Young Engineer Programme 2022 – Who Won?

Young Engineer Programme 2022 – Who Won?

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Could It Be You Flying to the AMPP Conference in the USA Next Time?

Conceived 10 years ago, and sponsored by BP throughout its history, the Young Engineer Programme (YEP) 2022 was held in Scotland for the first time. The final was in November 2022 and was attended by more than 40 people at the Palm Court Hotel, with another 15 online ─ the Aberdeen branch of the Institute of Corrosion put on a tremendous event.

Here’s the story of this latest YEP chapter, and details of how you could participate in the next YEP.

Why the Young Engineer Programme?

The aim of the Young Engineer Programme is simple, though extensive. The brainchild of our London branch, it is devised to:

  • Help tackle skills shortages in the industry
  • Prepare graduates for entry into the industry by helping to develop enhanced skillsets
  • Be the first stage to achieving MICorr/Ceng status

This was the fourth YEP in the history of a programme that has been interrupted by the Covid pandemic. With 24 candidates selected from more than 50 applicants, it proved to be not only as popular as ever, but equally challenging to name a winning team.

In each YEP, the candidates are divided into teams and set the task of developing solutions to a real-world corrosion case study.

Candidate selection criteria

Each year, selection criteria are determined. The 2022 criteria covered five elements:

  • Students in the early stage of their corrosion-related career
  • Two to six years of relevant experience
  • Aged 35 or under
  • Relevant academic background
  • Based in Aberdeen or willing to travel at their own expense

Creating the YEP teams

It was no easy task for the YEP committee to select students to take forward. The committee deserve special praise for the work they put into this and throughout the programme, especially Hooman Takhtechian (2021-2022 session chair) and Steve Paterson (YEP mentor supervisor/Case study organiser).

Six teams of four students were created, with team members chosen based upon:

  • Experience
  • Academic background
  • Employer

The challenge here was to ensure that all teams had an average experience of between four and four-and-a-half years of experience per team member and that no team had two or more members from the same company or from the same company as the team mentor.

The 2022 case study and the challenge set

The Young Engineer Program teams were faced with a highly complex and challenging case study with the following brief:

“A 15-year-old offshore platform in sweet service that had a record of poor corrosion management with the possibility of a new owner for another 10 years of service. The potential new owner is both difficult and demanding, and a subsidiary of an international operator. With the possibility of a tie-in of a new field with slightly sour fluids, it would be necessary to deal with an intermediary integrity services contractor.”

Based upon an actual platform in the North Sea, the teams were tasked to:

  • Assess and rank the key Integrity Management threats
  • Provide mitigation measures and a suitable corrosion management system
  • Deliver materials options for the required new pipeline
  • Management and impact of change in operations
  • Identify all other relevant factors to deal with the client effectively

To complete all of this, teams needed to:

  • Analyse and discuss the information and data provided
  • Identify any gaps in information and any assumptions that may need to be made
  • Perform a high-level risk assessment to identify key threats to the mechanical integrity of the pressurised systems (structural integrity was excluded)
  • Identify what further information or data was required for the other tasks in the exercise
  • Propose a systematic approach to manage the key threats including mitigation measures, corrosion control requirements, performance monitoring, and the resources required to manage the process
  • Propose materials of construction for a pipeline, including welding consumables, and any testing requirements to tie back the new reservoir to the platform, and explain the basis for the materials selection and how any corrosion threats will be mitigated
  • Identify what changes, if any, to the existing facilities would be required should the new sour reservoir be tied back to the platform
  • Propose a strategy for convincing the integrity management contractor that the approach is the optimal solution and that you are the right team to do the job

Oh, and present all the above in 20 minutes on the presentation night! And any team that overshot its 20 minutes were deducted points.

The quality of work completed and presentations made were so high that the judging panel of Chris Williams (BP, Sunbury), Susan Cushnaghan (formerly Shell Aberdeen), and Stephen Tate (2022 to 2024 ICorr President) certainly had their work cut out.

