The Unique Challenges of Managing Microbiological Corrosion

The Unique Challenges of Managing Microbiological Corrosion

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5 Obstacles Corrosion Professionals Must Navigate in MIC Prevention

Microbiological corrosion (MIC) is a significant threat in many industries. The consequences of failing to effectively manage MIC range from reduced structural integrity to catastrophic failures, extensive damage, financial losses, and loss of life. (We discussed seven such failures in our recent article, ‘Real Life Impacts of Microbiologically-Influenced Corrosion‘.

However, the management of MIC is not without unique challenges. The corrosion-causing microorganisms are diverse and thrive in some of the harshest environments. These include oil and gas pipelines, cooling systems, marine structures, and even household plumbing. MIC exhibits distinctive characteristics that distinguish it from other types of corrosion mechanisms, too.

In this article, we’ll take you on a journey that explores the challenges of managing MIC. It will highlight some essential knowledge that is required if we are to mitigate the detrimental effects of microbiological corrosion to enhance safety or working environments and increase the longevity of our industrial (and public) infrastructure.

The 5 Challenges of Managing Microbiological Corrosion

The unique challenges of managing MIC demand attention and proactive measures from corrosion professionals and the industries in which they operate. We see these challenges falling under five distinct categories:

  1. Standards: challenges in establishing guidelines, regulations, professional codes and risk assessment
  2. Identification of microbiological corrosion
  3. Assessment of severity and risk
  4. Treatment of MIC
  5. Monitoring of MIC

MIC is shrouded in mystery because it’s not as well understood as other corroiosn mechanisms. Yet to prevent it from causing the structural corrosion that leads to significant failures, and environmental and financial losses, we must address these challenges. To achieve this a proactive management approach is the key to ensure the safety and sustainability of critical infrastructure.

Let’s delve a little deeper into the understanding of these MIC management challenges.

Standards: Challenges in Establishing Guidelines and Regulations

The landscape of standards in the management of MIC is fractured. There is an absence of universally accepted standards, and this often leads to a lack of consistency in the approach to tackling MIC. This makes it difficult for corrosion professionals to establish and adopt comprehensive strategies.

Where guidelines exist, there is a considerable variation between different industries. Of course, some of this variation is due to the unique nature of each environment – and this also poses challenges for those who work within multiple industries. Navigating through a maze of divergent guidelines can be like walking through a minefield.

Any standardisation of guidelines and regulations would necessarily require personalisation to suit different sectors. We would need to consider a myriad of factors, including material compatibility, operational constraints, selection of fit-for-purpose materials, and environmental considerations for effective implementation of MIC management strategies.

Challenges in the Identification of Microbiological Corrosion

The microorganisms involved in MIC, and their ability to form biofilms, are complex and diverse, making it challenging to identify the exact MIC mechanisms in play. The analytical techniques to detect and identify microorganisms require specialist knowledge and tools.

“Different systems require different sampling procedures and planktonic sampling can be used to estimate the density and diversity of colonising microbe,” says Tony Rizk, CEO of Halo Sealing Systems Limited, and Course Lead for ICorr’s new MIC Training Courses. “In all cases, samples should be collected as close as possible to their source. The best representative samples are collected using online coupons, pigging sludge, surface scrapings, and sediment. Samples should be collected during normal operation and free of contamination. Collected samples should be preserved, transported and, if needed, stored at 4oC.”

Though we have witnessed significant progress in MIC science, very few have the required knowledge of the interplay between microorganisms, metallic surfaces, and environmental factors involved in the process. Such limited understanding is an obstacle to the development of effective MIC prevention and management strategies. Clearly, the way forward here is to aggressively share knowledge, and empower scientists and engineers to collaborate more effectively with a shared objective of unravelling the intricacies of MIC mechanisms and management.

A further complication that clouds the identification of microbiological corrosion is the overlap with other forms of corrosion. It is also common for MIC to co-exist with other corrosion mechanisms. Yet, to develop and implement effective prevention strategies, identification of MIC is critical. Not only is knowledge crucial here, but also the use of specific diagnostic tools and techniques.

Challenges in the Assessment of Severity and Risk

The third significant challenge is quantifying the extent of MIC damage. As MIC is often localised corrosion, assessing overall severity can be difficult – traditional techniques for assessing the extent of MIC damage may not be enough.

There is also a lack of predictive models to accurately forecast the progression of MIC and its effects on a structure or system – another reason we must collaborate in our research efforts to better understand unique MIC mechanisms. If corrosion scientists can develop data-led predictive models, corrosion engineers can use these to develop proactive MIC prevention strategies.

Finally, we must factor in the cost of MIC prevention and management. This means assessing its value to combat the economic impact of MIC. There is always a balance between the costs of impact and the costs of mitigation to be struck. Just how do we assess the long-term financial impact of microbiological corrosion?

