Corrosion Rate Of Carbon Steel Research Articles

Corrosion of High-Strength Carbon Steels in Siderite Supersaturated Water at Near Neutral pH

When carbon steel corrodes in anaerobic carbonated water, and the steel surface area to liquid volume is high, the concentration of ferrous and bicarbonate ions increases rapidly even though the corrosion rate is low. Such solutions with high bicarbonate concentration and a near neutral pH are believed to induce stress corrosion cracking of high-strength carbon steels. This work was conducted to investigate the solid precipitation in siderite supersaturated solutions. It was also an objective to measure the corrosion rate of high-strength carbon steel in solutions with high bicarbonate concentration at pH close to neutral. Preloading the solutions with ferrous ions and bicarbonate made it possible to measure desupersaturation and corrosion rate as function of time. The initial siderite supersaturation was more than 1,000 in the desupersaturation experiments. Despite this, the nucleation and growth of siderite was so slow that the solutions remained supersaturated for 100 h to 500 h at 10°C to 25°C. The ferrous ion concentration decreased from 1,200 mg/kg to 100 mg/kg in less than 24 h at 40°C, but did not reach equilibrium within 250 h. The precipitate was siderite at 5°C to 25°C. At 40°C, the solid was a mixture of siderite and chuckanovite in low salinity water and siderite with dissolved Ca2+ in artificial seawater. The corrosion rate of carbon steel at pH 6.7 to 7.2 at 25°C decreased to less than 0.01 mm/y in 5 h. Siderite precipitated and grew to a thin protective layer at the steel surface. Even though the solutions were highly supersaturated with respect to siderite throughout the experiments, the carbonate layer at the steel surface did not grow to more 5 μm thickness during 250 h to 400 h. The investigated steels were armor wires for flexible pipes. They have an oxide layer at the surface which is an inherent result of the manufacturing process. The presence of these oxides did not impede the formation of protective siderite layer.

The Inhibition Action of Viscum Album Extract on theCorrosion of Carbon Steel in Hydrochloric Acid Solution

Corrosion rate of carbon steel (CS) in 1M HCl was examined in the absence and presence of Viscum album plant extract as a corrosion inhibitor using weight loss, polarization, and impedance techniques. The effect of temperature and extract dose was studied using a weight loss test. The outcome data gained displayed that Viscum album extract plays as an inhibitor for CS in HCl and reduces the corrosion rate. The higher inhibition efficacy reached 96.3% for Viscum album at greater inhibitor doses (300 ppm) and temperature. Polarization data revealed that this extract acts as a mixed kind inhibitor. The surface analysis of CS was checked by different methods, which showed the formation of extract film on the CS surface. The adsorption of Viscum album plant extract was found to obey the Temkin model, and the data of adsorption free energy was more negative than -40 kJ/mol, which means that the adsorption is chemical.

Corrosion Rate of Carbon Steel A106 Gr B in Amine-CO2 Contained Solutions

Carbon dioxide (CO2) is one of the corrosive element which exists in oil and gas industries. To prevent CO2 corrosion on carbon steel pipelines, amine-base solvent and caustic solutions are commonly applied. Accordingly, effectiveness of amine base solvent and caustic solutions to reduce risk of corrosion becomes key parameters in determining service lifetime of pipelines made of carbon steel. In this research, the corrosion rate of carbon steel A106 Gr B in amine solutions combined with saturated CO2 gas and caustic solution was studied. The experiments were carried out in static conditions and the Linear Polarization Resistance (LPR) technique was used to measure the corrosion rate (as per ASTM G 5-94). It was found that the corrosion rate in the amine-based solution had shown remarkable results. Somehow, the corrosion rate in an amine-based solvent containing saturated CO2 gas has increased to 200%. The temperature increment to 50°C from room temperature has also increased the corrosion rate. Meanwhile, the caustic addition in amine solution has reduced the corrosion rate of carbon steel.

Study on microbial corrosion inhibition of carbon steel in circulating cooling water system

Although the industrial circulating cooling water system can save a lot of water resources, there will be serious scaling and corrosion during operation. Based on the environmental friendliness of microbial corrosion inhibition technology, this work evaluated the influence of microbial environmental indicators on the corrosion rate of carbon steel in circulating cooling water system by full factor experimental design. The results showed that under 10-50 mg/L ammonia nitrogen, 1-3 L/min aeration fluxes, the corrosion rate getting lower with the increase of ammonia nitrogen concentration and the decrease of aeration rate, while the microbial content had little effect on the corrosion rate.

A Laboratory Corrosion Inhibition Study of Carbon Steel Using 2-Mercaptobenzothiazole (MBT) Under Post-Combustion CO2 Capture Conditions

Corrosion mitigation is an important aspect of amine-based post-combustion carbon dioxide (CO2) capture operations due to the desire to use less expensive but corrosion-vulnerable materials such as low carbon steels in the construction of a capture system. In this study, the corrosion behavior of A106 (grade B) carbon steel with an in-house proprietary amine-based solvent was investigated in a laboratory environment at 80°C using an organic corrosion inhibitor, 2-mercaptobenzothiazole (MBT). The corrosion inhibition mechanism was interpreted by electrochemical methods and surface analyses. The results revealed that the corrosion rates of carbon steel were significantly retarded using MBT. The critical inhibitor concentration was determined to be lie between 10 ppm and 50 ppm under the tested conditions.