All teams were deserving of the huge praise they received for the diversity of their solutions, the professionalism of their presentations, and their enthusiasm for the task in hand. We should also mention that this is a testament to the incredible effort and contribution of all the YEP 2022 lecturers and course mentors.

The 10 lectures (and lecturers) that were delivered during the course of the YEP 2022 programme were:

Lecture Lecturer
Fundamentals of Corrosion Steve Paterson
Asset Integrity Management Stephen Tate
Coatings and Linings Michael Young
Case Study Steve Paterson
Presentation Skills Olubayo Latinwo
Materials Selection/Welding Martin Mweemba
Corrosion Under Insulation and Fire Management Clare Watt
NDT Appreciation Jim McNab
Introduction to Fitness for Service Assessments Pieter Van Der Vyer
Corrosion Aspects of O&G Production Chemistry George Winning
Introduction to Cathodic Protection Brian Wyatt

 

Team mentors were:

  • Steve Plant
  • Alistair Crichton
  • Bruce McKenzie
  • David Hills
  • Alireza Aghasadeghi
  • Muhammad Ejaz

And the winners are…

One team had to win, of course, and only by strict application of the marking criteria could the teams be separated. The criteria for the presentation were:

  1. Analysis of the scenario and current integrity status of the pressurised systems of the platform (20 marks).
  2. Application of a systematic methodology to manage corrosion and surveillance activities (20 marks).
  3. Viability of the proposed approach to prolong service life (10 marks).
  4. Assessment of material options for the new pipeline (10 marks).
  5. Assessment of the impact of change in operation with H2S (10 marks).
  6. Identification and assessment of factors in dealing with the client (10 marks).
  7. Overall quality and balance of the presentation, plus team coordination as demonstrated by the presentation (20 marks).

Time for the drumroll…

Congratulations to the winning team who were mentored by Alireza Aghasadeghi and who were:

  • Rosie Bird (PIM)
  • Jamie Hillier (Xodus)
  • Lee Hunter (PBS Offshore)
  • Christopher Slater (Stork)

The judges also awarded a Leadership Prize, based upon feedback about performance during the whole programme from mentors, judges, and committee members for teamwork and presentation skills. This was awarded to Eilidh Macdonald (Subsea 7).

All the winners won an all-expenses paid trip to the AMPP Annual Conference & Expo 2023 in March, courtesy of key sponsor BP.

Could you be a Young Engineer Program winner?

We are already planning YEP 2024, to be managed by Young ICorr and pencilled in to take place in London. To register your interest in becoming a team member for the next YEP, please email our Young ICorr Chair James McGladdery. It’s the first step to becoming one of the next winners of this prestigious programme.

Corporate Membership – Introducing AkzoNobel International Paint and Carboline Europe

Corporate Membership – Introducing AkzoNobel International Paint and Carboline Europe

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Benefitting from Corporate Membership of ICorr

Our corporate membership continues to grow, with more companies taking advantage of the benefits of becoming a corporate member. We try to introduce as many of our new corporate members through our blog as is possible.

Who is the latest to have joined our expanding presence in the global corrosion conversation?

We’re pleased to welcome AkzoNobel International Paint and Carboline Europe as our latest corporate members.

AkzoNobel International Paint

A leading supplier of protective coatings, with products that range from finish to surface tolerant, and include intermediate, primer, and primer-finish. Its speciality coatings include lining, passive fire protection, subsea, abrasion resistant, and Splashzone, as well as repair and protection for structural concrete, and temperature resistant coatings.

The industries it serves include construction, mining, offshore and onshore oil and gas, thermal power, transportation and pipeline, water and waste, and wind power.

AkzoNobel International Paint has invested in a new team to work on specifications for major global projects. To aid this, the company has selected to engage with the Institute of Corrosion as corporate members, with the specific aim of networking with other engineers in this field.

Its membership is already beginning to pay dividends, with engagement in the development of the Sustainability Conference in Newcastle (the home of International Paint) which is planned for June 2023.