Challenges in the Treatment of MIC

When considering treating MIC, we are faced with three challenges:

  1. Deeper knowledge is needed to select effective treatment options based on factors such as the specific environment, microorganisms involved, the severity of the corrosion, and the impact of treatment on the environment and infrastructure itself.
  2. Selecting suitable inhibitors and biocides requires an understanding of specific microbial species, operating conditions and geochemical composition, as well as understanding how the treatment will affect the structure over time.
  3. Implementing treatment in piping, confined and concealed spaces and large infrastructure is a complex process, and suitable application techniques must be selected and executed. Corrosion engineers and industrial microbiologists must also consider the long-term maintenance requirements post-treatment.

Challenges in Continuous Monitoring of MIC

If we are to instigate effective and timely mitigation and intervention for MIC, continuous monitoring is crucial. DNA technologies have improved MIC monitoring processes, yet their adaptation is still, relatively speaking, in its infancy. Sporadic inspections are unlikely to capture the rapid progression of MIC – reliable, real-time monitoring techniques are needed.

It’s also true to say that monitoring MIC is challenging because MIC often occurs in highly inaccessible locations, including offshore structures, underground pipelines, or submerged equipment. Not only might accessibility be limited, but we must also consider safety when conducting routine inspection of installing monitoring equipment.

The data collected can also be complex. It requires expertise to translate into meaningful conclusions about microbial activity, corrosion rates, and other relevant parameters. Incomplete or misinterpreted data can lead to ineffectual MIC management.

Overcoming the Challenges of MIC Management Starts with Understanding MIC

The challenges associated with managing microbiological corrosion are multifaceted. The lack of universally accepted standards, difficulties in identifying and assessing MIC, selecting suitable treatment strategies, and implementing continuous monitoring are hurdles that require dedicated effort to overcome.

It’s crucial that we invest in research, collaboration, and professional development. Enhancing our knowledge will help us to manage MIC more effectively. This will enable us to embrace the proactive approach that will safeguard our critical infrastructure for the future.

ICorr’s MIC Training Courses are designed to provide you with the detailed knowledge required to manage MIC.

  • The one-day MIC Awareness Course delivers an overview of MIC phenomenon including corrosion-influencing microorganism groups, monitoring techniques, control methodologies, affected materials and identification, and managing MIC. It also discusses some of the MIC high-profile failures.
  • The four-day Microbiologically-Influenced Corrosion (MIC) Course incorporates theoretical and practical sessions with a focus on providing detailed knowledge on managing and conducting an MIC control program. It includes sampling and monitoring strategies, data interpretation and presentation, and identification of potential risks. On completion of the entire course an ICorr ‘MIC Technologist’ certificate of attendance is awarded. For attendees who also take and pass the additional examination, an ICorr ‘Certified MIC Technologist’ certificate is awarded.

To learn more, please email the Institute of Corrosion for information about our new MIC Training Course.

Articles in This MIC Corrosion Series:

Bio-Corrosion Basics: What Is MIC Corrosion?

Real Life Impacts of Microbiologically Influenced Corrosion

The Unique Challenges of Managing Microbiological Corrosion

Introducing ICorr’s Microbiologically-Influenced Corrosion Courses

Real Life Impacts of Microbiologically Influenced Corrosion

Real Life Impacts of Microbiologically Influenced Corrosion

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MIC ─ Leaving Its Mark on the World

As we discussed in a previous article, we discussed how microbiologically-influenced corrosion (MIC) – also known as microbial corrosion – occurs when sessile microorganisms alter the physiochemical conditions on a metal surface. MIC increases corrosion rates, leading to a premature and severe type of corrosion. Biocorrosion can be highly destructive, leading to disastrous consequences in several industries.

In this article, we outline three notable examples in the oil and gas industry, and how MIC can be influential in other sectors.

The Aliso Canyon Leak, 2015

The Southern California Gas Company (SoCalGas) provides gas to over 21 million customers in Los Angeles and Southern California. The utility company injects gas into natural underground storage areas. A fracture of the 7” casing and a 19” axial split was caused by external MIC.

The failure leaked around 109,000 metric tons of methane over a period of five months. The incident was the largest methane leak in US history and caused substantial gas supply shortage to power stations.

More than 8,000 households were evacuated. The cost to the utility exceeded USD 2 billion including civil lawsuits settled for US$ 1.8 billion on 27/9/2021.

Methane has 28 times greater global warming potential than carbon dioxide and indicates the environmental damage and effect on global warming.