Microbiologically Influenced Corrosion Behavior of Carbon Steel in the Presence of Marine Bacteria Pseudomonas sp. and Vibrio sp.

The microbiologically influenced corrosion (MIC) behavior of carbon steel is investigated in the presence of Vibrio and Pseudomonas. Sterilized natural seawater inoculated with Pseudomonas, Vibrio, and the mixture of Pseudomonas and Vibrio, separately, and they are utilized as the media for corrosion characterizations, which are closer to the natural environment in seawater. Weight loss measurements, electrochemical techniques (the open-circuit potential, electrochemical impedance spectroscopy (EIS), and potentiodynamic polarization curves), and surface analysis (scanning electron microscopy (SEM)) are performed to explore the synergistic effect of Pseudomonas and Vibrio on the corrosion behavior of carbon steel. As seen from the growth curves of bacteria, the growth and propagation of Pseudomonas and Vibrio are affected by their metabolic activities. Besides, the results obtained by SEM show that more severe pitting corrosion is observed on the coupons exposed to the sterilized natural seawater inoculated with the mixture of Pseudomonas and Vibrio. Further, the results from electrochemical measurements and weight loss measurements suggest that under the synergistic effect of Pseudomonas and Vibrio, the initial corrosion rate of carbon steel is inhibited, while the latter corrosion is enhanced.

Influence of NaCl concentration on microbiologically influenced corrosion of carbon steel by halophilic archaeon Natronorubrum tibetense

The influence of NaCl concentration on microbiologically influenced corrosion (MIC) of Q235 carbon steel by the halophilic archaeon Natronorubrum tibetense was investigated by immersion tests and electrochemical measurements. An increase in NaCl concentration from 0 g/mL to 0.1 g/mL promoted the anodic dissolution of carbon steel and accelerated its corrosion, but MIC did not occur. A further increase in NaCl concentration to 0.2 g/mL led to MIC in inoculated medium, and the occurrence of the MIC resulted in further aggravation of carbon steel corrosion. Once the NaCl concentration reached 0.3 g/mL, the high concentration of chloride ions greatly interfered with the adsorption of dissolved oxygen and the attachment of N. tibetense cells to the surface of carbon steel, thus reducing the corrosion rate of carbon steel and inhibiting the MIC.

Study the Effect of Adding Titanium Powder on the Corrosion Behavior for Spot Welded Low Carbon Steel Sheets

Carbon steel is a widely used material in many different applications which require high welding, such as panels for appliances or automobiles. However, the effect of the spot welding process itself has reduced corrosion resistance. On the other hand, during spot welding can have poor corrosion behavior leading to weld failure. This study proposes a new approach in resistance spot welding carbon steel sheets by adding a small amount of titanium powder between the faying surfaces to improve the corrosion resistance. The corrosion behavior of spot welded carbon steel in 1 molarity aqueous sulfuric acid solution has been studied using potentiodynamic polarization measurements in the presence and absence of titanium powder additives in joining carbon steel sheets during the spot welding process at various conditions. It was observed that, the corrosion rate reduced when adding titanium powder for both cases increasing spot welding current and time compared with specimens without adding titanium powder. Microstructural changes were occurred during the spot welding process which has observed in the assayed samples using scanning electron microscope. There was an alteration the corrosion rate of low carbon steel when adding titanium powder.

A Machine Learning‐Based Model for Predicting Atmospheric Corrosion Rate of Carbon Steel

The purpose of this study is to develop a practical artificial neural network (ANN) model for predicting the atmospheric corrosion rate of carbon steel. A set of 240 data samples, which are collected from the experimental results of atmospheric corrosion in tropical climate conditions, are utilized to develop the ANN model. Accordingly, seven meteorological and chemical factors of corrosion, namely, the average temperature, the average relative humidity, the total rainfall, the time of wetness, the hours of sunshine, the average chloride ion concentration, and the average sulfur dioxide deposition rate, are used as input variables for the ANN model. Meanwhile, the atmospheric corrosion rate of carbon steel is considered as the output variable. An optimal ANN model with a high coefficient of determination of 0.999 and a small root mean square error of 0.281 mg/m2.month is retained to predict the corrosion rate. Moreover, the sensitivity analysis shows that the rainfall and hours of sunshine are the most influential parameters on predicting the atmospheric corrosion rate, whereas the average chloride ion concentration, the average temperature, and the time of wetness are less sensitive to the atmospheric corrosion rate. An ANN‐based formula, which accommodates all input parameters, is thereafter proposed to estimate the atmospheric corrosion rate of carbon steel. Finally, a graphical user interface is developed for calculating the atmospheric corrosion rate of carbon steel in tropical climate conditions.