Carboline Europe

Offering more than 35 product lines, Carboline is also a major protective coating and fire protection suppliers in the market, focusing on coatings, linings, and fireproofing. Its focus is to solve customers’ problems – a mission it has maintained since the company was founded in 1947.

Like International Paint, Carboline supplies many industries including infrastructure, energy, and mining.

With a significant market share in the United States, the company now plans to develop its business more aggressively in Europe. To this end, they have invested in a new management team with the remit to develop appropriate business strategy.

Carboline’s objective for its membership is to engage more fully in technical debate, through formal and informal networking opportunities. They have already engaged with the London Branch of ICorr to stage a ‘summer event’ in London in 2023.

You don’t have to be a big company to benefit from corporate membership of ICorr

Our corporate membership packages are available to all sizes of companies, from those with five employees to those with thousands.

AkzoNobel International Paint and Carboline have chosen to become corporate members for many reasons – not least to enable their people to network more effectively, to share and learn from commercial and academic expertise, and to engage in the corrosion conversation on a wider and deeper scale.

Corporate membership of the Institute of Corrosion delivers many benefits, including:

  • The option to have as many employees as required in the program (the minimum number is five)
  • Each employee receives a copy of the Institute’s Corrosion Magazine (6 copies/year)
  • Advertising in Corrosion Management Magazine and listing in the ICorr Website Members Directory free of charge
  • Access to Career Development & Progression Programme (CDPP) and to the Institute’s Online Resources and Libraries
  • Discount of 10% on all Conferences and Symposia and selected ICorr Training courses

This is the highest grade of membership of the Institute of Corrosion, and will help boost your profile within the corrosion industry.

For more information and to join the Institute of Corrosion as a Corporate Member, please email our admin team.

The Role That Corrosion Management Plays in Sustainability of Wind Turbines

The Role That Corrosion Management Plays in Sustainability of Wind Turbines

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​Corrosion Is Key to the World’s Net Zero Goals

The world is waking up to the need for sustainability, but is struggling with how to achieve it. How can we meet our current energy needs without compromising the ability of future generations to meet their own needs?

Sustainability is a concept that’s essential to our survival as a species, as we face increasing pressure on our natural resources due to population growth, urbanisation, and climate change. A key piece of the puzzle is to transition to renewable energy sources, and wind turbines are a prime example of this. But their viability is impacted by corrosion.

By understanding the challenges and opportunities presented by corrosion in wind turbine structures, we can work towards a more sustainable and resilient future.

In this article, we delve into the topic of wind turbines and sustainability, focusing on corrosion:

  • We explore how wind turbines are affected by corrosion, and the impact that it has on their lifespan and efficiency.
  • We also look at current methods for preventing and mitigating corrosion in wind turbines, and discuss potential future developments in the field.

Just how important are wind turbines?

The amount of energy produced by wind turbines is rocketing. According to the International Energy Agency, wind electricity generation increased by 17% in 2021 ─ that’s 55% faster growth than in 2020. The majority of this growth (perhaps surprising to most) came in China.

In the coming years, there are ambitious plans to increase the amount of electricity produced by wind even further. China plans to generate a third of its energy from renewables by 2025, with 18% from wind and solar. The EU is targeting 40% renewables by 2030.

The UK is already a world leader in wind power. It produces over 75 million MWh per year from wind. That’s enough to power 20 million homes. It has more offshore wind capacity than any other country in the world. In the second quarter of 2022, the UK’s wind farms produced almost 40% of the energy generated across the UK.

If the UK is to meet its target of net zero by 2050, and the world to meet its longer-dated targets, wind turbines are crucial. But there is a problem looming: corrosion.

How wind turbines are affected by corrosion

Wind turbines work by harnessing the kinetic energy of wind and converting it into electricity:

  • They consist of a rotor with blades that rotate when the wind blows.
  • In turn, this spins a shaft connected to a generator.
  • The electricity generated by the turbine is then transmitted to the grid and distributed to homes and businesses.