The Prudhoe Bay Oil Spill, 2006

A 34” pipeline operated by BP and partners including Exxon Mobil Corp and ConocoPhillips spilled over 267,000 gallons of crude. It was the biggest oil spill in Alaska’s history and devastated 7,700 m2 of pristine land. The spill originated from a ¼” hole in the pipeline that was caused by internal MIC.

The company was fined US$ 255 million in addition to the loss of production and cost of containment. The pipeline was decommissioned and replaced with a 20” pipeline provided with facilities to enhance inspection and monitoring.

The incident caused shockwaves on the international market and the price of oil on NYMEX jumped by US$2.22 a barrel while BP shares dropped by 2%.

The El Paso Pipeline, New Mexico, 2000

An explosion in the El Paso pipeline in New Mexico caused a huge crater (around 51 feet wide and 113 feet long), damaged bridges, and cost the company a US$15.5 million penalty. Damage to property cost US$1 million. Multiple lives were lost.

The ensuing investigation showed the “presence of acid-producing bacteria in all samples obtained from the corrosion pit areas” with “striations and undercutting features that are often associated with microbial corrosion.” The presence of contaminants that included oxygen, hydrogen sulphide, and carbon dioxide also contributing.

It was a horrific event that could have been avoided with effective corrosion prevention. An error that El Paso was required to correct – costing almost US$90 million to upgrade the 10,000-mile pipeline system.

MIC Isn’t Restricted to Oil and Gas Structures

Though mostly studied by the oil and gas industry and because of the highly publicised and detrimental impact of failures in the energy sector, microbiologically-influenced corrosion affects other sectors, too, causing pitting corrosion, galvanic corrosion, and crevice corrosion, among others. Examples of microbiologically-induced corrosion include:

·       Water Distribution Systems

Microorganisms that are present in water, like sulphate-reducing bacteria, can produce hydrogen sulphide gas that accelerates corrosion. The result can be pipe leaks and issues with water quality.

·       Power Plants

Algae and bacteria can form biofilms on metal surfaces – particularly in heat exchangers and cooling systems. These biofilms can produce the conditions that accelerate corrosion, impairing heat transfer efficiency, reducing equipment lifespan, and increasing maintenance costs.

·       Marine and Offshore Structures

Marine environments provide good conditions for certain microorganisms to thrive. MIC can affect the metal components of ships, offshore platforms, and coastal infrastructure – and attacking coatings and submerged structures – and increasing maintenance requirements.

·       Water and Wastewater Treatment Facilities

The combination of aggressive water chemistry and microorganisms can lead to corrosion of pipes, pumps, valves, and other equipment in water and carbon-rich wastewater treatment facilities. The outcome is a reduction in efficiency of treatment processes and increased maintenance costs.

·       Chemical and Petrochemical Plants

Colonising surfaces and forming biofilms that induce corrosion in pipelines, storage tanks, and other metal components. This can result in leaks, process disruptions, and safety hazards.

The Bottom Line

Disasters that are, at least in part, caused by microbiologically-influenced corrosion have left indelible marks on our economies, environments, and industries. They have caused horrendous environmental disasters, huge financial and reputational costs, and loss of lives.

The examples we’ve discussed in this article highlight the destructive nature of MIC, and the need to prevent it and use effective treatment regimes to mitigate it.

It’s crucial that we continue to expand our understanding of MIC, the susceptibility of materials to microbiologically-induced corrosion in conjunction with other corrosion mechanisms, and improve the evaluation of microbiologically-influenced corrosion. If we can achieve this, we can help to create a safer and more sustainable world for all in it. However, doing so means we must strive to overcome the challenges associated with MIC – a topic that we explore in our next article in this series.

“MIC is such a misunderstood field of the industry that not all failures are openly investigated. The examples in this article are the tip of the iceberg,” says Tony Rizk, PhD, Ex-Honorary Reader at Manchester University, and Course Lead.

“A particular problem is that some corrosion engineers have been reluctant to recognise MIC as a problem. In one case in which I was involved, a lead engineer (and a distinguished figure in the industry) did not believe in MIC and consequently the project design was commissioned based on only one SRB test.  Strange, but true.”

To improve your knowledge and practical capability in the war against MIC, please email the Institute of Corrosion for information about our new MIC Training Course.

Articles in This MIC Corrosion Series:

Bio-Corrosion Basics: What Is MIC Corrosion?

Real Life Impacts of Microbiologically Influenced Corrosion

The Unique Challenges of Managing Microbiological Corrosion

Introducing ICorr’s Microbiologically-Influenced Corrosion Courses

(Image attribution: https://flickr.com/photos/33246316@N02/23807396891)
The Unique Challenges of Managing Microbiological Corrosion

Bio-Corrosion Basics: What Is MIC Corrosion?

