding. We discuss the application of X-ray scattering to a wide variety of electrochemical systems, ranging from metal and oxide single crystals to nanoparticles and even full devices. We show how structural data on bulk phases, electrode-electrolyte interfaces, and nanoscale morphology can be obtained and describe recent developments that provide highly local information and insight into the composition and electronic structure. These X-ray scattering studies yield insights into the structure in the double layer potential range as well as into the structural evolution during electrocatalytic processes and phase formation reactions, such as nucleation and growth during electrodeposition and dissolution, the formation of passive films, corrosion processes, and the electrochemical intercalation into battery materials.

Substrate Protection with Corrosion Scales: Can We Depend on Iron Carbonate?

Controlling corrosion with naturally occurring corrosion scales is potentially a more environmentally sustainable alternative to current approaches, including dosing of organic corrosion inhibitors. We report operando grazing incidence X-ray diffractograms correlated with electrochemical measurements to elucidate the growth and corrosion protection properties of a corrosion scale composed of FeCO₃ crystallites, which is encountered in various key energy industry applications. Data, acquired as a function of time from high-purity iron immersed in CO₂-saturated deionized H₂O at pH 6.8 and T = 80 °C, show that the FeCO₃ scale not only prevents corrosion of the covered substrate but also acts as a significant interfacial diffusion barrier for corrosion reagents and/or products once sufficient coverage is achieved. Most notably, from a corrosion engineering perspective, however, it is determined that corrosion occurring in gaps between scale crystallites remains appreciable; this important insight is gained through the analysis of electrochemical impedance spectra to estimate the variation in electrochemically active surface area as scale coverage increases. These results indicate that naturally occurring FeCO₃ scales are not a tenable solution for corrosion protection, as even in their intact state they are highly likely to be, at best, semiprotective.

Electrochemical and thermodynamic study on the corrosion performance of API X120 steel in 3.5% NaCl solution

The present work studied the effect of temperature on the corrosion behavior of API X120 steel in a saline solution saturated with CO2 in absence and presence of polyethyleneimine (PEI) as an environmentally safe green inhibitor. The effect of PEI on the corrosion behavior of API X120 steel was investigated using destructive and non-destructive electrochemical techniques. The overall results revealed that PEI significantly decreases the corrosion rate of API X120 steel with inhibition efficiency of 94% at a concentration of 100 μmol L-1. The adsorption isotherm, activation energy and the thermodynamic parameters were deduced from the electrochemical results. It is revealed that the adsorption of PEI on API X120 steel surface follows Langmuir adsorption isotherm adopting a Physi-chemisorption mechanism. Finally, the samples were characterized using scanning electron microscopy (SEM) and atomic force microscopy (AFM) techniques to elucidate the effect of aggressiveness of corrosive media on the surface morphology and the corrosion performance of API X120 steel. The surface topography result indicates that the API X120 steel interface in PEI presence is smoother than CO2 with Cl- ions or Cl- ions only. This is attributed to the compact protective film limits the aggressive ions transfer towards the metallic surface and reduces the corrosion rate. Moreover, PEI inhibition mechanism is based on its CO2 capturing ability and the PEI adsorption on the steel surface beside the siderite layer which give the PEI molecules the ability to reduce the scale formation and increase the corrosion protection due to capturing the CO2 from the brine solution.

Baltic Sea methanogens compete with acetogens for electrons from metallic iron

Microbially induced corrosion of metallic iron (Fe⁰)-containing structures is an environmental and economic hazard. Methanogens are abundant in low-sulfide environments and yet their specific role in Fe⁰ corrosion is poorly understood. In this study, Sporomusa and Methanosarcina dominated enrichments from Baltic Sea methanogenic sediments that were established with Fe⁰ as the sole electron donor and CO₂ as the electron acceptor. The Baltic-Sporomusa was phylogenetically affiliated to the electroactive acetogen S. silvacetica. Baltic-Sporomusa adjusted rapidly to growth on H₂. On Fe⁰, spent filtrate enhanced growth of this acetogen suggesting that it was using endogenous enzymes to retrieve electrons and produce acetate. Previous studies have proposed that acetate produced by acetogens can feed commensal acetoclastic methanogens such as Methanosarcina. However, Baltic-methanogens could not generate methane from acetate, plus the decrease or absence of acetogens stimulated their growth. The decrease in numbers of Sporomusa was concurrent with an upsurge in Methanosarcina and increased methane production, suggesting that methanogens compete with acetogens for electrons from Fe⁰. Furthermore, Baltic-methanogens were unable to use H₂ (1.5 atm) for methanogenesis and were inhibited by spent filtrate additions, indicating that enzymatically produced H₂ is not a favorable electron donor. We hypothesize that Baltic-methanogens retrieve electrons from Fe⁰ via a yet enigmatic direct electron uptake mechanism.