The vast majority of wind turbines are horizontal-axis turbines, which have blades that rotate around a horizontal axis, and they can be found in various sizes and configurations. It’s a lot of moving parts.

Of course, wind turbines are built to withstand the harsh conditions of the natural environment, but even the most robust structures can be affected by corrosion. In the case of wind turbines, corrosion can occur on various components, such as the blades, the tower, and electrical components. This corrosion happens in several ways.

Wind turbines are affected by corrosion through exposure to the elements. A turbine’s components are constantly exposed to wind, rain, snow, and other weather conditions which can cause a variety of forms of corrosion. For example:

  • The blades of a wind turbine are exposed to UV radiation, which can cause UV degradation, leading to cracks and delamination.
  • The tower and other components can be affected by corrosion due to exposure to saltwater, which is commonly found near coastal areas.
  • Another common form of corrosion that affects wind turbines is galvanic corrosion. This is a particularly challenging form of corrosion to prevent, as it often occurs in hard-to-reach areas of the turbine.
  • Ultra violet (UV) degradation from sunlight and blade erosion, which degrades the coating on the blade as the tips of the blade can reach speeds of 300km/h.

The impact of corrosion on wind turbines

Corrosion can have a significant impact on a wind turbine:

  • It can lead to a reduction in the efficiency of the turbine, which can result in a decrease in the amount of electricity generated.
  • It can also lead to structural damage, reducing the lifespan of the turbine and increasing the need for maintenance and repairs.

According to the National Renewable Energy Laboratory, the lifetime of wind turbines is around 20 years. It’s a big, expensive piece of equipment to manufacture and install. If corrosion is not addressed on time, the turbine lifespan can be reduced. And good corrosion practice prolongs both reliability and turbine life.

In other words, by taking steps to protect wind turbines from corrosion, we can ensure that they continue to generate clean, renewable energy for much longer. This reduces costs and environmental impact (wind turbine blades cannot, yet, be recycled effectively).

Prevention and mitigation of corrosion in wind turbines

Clearly, preventing and mitigating corrosion in wind turbines is crucial for ensuring their longevity and efficiency.

There are a number of methods currently used to protect wind turbines from corrosion, and these can be divided into two main categories: passive and active corrosion prevention.

·       Passive corrosion prevention methods

These include the use of coatings, such as paint and galvanizing, and the use of corrosion-resistant materials, such as stainless steel and aluminum.

Coatings work by creating a barrier between the metal and the environment, which slows down the corrosion process. For example, coatings like paint and galvanizing provide a physical barrier that protects the metal from exposure to the elements. However, coatings can wear off over time, and they may not be effective in areas that are difficult to reach.

·       Active corrosion prevention methods

These include the use of cathodic protection and corrosion inhibitors, and the use of monitoring systems to detect and track the progression of corrosion.

These methods actively control the corrosion process, rather than merely slowing it down. For example, cathodic protection systems use electrical current to prevent corrosion from occurring, while inhibitors are chemical compounds that can be added to the environment to slow down the corrosion process.

The effectiveness of corrosion prevention methods depends on various factors, such as the environment in which the turbine is located, the type of corrosion that is occurring, and the type of material that is being protected.

Looking ahead, there are several potential developments in the field of corrosion prevention for wind turbines that show promise.

For example, the use of advanced materials (such as nanocomposites, which have superior corrosion resistance properties) could greatly improve the durability of wind turbine components.

Additionally, the use of advanced monitoring systems (such as ultrasonic and infrared imaging) could help detect corrosion at an early stage, allowing for timely repairs and maintenance.

The field of corrosion prevention for wind turbines is constantly evolving, and new technologies and materials are being developed to improve the durability of wind turbine components. By continuing to invest in research and development in this area, we can work towards creating wind turbines that are more sustainable and resilient.