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An Introduction to Microbiologically Influenced Corrosion

Microbiologically Influenced Corrosion (MIC) refers to the effect of metabolic activities of colonising microbial populations on the kinetics of the corrosion process. Microorganisms are ubiquitous and the phenomenon is caused by bacteria that settle and stick to the metal surface – known as sessile colonies. Zones of established biofilm are anodic with different physiochemical conditions on the metal surface.

MIC is the least understood corrosion phenomenon. It affects systems in different industries with traces of water and is predominantly manifested in the form of localised corrosion (pitting).

Corrosion is a natural process. It can’t be stopped but can be controlled. It is an electrochemical process involving the flow of electrons and ions. Microbial metabolic activities can accelerate corrosion reactions. The annual cost of corrosion in the oil and gas industry is estimated at USD 13.5 billion per annum and MIC is the cause of around 20% of all corrosion failures. Sulphate-reducing bacteria (SRB) are the best-known corrosion-causing microbes. However, there are other equally detrimental microbial groups that are responsible for premature failures.

Corrosion is a huge threat to the world’s infrastructure, at a cost estimated to be more than 3% of global GDP. It threatens the fabric upon which the human world exists. From oil and gas installations and pipelines to wind turbines, water systems, bridges, nuclear energy… the list is without end.

Most people are well versed in how the corrosion of metals is generally accepted to occur – electrochemical reactions cause metals to deteriorate.

You may also hear MIC referred to as microbial corrosion, microbial influenced corrosion, bio corrosion, or microbiological induced corrosion.

Unmasking MIC: Understanding the basics

The existence of active microorganisms and water accelerates the corrosion process, and can cause an alarming corrosion rate. It can also cause clogging as microorganisms secrete slimy waste by-products (extracellular polymeric substance – think of this like the fungus that grows on a piece of fruit after it has started to turn brown).

The science behind Microbially Influenced Corrosion

MIC is a complex process involving:

  • Different types of microorganisms (bacteria, fungi, algae, and archaea);
  • Construction metal; and
  • Handled media

Microorganisms attach themselves to the surface of a metal to form a biofilm. This alters the chemical and physical properties on the metal’s surface and creates an environment that accelerates corrosion.

The actual processes involved in MIC include the production of corrosive metabolic by-products, the creation of localised anodic environments, and the physical disruption of protective surface layers. Biofilm can consist of both organic and inorganic materials and layers of different microbial groups. The availability of nutrients and tolerable operating conditions can lead to exponential growth of microorganisms, and therefore accelerate the effects of MIC.

It’s worth noting that in biological corrosion:

  • Archaea can grow at temperatures above 80oC (‘Archaea are microorganisms that define the limits of life on Earth. They were originally discovered and described in extreme environments, such as hydrothermal vents and terrestrial hot springs. They were also found in a diverse range of highly saline, acidic, and anaerobic environments’ – Encyclopedia Britannica.)
  • Bacteria can tolerate extreme conditions, including high pressure and temperature
  • Algae can be problematic on a multitude of surfaces, including concrete

Microorganisms are omnipresent and accelerate corrosion in different ways including:

  • Generating acids that can be utilised by other groups and lower pH leading to a fast acid-driven corrosion.
  • Forming corrosion products that accelerate corrosion e.g. iron sulphide.
  • Working in cyclic effect with detrimental effect on corrosion. While SRB generates the highly toxic and corrosive H2S, sulphur-oxidising bacteria convert sulphide to highly corrosive by-products including elemental sulphur or sulpheric acid.

Among the complexities of MIC is that there are several groups of bacteria involved. Two of the most common are:

  • The anaerobic sulphate-reducing bacteria reduce sulphate to sulphide.
  • The extremely aggressive aerobic iron-oxidising bacteria (IOB) oxidise ferrous (Fe2+) to ferric (Fe3+) and destabilise the oxide layer.

Conditions favouring Microbiologically Induced Corrosion

There are many elements that play a part in MIC. All the following can contribute to the severity of MIC and the corrosion problem:

  • The type and surface finish of construction materials, operating conditions including shear stress, temperature, deposition of solids, dissolved oxygen, etc.
  • The type of colonising microorganisms.
  • Nutrient availability and geochemical composition.

When examining the effects of MIC, we know that certain conditions will encourage its occurrence. The microorganisms that cause MIC are often found in highest concentration in crevices, stagnant zones, sediments, and damaged protective coatings. They deposit and multiply in the presence of water, with an adequate supply of nutrients, a suitable temperature range, and a wide range of pH.

Why we should care about MIC

Reducing bacteria to mitigate MIC mechanisms may sound like a microscopic issue, but MIC failures can have huge implications. It can damage the integrity of our infrastructure, add to safety concerns, and cause financial losses. It is complex (and fascinating), and affects pretty much everything around us. In short, it is a challenge that we cannot ignore.