Corrosion of carbon steel and the passivating properties of corrosion films formed under high-PT geothermal conditions

Corrosion is a major obstacle to a safe implementation of geotechnical applications. Using a novel approach that includes vertical scanning interferometry (VSI) and electrochemical impedance spectroscopy (EIS) we discuss time-dependent carbon steel corrosion and film formation at geothermally relevant temperatures (80-160 °C) in CO₂-saturated mildly acidic NaCl brine. Iron dissolution kinetics follows a logarithmic rate at 80 and 160 °C and a linear rate at 120 °C. At 80 °C, high initial corrosion rates (first 24 h) generate H₂ at a minimum rate of 12 μmol h^-1 cm^-2 and lead to the formation of a continuous ~100 μm thick porous corrosion film. It exhibits a duplex structure with a crystalline outer FeCO₃ layer and an inner layer composed of a skeletal network of Fe₃C impregnated with FeCO₃. Being an electrical conductor we hypothesize the Fe₃C to strongly enhance corrosion rates by providing additional cathodic sites. Pseudo-passivity due to an anodic film-forming reaction (presumably Fe-oxide) was observed at 120 and 160 °C, soon followed by the initiation of pitting at 120 °C. Steady-state corrosion rates at 160 °C are at least one order of magnitude lower than for 120 °C. Our experimental approach demonstrated potential for general applicability in studying corrosion-related phenomena.

Emerging surface characterization techniques for carbon steel corrosion: a critical brief review

Carbon steel is a preferred construction material in many industrial and domestic applications, including oil and gas pipelines, where corrosion mitigation using film-forming corrosion inhibitor formulations is a widely accepted method. This review identifies surface analytical techniques that are considered suitable for analysis of thin films at metallic substrates, but are yet to be applied to analysis of carbon steel surfaces in corrosive media or treated with corrosion inhibitors. The reviewed methods include time of flight-secondary ion mass spectrometry, X-ray absorption spectroscopy methods, particle-induced X-ray emission, Rutherford backscatter spectroscopy, Auger electron spectroscopy, electron probe microanalysis, near-edge X-ray absorption fine structure spectroscopy, X-ray photoemission electron microscopy, low-energy electron diffraction, small-angle neutron scattering and neutron reflectometry, and conversion electron Moessbauer spectrometry. Advantages and limitations of the analytical methods in thin-film surface investigations are discussed. Technical parameters of nominated analytical methods are provided to assist in the selection of suitable methods for analysis of metallic substrates deposited with surface films. The challenges associated with the applications of the emerging analytical methods in corrosion science are also addressed.

Development of an electrochemically integrated SR-GIXRD flow cell to study FeCO3 formation kinetics

An electrochemically integrated Synchrotron Radiation-Grazing Incidence X-Ray Diffraction (SR-GIXRD) flow cell for studying corrosion product formation on carbon steel in carbon dioxide (CO₂)-containing brines typical of oil and gas production has been developed. The system is capable of generating flow velocities of up to 2 m/s at temperatures in excess of 80 °C during SR-GIXRD measurements of the steel surface, enabling flow to be maintained over the course of the experiment while diffraction patterns are being collected. The design of the flow cell is presented, along with electrochemical and diffraction pattern transients collected from an initial experiment which examined the precipitation of FeCO₃ onto X65 carbon steel in a CO₂-saturated 3.5 wt. % NaCl brine at 80 °C and 0.1 m/s. The flow cell is used to follow the nucleation and growth kinetics of FeCO₃ using SR-GIXRD linked to the simultaneous electrochemical response of the steel surface which were collected in the form of linear polarisation resistance measurements to decipher in situ corrosion rates. The results show that FeCO₃ nucleation could be detected consistently and well before its inhibitive effect on the general corrosion rate of the system. In situ measurements are compared with ex situ scanning electron microscopy (SEM) observations showing the development of an FeCO₃ layer on the corroding steel surface over time confirming the in situ interpretations. The results presented demonstrate that under the specific conditions evaluated, FeCO₃ was the only crystalline phase to form in the system, with no crystalline precursors being apparent. The numerous capabilities of the flow cell are highlighted and presented in this paper.

Corrosion chemistry closing comments: opportunities in corrosion science facilitated by operando experimental characterization combined with multi-scale computational modelling

Recent advances in characterization tools, computational capabilities, and theories have created opportunities for advancement in understanding of solid–fluid interfaces at the nanoscale in corroding metallic systems. The Faraday Discussion on Corrosion Chemistry in 2015 highlighted some of the current needs, gaps and opportunities in corrosion science. Themes were organized into several hierarchical categories that provide an organizational framework for corrosion. Opportunities to develop fundamental physical and chemical data which will enable further progress in thermodynamic and kinetic modelling of corrosion were discussed. These will enable new and better understanding of unit processes that govern corrosion at the nanoscale. Additional topics discussed included scales, films and oxides, fluid–surface and molecular–surface interactions, selected topics in corrosion science and engineering as well as corrosion control. Corrosion science and engineering topics included complex alloy dissolution, local corrosion, and modelling of specific corrosion processes that are made up of collections of temporally and spatially varying unit processes such as oxidation, ion transport, and competitive adsorption. Corrosion control and mitigation topics covered some new insights on coatings and inhibitors. Further advances inoperandoorin situexperimental characterization strategies at the nanoscale combined with computational modelling will enhance progress in the field, especially if coupling across length and time scales can be achieved incorporating the various phenomena encountered in corrosion. Readers are encouraged to not only to use thisad hocorganizational scheme to guide their immersion into the current opportunities in corrosion chemistry, but also to find value in the information presented in their own ways.