The bottom line

Wind turbines are a vital tool in the transition to a more sustainable and resilient future. As renewable energy sources, they play a crucial role in reducing our dependence on fossil fuels and fighting climate change.

Indeed, Greater Gabbard, off the northeast coast of England, will become the largest offshore windfarm in the world. Blades will exceed 100 metres in length, and each turbine will be capable of producing 14MW of electricity. You’ll have a chance to see these being tested at the Ore Catapult during our conference ‘Integrity Engineering for a Sustainable Future’ in June 2023.

However, like any machine, wind turbines are not immune to the effects of corrosion. This can have a significant impact on lifespan and efficiency, reducing overall effectiveness as a renewable energy source.

Preventing and mitigating corrosion in wind turbines is crucial. A variety of methods are currently used to protect wind turbines from corrosion, and these methods have different levels of effectiveness depending on many factors.

The field of corrosion prevention for wind turbines is constantly evolving, and new technologies and materials are being developed to improve the durability of wind turbine components. It’s crucial that we continue to invest in research and development in the field of corrosion prevention for wind turbines. By doing so, we can work towards creating wind turbines that are more sustainable, resilient, and efficient.

To learn more about the sustainability initiatives developed and promoted by the Institute of Corrosion (like the conference on Integrity Engineering for a Sustainable Future), please email us.

Integrity Engineering for a Sustainable Future

Integrity Engineering for a Sustainable Future

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​Engineering Corrosion in a Changing World – Sustainability, Costs, and Solutions

We’ve come a long way from burning wood for energy. As we’ve progressed to burning coal, oil, and gas, the hydrocarbon energy industry has played a major part in lifting 80% of the population out of poverty. However, it’s become clear that this path isn’t sustainable. The discovery, extraction, generation, and distribution of hydrocarbons creates a huge amount of effluent that must be dealt with – we’re now integrity engineering for a sustainable future.

The good news is, we have the power to change that – and the corrosion control industry has a big role to play in creating sustainable solutions for the energy sector. In fact, achieving the net zero emissions target depends upon effective corrosion management (including in carbon capture and storage).

It’s time to focus on the sustainability conversation

Solutions come from discussing problems and brainstorming around them. We have the technology and know-how to design systems and procedures that will provide corrosion control for the life of an asset. However, cost must always be considered. Too often it causes reduced performance between concept and construction.

Imagine designing systems and procedures that not only protect assets, but also help us reach net zero emissions. And while cost is always a consideration, it mustn’t be the deciding factor in creating a better future.

Getting serious about integrity engineering for a sustainable future

The Institute of Corrosion has joined forces with the North of England Institute of Mining and Mechanical Engineers to host a not-to-be-missed event for all those involved in (or interested in) the challenges facing the energy industry and how we can address them. Among the topics open for discussion will be:

  • New ways to provide energy
  • Repurpose of existing resources
  • Effects on sustainable corrosion control solutions

At this event, leading players in the field will present, debate, and challenge current engineering solutions as we seek to gain greater perspective on how to meet our future environmental requirements.

All participants will gain a greater understanding of the value chain and the journey from concept to end user, as well as the challenges experienced by all players in the energy sector.

The North East – the perfect location to discuss integrity engineering for sustainability

The conference will take place in the exceptional Neville Hall in the centre of Newcastle. Within walking distance of many fantastic hotels, Neville Hall is easily accessed by car and train. It houses many excellent facilities, including lecture theatres, breakout rooms, and a superb library. But the quality of Neville Hall is not the only reason for hosting the conference in the North East.

This region of the UK has been a powerhouse in the energy industry for centuries. It’s not just a prime location with easy access for those in the energy sector ─ it also has a rich history in energy production. Geographically and geologically significant, the North East boasts coal, steel, and chemicals production. It’s a hub for the distribution of North Sea energy to London and the South East. It’s an ideal location for delegates, asset owners, fabricators, paint manufacturers, researchers, applicators, and more from around the UK. But most importantly, this is the region that houses two of the UK’s most significant carbon capture projects and the noteworthy wind turbine centre in the Port of Blythe.