Tony Rizk, PhD, Ex-Honorary Reader at Manchester University, and Course Lead for ICorr’s new MIC Training Courses, says:

“Microbiologically-influenced corrosion is a major problem in industrial systems and has been responsible for a number of high-profile failures, including the Prudhoe Bay Oil Spill, Alaska in 2006 and the methane leak from a South California storage facility in 2015.

“It is estimated that around 20% of all corrosion failures are due to MIC. Despite this, MIC is not considered a major topic in corrosion training curricula.”

Understanding the causes and mechanisms of MIC helps us to mitigate its impacts, improving safety and sustainability of our infrastructure.

Our next article in this series will discuss real-life impacts of MIC. In the meantime, if you would like to up your game in the least understood phenomenon of corrosion, please email the Institute of Corrosion for information about our new MIC Training Course.

Articles in This MIC Corrosion Series:

Bio-Corrosion Basics: What Is MIC Corrosion?

Real Life Impacts of Microbiologically Influenced Corrosion

The Unique Challenges of Managing Microbiological Corrosion

Introducing ICorr’s Microbiologically-Influenced Corrosion Courses

What Is the Role of the Branches in the Institute of Corrosion?

What Is the Role of the Branches in the Institute of Corrosion?

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Sharing Corrosion Expertise, Experience, and Knowledge at the Regional Level

Within the structure of the Institute of Corrosion, our branches play a key role. They help to bring us closer to our members, and communicate our values, vision, and mission. It’s important to us that we connect with our membership, and the branches provide incredible forums for this to happen.

The branches run semi-autonomously: we understand that they are closest to their branch members and are best placed to create and deliver their own programs.

We caught up with the Chairs of the Aberdeen and London branches (Dr Ejaz Muhammad and Polina Zabelina, respectively) to explain how their branches operate.

Structure of ICorr branches

Each branch is overseen by a committee, usually of 10 to 12 people. These take roles that range from the Chair to Marketing, and include treasurer, events, and technical programme planning.

“All committee positions are voluntary,” says Ejaz. “Each member makes a commitment of time toward the management of the branch. It’s enjoyable work, a great way to enhance your network, and helps toward professional development and industry awareness.”

And who makes a good committee member?

“Of course, you must be a member of the Institute of Corrosion to become a committee member,” Polina explains. “After this, we welcome people with or without previous committee experience. The most important ingredients are dedication to building on existing branch success and the ability to dedicate time.”

“Yes,” agrees Ejaz. “The desire to help the corrosion community is the primary quality needed.”

Roles and responsibilities of the branches

The branches have a great deal of autonomy, setting annual technical programmes, liaising with industry experts and other professional bodies and sister institutions. There’s a lot of work that goes into planning, scheduling, and running yearly programmes.

“Here in the London branch, we organise face-to-face and virtual presentations. Our aim is to bring the London corrosion community together and share information and news about corrosion management with all the industries present here. We have a monthly meeting (every second Thursday of the month between October and April). There are complementary welcome drinks, buffet, and bar. And always an enlightening technical presentation is included.” says Polina. “In addition, from this year we are running summer webinars between June and September. The first of the series is taking place on 9th June.”

“It’s similar in the Aberdeen branch,” Ejaz comments. “The committee is responsible for setting the annual technical programme – of course while interfacing with the ICorr Head Office in Northampton. In our case, our programme runs from August to June. Once finalised, we get support from branch sponsors and regional companies – 17 in total this past year. In turn, they benefit from the exposure that being affiliated with the branch brings to their operations. Our branch meetings are well attended, with as many as 80 ICorr members at any single meeting.”

“Then there’s the social side,” says Polina. “We have some great events. Our Christmas lunch is always popular. There’s a social event in May (this year it was a boat trip). In June, we’re holding a sponsored event in the Tower of London.”

How can you become an affiliated member of your local ICorr branch?

The contribution that is made to local and regional corrosion communities, industry, academia, and engineers through the effort of our branches is crucial in delivering ICorr’s mission.

We’re extremely proud of the amazing work that is done at the branch level. The enthusiasm and dedication shown by committee members does not go unnoticed at Head Office.

There are six regional branches of ICorr. Each has its own dedicated page on the ICorr website, where you can learn more about their activities, meetings, technical programmes, and sponsors. Click on the branch closest to you to learn more:

Before we go, a final word from Polina and Ejaz:

“Joining a professional organization’s committee can be an amazing experience for you and an opportunity to build skills that will help you further your career,” says Polina. “I can’t tell you how much my membership of ICorr at the branch level means to me. There’s a huge range of people involved here, with a wealth of knowledge and experience that they’re eager to share. Some of our committee members have been on the committee for years, while others have only recently joined. Being involved with ICorr, and in such a vibrant corrosion community as the London branch, is something I would recommend to all in the field of corrosion.”