How can you become involved in the sustainability conversation?

The conference is a one-day event, divided into four sessions. Each session will have an expert chair, leading and facilitating discussion. There will also be a conference dinner in the evening, and an optional site visit the morning following the day of the conference.

For further details, to learn how to book your place as a delegate, or to enquire about conference sponsorship opportunities, please email ICorr or david.mobbs@c-i-m.co.uk.

We have also launched our call for presentations. If you would care to present at the event, please email an abstract of no more than 300 words including your name, organisation, presentation title, and main theme/title to barry.turner17@gmail.com.

Oil and Gas Asset Management: The Part That Corrosion Management Plays

Oil and Gas Asset Management: The Part That Corrosion Management Plays

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Corrosion Science and Engineering in Action in Oil and Gas

As the world attempts to slow the effects of climate change, many strategies are being explored and employed. With so many new technologies and renewable energy sources being deployed, it can feel like traditional energy and oil and gas assets are being left behind.

Yet recent events have shown that this simply is not the case. The world is a long way from jettisoning oil and gas assets from the energy mix. And effective corrosion management is still key to successful operation of oil and gas assets. This can not only prolong the life of assets and pipelines, but it can reduce the release of toxins and harmful by-products into the environment.

Why corrosion management is crucial in oil and gas assets

Corrosion can lead to the failure of oil and gas assets. The resulting leaks and spills can be dangerous to the environment and human health. It can also increase the cost of operating oil and gas assets by requiring frequent repairs and replacement of corroded components.

Therefore, it is important to implement effective corrosion management strategies to ensure the long-term viability and safe and reliable operation of oil and gas assets.

What causes corrosion in Oil and Gas assets?

Corrosion in oil and gas assets is caused by a combination of factors, including exposure to harsh chemicals and high temperatures. The main cause of corrosion in these assets is the presence of high concentrations of water, and CO2.

High temperatures can accelerate the corrosion process, particularly in areas where CO2 is in contact with water or other liquids. Additionally, high temperatures can cause metal components to expand and contract, which can lead to stress on the materials and accelerate corrosion.

Other factors that can contribute to corrosion in oil and gas assets include exposure to other chemicals, such as sulfur compounds, chlorides, and hydrogen sulfide, as well as the presence of microorganisms, such as bacteria and fungi. Interaction with CO2 and water create an environment that is more corrosive to metal surfaces.

How does corrosion occur in oil and gas assets?

The corrosion of different materials used in oil and gas assets can occur in different ways, depending on the specific properties of the material and the environmental conditions.

The three most common types of corrosion found in Oil and Gas assets are pitting, crevice, and galvanic corrosion:

  • Pitting corrosion is the localized corrosion of a metal surface, resulting in small holes or pits. In Oil and Gas assets, pitting corrosion can occur in pipelines, valves, and other components that come into contact with CO2, especially in areas where the CO2 is in contact with water or other liquids.
  • Crevice corrosion is a form of localized corrosion that occurs in tight spaces or crevices, such as the area between a gasket and a pipe flange. In oil and gas assets, crevice corrosion can occur in joints and connections, such as flanges and gaskets, that come into contact with CO2.
  • Galvanic corrosion is a type of corrosion that occurs when two dissimilar metals are in contact with an electrolyte, such as water or CO2. In oil and gas assets, galvanic corrosion can occur in joints and connections where dissimilar metals, such as steel and aluminum, are used.

For example, carbon steel is a commonly used material in oil and gas assets, but it is highly susceptible to pitting and crevice corrosion in the presence of CO2 and water. Stainless steel, on the other hand, is more resistant to corrosion but can still be affected by high temperatures and the presence of other corrosive agents.

Corrosion Management Strategies in Oil and Gas assets

Currently, there are several strategies that can be used to manage corrosion in oil and gas assets. Of course, regular inspection and maintenance is crucial, as is the use of coatings and inhibitors, and material selection.

Regular inspection and maintenance

Regular inspection and maintenance are essential for early identification and addressing of corrosion problems. This includes visual inspections, non-destructive testing, and monitoring of corrosion rates.

Coatings and inhibitors

Coatings and inhibitors can be used to protect metal surfaces from corrosion. Coatings, such as paint or epoxy, can provide a physical barrier to prevent corrosion. Inhibitors, such as corrosion inhibitors, can be added to slow down the corrosion process. These are commonly used in oil and gas assets and can be effective in preventing corrosion, but it’s important to note that the selection of the right coating or inhibitor depends on the specific conditions of the asset, and regular monitoring and maintenance is still needed.

Material selection

Material selection is a crucial aspect of corrosion management in oil and gas assets. The use of corrosion-resistant materials, such as stainless steel, can significantly reduce the risk of corrosion. However, it’s important to note that no material is completely immune to corrosion, and other strategies such as coatings and inhibitors should be considered as well.

The future of corrosion management in oil and gas assets

Managing corrosion in oil and gas assets requires a multi-faceted approach, and the best strategy for a specific asset will depend on the specific conditions and materials used. For example:

  • Regular inspection and maintenance are essential for identifying and addressing corrosion problems early on, but they can be costly and time-consuming
  • Coatings and inhibitors can be effective in preventing corrosion, but they can also be costly and require regular monitoring and maintenance
  • Material selection can significantly reduce the risk of corrosion, but it’s important to note that no material is completely immune to corrosion

Corrosion can lead to unsafe operation of oil and gas assets, as well as increasing the cost of operating by requiring frequent repairs and replacement of corroded components.

While current corrosion management strategies are effective at controlling corrosion at oil and gas assets, it is important to continue to research, experiment, and develop innovative techniques for corrosion management. As the technology and conditions in oil and gas assets evolve, so should the strategies used to manage corrosion.

Every improvement that we can make will improve the viability and safety of our oil and gas assets. The Institute of Corrosion is in the perfect position to help industry and academia deliver these improvements.

To learn more about how the Institute of Corrosion is helping to promote and deliver greater safety and operational effectiveness in the world’s oil and gas assets, and discover how you can get involved, please email the Institute of Corrosion.

Carbon Capture and Storage: The Part That Corrosion Management Plays

Carbon Capture and Storage: The Part That Corrosion Management Plays

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Corrosion Science and Engineering in Action in Climate Change Technology

Carbon capture and storage is a technology that could be crucial in our attempts to slow the effects of climate change. The methodology is relatively simple:

  • Carbon dioxide (CO2) is captured from power plants and industrial sources before it is released into the atmosphere.
  • Captured CO2 is then transported and stored underground in geological formations, such as depleted oil and gas reservoirs, deep saline aquifers, and coal seams that can no longer be mined.

This process can significantly reduce CO2 emissions released into the atmosphere from power generation and heavy industry.

However, the long-term storage of CO2 in underground reservoirs poses many technical challenges. One of these is corrosion management of the pipelines used to transport CO2.to carbon capture and storage (CCS) facilities.

Why corrosion management is crucial in carbon capture and transportation

Pipelines are often made of materials that are vulnerable to corrosion, and, if left under-managed, this can lead to various problems. For example, corrosion can cause equipment to leak or fail, potentially releasing the captured carbon dioxide into the environment.

Effective corrosion management helps to ensure the safe and reliable operation of the system, while also protecting the environment. By proactively managing corrosion, the efficiency and longevity of the system can be maintained, reducing the costs and potential risks associated with equipment failure – including the risks to the environment and human health.

Therefore, corrosion management should be considered as a crucial aspect of carbon capture and transportation systems.

What causes corrosion in CCS facilities and transportation?