“I’d certainly second Polina’s words,” says Ejaz. “I’m blown away by the depth of experience present at every one of our meetings. Being involved at branch level is an excellent opportunity to develop your network and deepen your knowledge of the trends in the corrosion industry.”

If you’d like to know more about becoming an affiliated member of either the London or Aberdeen branches, you can reach out directly to Polina or Ejaz on LinkedIn:

Meeting Dr Liane Smith CBE

Meeting Dr Liane Smith CBE

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“An Award for All in Corrosion”

The CBE (Commander of the British Empire) is one of the highest awards the Monarch can bestow on an individual. King Charles presented his first New Year Honours in January 2023, and among the recipients of the CBE was Dr Liane Smith.

Dr Smith’s CBE was originally made in the 2022 New Year Honours list of 2022 by HM Queen Elizabeth, for services to engineering and materials science.

Now, it’s not every day you get to grill a CBE. But we were given the opportunity recently. And a very great pleasure it was, too. Read on to learn about Dr Smith’s career, thought for the future, and, of course, her memories of the investiture on 31st January 2023.

What did you aspire to be when you were younger?

When still a child, I was always fascinated by the oil refinery at Stanlow when we drove past it as we headed for family holidays in Wales. I remember asking my teachers who knows what a refinery does. My chemistry teacher, who had a background in industry, simply said, “Chemical engineers.” So that’s what I set my heart on becoming.

I was advised that it was easier for girls to get into this field via the pure science route of chemistry, before shifting to engineering. Well, it was the 1970s!

So, how did you end up as a corrosion specialist?

I studied hard, and was accepted into Cambridge, where I read physical sciences including the option of Metallurgy and Materials. After two years of major chemistry, things were getting extremely serious. I’d also found Metallurgy and Materials exciting and interesting – so I shifted to this for my final year.

What was your first job like?

You know, there was a curious twist to my first job. I started my working career at Shell’s Research and Development Centre at Chester. Next door to Stanlow, the source of my initial interest in engineering.

I had asked to be able to do a PhD. Shell agreed, on the proviso that I wouldn’t be required to spend too much time away. I secured a ‘guaranteed’ three-year project. Shell agreed to publish the results – a key requirement of the PhD. The University of Sheffield offered flexible arrangements.

I had a 6kW CO2 laser to weld steel. Wonderful fun! I examined the welds using the electron microscopes at Sheffield during the weekends.

You decided to stick with Oil and Gas. How did your career progress?

I’d been working for Shell for four years when I requested a transfer. I was fortunate that a potential move to Head Office in the Netherlands became available.

I spent 2 years in the group that was conducting in-house Front End engineering & Design (FEED) studies at that time. I had the responsibility for selecting materials. There were no guidelines to follow. Scary stuff for a young engineer. So, I started to collect information on materials performance – a habit that has continued throughout my career.

It was here that I started to study CO2 corrosion problems with my boss Dr Kees de Waard, a famous expert in this field. I learned so much from him, and we’ve remained great friends.

From here, I spent a further two years with NAM – the largest gas company in the Netherlands. There I dealt with sour service processing plant and pipelines. I was also a senior welding engineer, with responsibilities for developing welding procedures for Alloy 825 clad pipelines along with my fellow welding experts within the company.

What have you enjoyed most about your career in corrosion?

Ask any engineer what they enjoy most, and you’ll probably receive the answer, “Being a part of a team that created something special, and seeing it come to life.” I’m no different, though in 42 years I’ve seen a few projects designed, built, operated and completely decommissioned and removed!

I’ve been blessed to work with great people in fantastic teams, and on some wonderful projects, at FEED or detailed engineering stages. Many large projects, too.

Perhaps the largest was the Shah gas project in Abu Dhabi, where I advised on materials from the wells through all the processing and through to a sulfur pelletising plant and trains to the coast.

I have also worked with some wonderful materials manufacturers across the globe, helping them to optimise their products for challenging service (like high-strength hydrogen-resistant steel). Making breakthroughs on products that open new markets is a fantastic feeling, too.

Increasingly, I work with operators who have enormous challenges to ensure existing assets remain operational as they reach or exceed their design life. It’s both challenging and satisfying to get into the detail of the history of operation, and then model the likely remaining wall thickness or tolerance to known defects so that safe limits can be put on continued operations.

What career advice would you give to a young corrosion specialist? 

Oh, this is easy to answer. Three things, really:

  • First, you made an exceptionally good choice of career. Thermodynamics is on your side!
  • Next, don’t over-plan your career. Go with the flow, and take opportunities as they arise.
  • Third, work hard. Take pride in your work, and accept the reward of the satisfaction in doing a good job.