Corrosion in CO2 pipelines is somewhat different from the conventional CO2 corrosion that occurs during the transportation of oil and gas. In these systems water mixed with oil is unavoidable – it’s in the ground with the oil. CO2 is also usually present in large quantities because oil and gas fields tend to contain CO2. During transportation, the CO2 dissolves in the water and acidifies it. This can lead to corrosion of the metallic material from which the pipeline is made.

With CCS on the other hand, we are normally transporting CO2 in its dense phase – either as a liquid or as a ‘supercritical’ fluid which is not quite a liquid and not quite a gas (a fluid with a mixture of the two properties). From a corrosion perspective, if we could ensure that we only have pure dense-phase CO2 in the pipeline (with no water or other impurities present), there would be no corrosion.

The corrosion problem exists because of the way in which the CO2 is produced before being delivered to the pipeline or other transportation system. For example, CO2 generated by the burning of a fossil fuel in a power station is captured in a solvent and later released from the solvent in a secondary step and pumped into the pipeline. Impurities are created during this process. Sulphur oxides, nitrogen oxides, carbon monoxide, hydrogen sulphide, and water can all be present. It’s the water that can initiate the corrosion problem.

How does corrosion occur in CCS transportation?

When water condenses in the pipeline, other impurities will dissolve in the water, as well as the CO2.

“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,” explains Gareth Hinds of the National Physical Laboratory (NPL). “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.”

Corrosion Management Strategies in CCS Facilities

In oil and gas installations and transportation, corrosion is quite predictable. It can be managed with inhibitors, coatings and cathodic protection. It is not so straightforward in CCS facilities and pipelines.

In dense-phase CO2, the concern is the impurities. It is difficult to predict where these will condense, nor do we know what reactions will happen between the impurities.

In short, it is crucial to consider corrosion as a priority in both the design and operation of CCS pipelines. Any leak can lead to many issues, including potential loss of life where ground level CO2 concentration rises above 100,000 ppm.

Corrosion management in CCS transportation is largely concerned with specifying impurity limits at the inlet to the pipeline – and maintaining these for the life of the pipeline. Therefore, the industry must focus on ensuring impurities are kept within limits that don’t propagate bulk phase reactions and form aqueous phases.

The future of corrosion management in CCS facilities

As long ago as 2014, the Materials Performance magazine published an article discussing the pipeline corrosion issues related to carbon capture, transportation, and storage. It explored a range of potential advances in corrosion management in CCS, including:

  • Using sealants made from inorganic materials
  • Continuing research into the compatibility of non-metallic materials (polymers, ceramics, and plastics) in dense phase CO2 containing impurities
  • Evaluation and testing of suitable corrosion inhibitors

There has been much work into all such considerations, but the work is not yet concluded. Indeed, corrosion is such a complex subject that research and discovery is likely to have no end. Writing in Corrosion Management Magazine, Gareth Hinds notes some of the corrosion management issues that the CCS industry faces:

“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. The requirements for ship transport are typically more stringent than those for pipelines, with lowest temperatures representing the worst-case scenario.

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.

For CO2 specifications, thresholds in relation to acid drop out are set based on limited available data (often not lower than 25°C) 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 these issues.”

The bottom line – It’s a question of delivering sustainability

There is no simple answer to managing corrosion in CCS facilities and pipelines more effectively. There are no internationally agreed specifications for CO2 composition during pipeline transport, despite general industry guidance on impurity limits. Currently, the responsibility lies with the pipeline operator.

The Institute of Corrosion is at the forefront of this conversation on the international stage. We understand that the corrosion industry – engineering and academia – has a great opportunity and responsibility to deliver the knowledge and solutions required to create a more sustainable planet.

The Institute of Corrosion, partnering with the North of England Institute of Mining and Mechanical Engineers, is hosting a not-to-be-missed conference on Integrity Engineering for a Sustainable Future. Delegates will have the opportunity to learn more about the advances being made in corrosion management across the energy industry, as well as networking with some of the most prominent experts involved in the corrosion conversation.

To learn more about how the Institute of Corrosion is helping to combat climate change, and how you can get involved, please email the Institute of Corrosion.