There’s one other piece of advice I share specifically with females. You don’t need to build a career before you “take a break” to have kids. You don’t take a break from life – you get on with it and make it work. It’s amazing how you and your partner can make parenthood and the jobs work together. 

What is in store for corrosion professionals?

Plenty. By definition, corrosion isn’t about to disappear any time soon, our role is just to control it within manageable rates and forms, but as we learn more about it, and as industry develops in its breadth and geographical reach, the flow of new challenges will continue.

Would you recommend joining a professional body?

I’m very positive about membership of professional engineering institutions. I think that being a chartered engineer (in my case, through IOM3) is something to aspire to and work for. The maintenance of high standards in our profession is something that professional bodies, including the Institute of Corrosion, promote and uphold. They also establish a common core of skills for our profession for people entering it from different routes and at different levels of experience. And this is crucial in a rapidly advancing world.

What’s your favourite food?

I’m omnivorous, which helps enormously when travelling and you’re unable to identify the content of your dinner!

At home, we’re fortunate to be surrounded by farms. So we get to eat a lot of very fresh and organic food. I have to say, though, I’m particularly partial to a well-matured steak.

What do you like doing most outside of your professional life?

I love singing in choirs and have quite a high soprano voice. I’ve sung with many groups across the UK, and other countries in which I have been based over the years. And it’s not just the singing I enjoy; it’s a great way to make friends, too.

Tell us a secret about yourself, something that might surprise people who don’t know you.

I got married when only 20 years old. That’s something that many would find unbelievable today. It was a decision that worked out incredibly well. This year we celebrate 43 years together.

And here’s something that very few know about me. My maiden name is Smith, and I married a John Smith! When I was in the Netherlands the personnel department automatically called me Mevrouw Smith-Smith, which I said was ridiculous and I insisted to be just ‘Smith’.

And my friends and colleagues at Shell named me Smith Squared for a laugh!

Memories of Receiving the CBE

Of course, we couldn’t let Liane go without divulging a few details about being awarded Commander of the Order of the British Empire. It’s not every day you get to meet a CBE:

What was it like meeting our new King?

Quite the most wonderful privilege. It was in Windsor Castle and the rooms were stunning, the organisation immaculate, and the King was so friendly and interested.

How challenging was it to select your outfit for the day?

The dress and jacket were easily selected from my wardrobe. But I decided to invest in a new hat. It was fun to try on numerous options. My sons and husband wore morning dress and looked amazing, too.

Did you have to undergo any ‘instruction’ prior to meeting King Charles?

We were told where to stand and how to address him (Your Majesty, and then Sir thereafter). Plus, we were advised that he liked to shake hands, so not to hesitate if it was offered, which it was, and I did.

How did your sons react to the news when you finally were able to tell them during the Christmas/New Year break?

They were absolutely delighted and impressed. They’re waiting for me to get a coat of arms designed so they can use it also!

How has your CBE affected you in your professional life?

To be honest, I don’t see this as a recognition for my efforts in this industry and this profession. It’s an accolade that is for all of us. On a personal level, the most fantastic aspect was the response to me posting it on my LinkedIn page. Such a wonderful, positive response from so many people across the globe.

I don’t think it changes anything about how I do my professional life, but it shortens the CV!

Where on earth do you go from here?!

Currently, I’m still delving into the impact of corrosion on assets and trying to assist clients to achieve their objectives. It’s not stopped keeping me engaged and busy. As I said earlier, in the world of corrosion, our job is never complete!

Carbon Capture and Storage – The Impurities Conundrum

Carbon Capture and Storage – The Impurities Conundrum

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Is Collaboration on Impurity Standards for CO2 Pipeline Transport Feasible?

Carbon capture and storage on a large scale is crucial in the mitigation of climate change. The more effectively we can introduce suitable carbon capture technology to achieve this, the more effective the fossil fuel industry will be in its response to combat CO2 emissions.

In our efforts to implement carbon capture, utilisation, and storage (CCUS) projects, we cannot ignore the impact of impurities in the CO2 stream. These impurities arise from various combustion processes at industrial sources and include water, nitrogen oxides (NO­x), sulphur oxides (SOx) and hydrogen sulphide (H2S). If not properly controlled and monitored, they can lead to corrosion of CO2 pipelines. Yet there are no agreed international specifications for impurity limits and CO2 composition during pipeline transport.

As conscientious corrosion scientists, engineers, and industry leaders, shouldn’t we be pushing for defined impurities standards and limitations to ensure long-term feasibility, improve sustainability, and help to deliver positive environmental change to our planet by reducing greenhouse gas emissions?

Impurities in carbon capture and storage systems are costly

Impurities in carbon dioxide during transportation and storage can affect components in the system. Research has shown that even a small level of impurities can alter a CO2 stream (and affect geological formations deep underground in permanent storage locations). This results in physical changes, such as phase behaviour and density of CO2:

  • Higher-density carbon dioxide can reduce system capacity
  • A change in phase behaviour can result in sub-par performance of the system

Both effects increase the costs of operation of carbon capture and storage systems.

Impurities in carbon dioxide also cause chemical effects within carbon storage and transport systems. However, unlike physical effects, these can take some time to become apparent. One such effect is an increase in dissolution rate in the caprock of a storage system, affecting both the reservoir capacity and injectivity. Another is the damaging corrosive effect of impurities in CO2 pipelines. As Gareth Hinds of the National Physical Laboratory (NPL) and a previous President of the Institute of Corrosion explains:

“From a corrosion perspective, the most important impurity to consider is water. When the water concentration is below its solubility limit in dense phase CO2 (~ 2500 ppm under typical pipeline operating conditions in the absence of other impurities), no corrosion will occur. However, the presence of other impurities can increase the likelihood of corrosive phases forming, either by reducing the water solubility or via chemical reactions between different impurities.

“Acid dropout is the most significant concern for pipeline operators, whereby highly corrosive aqueous phases, such as nitric and sulphuric acid, can form as a result of reactions between water, NOx, SOx, O2 and H2S impurities.”

Removing impurities from carbon capture and storage systems is also costly

The more of these detrimental impurities we can remove after we capture the carbon dioxide, the more effective and sustainable the system will become.

Herein lies the conundrum facing us. The potential corrosion caused by the impurities contained within captured CO2 can be extremely costly. But to separate these impurities can also have a significant financial impact on the cost of a carbon capture project.

Consequently, the feasibility of a CCUS system requires a degree of balancing between functionality and commercial viability. It’s a question of balancing the cost of purification versus the impact of the remaining impurities on the pipeline lifetime.

Why do we need standards for setting acceptable impurity limits in carbon capture and storage systems?

It is generally not commercially viable to remove all impurities from CO2 streams. However, to ensure that projects remain feasible while complying with regulations, we require suitable standards of acceptable impurities.

Guidelines and best practices have been published by many international bodies. These include Det Norske Veritas (DNV) and the International Organization for Standardization (ISO). While such moves are to be welcomed, Gareth points out that further research is required:

“Under current regulations, the responsibility lies with the pipeline operator to carry out their own assessment and specify impurity limits during the design phase of a given CO2 pipeline project,” he says. “These limits can vary significantly depending on the composition of the CO2 stream, the economics of the purification technologies used and the operating conditions of the pipeline.

“For CO2 specifications, thresholds in relation to acid dropout are set based on limited available data (often not lower than 25oC) and are therefore likely not conservative enough. The development of reliable standard test methods that are more representative of service conditions will go a long way towards addressing the issues.”

The challenges of regulating impurity standards for carbon capture and storage

Writing in Corrosion Management, the leading journal for corrosion control and prevention, Gareth highlights some of the key challenges facing the regulation and standardisation of acceptable impurity levels in the CCUS as we seek to reduce carbon emissions from many industries, including oil and gas:

“Assessment of the risk of water and acid dropout in CO2 pipelines due to the presence of multiple impurities is a complex process, which requires an understanding of the thermodynamics of fluid composition, the impact of operating temperature and pressure variations (including potential upset conditions) and interactions between impurities.

“In addition, published corrosion rate data in the open literature should be treated with caution due to challenges in control of test parameters and the high degree of uncertainty around the correlation between laboratory test data and real-world application. Combined with the relative lack of service experience in transport of CO2 captured from a range of industrial sources, this often leads to a degree of over-conservatism in materials selection.”

The bottom line

Impurities within captured CO2 are a significant concern, affecting operation, safety, and environmental sustainability. The costs associated with the presence of these impurities can be high, as can the costs of removing them.

Some international bodies have established guidelines for acceptable and safe levels of impurities within captured CO2. However, in the most part the responsibility lies with pipeline operators to conduct assessment and specify impurity limits during the design phase of a CO2 pipeline project.

Isn’t the current carbon capture and storage landscape in need of a more highly focused, collaborative approach to this issue?

Shouldn’t we work more stringently towards internationally recognised standards for impurities in CO2 in carbon capture, storage, and transportation?

And shouldn’t such standards be regularly updated as our knowledge and understanding of CCUS technologies improves with more robust data?

And finally, because each carbon capture and storage project is so unique, is it feasible to create a single set of standards?

We’d love to hear what you think. Or, if you have any questions that you would like to ask an expert, please feel free to get in touch by emailing the Institute of Corrosion.

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