Characterize of Corrosion Rate and Mechanical Properties of Low Carbon Steel in Potassium Chromate Solution

Corrosion is one of the degradation materials in Industrial problem. One of the processing to choose material is to determine how to have resistance to all the environment. This research is carried out to determine characterize the effect of various temperatures (150, 200, 250 °C) and time (4,6 and 8 hours) of exposure of Low Carbon Steel in corrosion rate and mechanical properties by using Mass Balance method and Potassium Chromate vapor as medium corrosion. The results have been shown that the increasing temperature ids increasing corrosion rate which is the maximum value is 5,1215 x 10−4 miles/years. The difference in corrosion rate increasing by 6,3 % based on increasing temperature. The microstructure has shown is intergranular corrosion mode.

CO2 Top-of-Line-Corrosion; Assessing the Role of Acetic Acid on General and Pitting Corrosion

Based on a review of both literature and field data, it is apparent that the role of acetic acid (HAc) in oilfield brines is both extremely complex and somewhat controversial. Although it is commonly believed that the presence of this organic compound enhances both the general and the localized corrosion rate of carbon steel, HAc has recently been reported to also act as a weak general corrosion inhibitor in specific aqueous environments. These observations prompted a study into whether such behavior is apparent in a CO2 top-of-line corrosion (TLC) scenario, i.e., when HAc dissolves into condensed water that forms on the upper internal wall of carbon steel pipelines during wet-gas stratified flow. Four different water condensation rates/temperature TLC conditions were selected to investigate the role of HAc on both the kinetics and mechanism of carbon steel dissolution. A miniature three-electrode setup was developed to characterize the real-time TLC response through the implementation of electrochemical measurements. Surface analysis techniques (microscopy and profilometry) were also performed to complement the electrochemical results. Collective consideration of the corrosion response and condensate chemistry indicates that similar effects were observed to those reported in the literature for bulk aqueous environments, in that the introduction of HAc can result in either accentuation or a minimal/inhibitive effect on general corrosion depending upon the operating conditions. The minimal/inhibitive effects of HAc were apparent at a surface temperature of 20.5°C and water condensation rate of 0.5 mL/m2·s, as no significant increase in corrosion was observed, despite a significant reduction in condensate pH being generated by the presence of HAc. X-ray photo-electron spectroscopy analysis of the inhibited steel specimen in the presence of HAc revealed the presence of iron acetate on the steel surface, which may have been at least partially responsible for the observed inhibitive effect. Extended duration experiments over 96 h revealed that both general and localized corrosion are not significantly affected by HAc addition at low temperature, whereas the level of degradation increases at higher surface temperature over longer periods.

ANALYSIS OF CORROSION RATE OF ASTM A 387 GRADE 12 AND A 283 GRADE FOR SULFURIC ACID TANK MATERIAL

Corrosion is a process of degradation metal quality which is very detrimental in the industry. Especially in an industries related to utilization of acidic liquids such assulfuric acid, hydrochloric acid, etc. If corrosion rate of carbon steel can be estimated, the prediction of remaining life of carbon steel, and the preventive methods of corrosionwould be more appropriate. This will reduce technical, economic and aesthetic losses. The aims of this study was to determine corrosion rate of carbon steel in sulfuric acid. This study used ASTM A 387 Grade 12 and ASTM A 283 Grade A carbon steel type fortank material, where one material is represented by 5 specimen. The corrosion rate of Specimens were measured by the weight loss method for 31 days. The 5 specimens were divided into 3 regions where specimens no.1 and 2 were immersed in sulfuric acid , specimens no.3 were in the middle area or zone level (partially immersed), and specimens no.4 and 5 were not immersed in sulfuric acid. The highst corrosion rate occured on specimen No.3 with maximum corrosion rate was 0,097 mm/y for ASTM A 387 Gr 12 and 0,096 mm/y untuk material ASTM A 283 Gr A. The results of corrosion rate on ASTM A 387 Grade 12 material are lower than corrosion rate of ASTM A 283 Grade A material. This is caused by presence of Mo and Cr alloy elements in ASTM A 387 Grade 12.

Monitoring of Carbon Steel Corrosion in Soil Under Wet-Dry Cyclic Conditions

Corrosion of carbon steel in soil is affected by various factors such as particle size, water content, soli depth, pH, temperature and microorganisms. Based on the results of exposure tests conducted in the past, it is common to design a steel material with a 1 mm "corrosion allowance" in 100 years. However, environmental factors of soil change depending on regions and seasons. Thus further improvement and rationalization of design are required to reduce material cost.Water content is one of important environmental factors that determines the ratio of the gas and liquid phases in soil, and it is considered to have an influence on corrosion. In addition, the corrosion rate near the soil surface may change significantly due to cyclic wet-dry such as rainfall and daily humidity changes. In this study the corrosion rate of carbon steel in simulated soil under cyclic wet-dry was monitored by electrochemical impedance method, and the effect of cyclic wet-dry on carbon steel corrosion was examined.A pair of identical carbon steel plates (10 × 5 mm) were embedded in an epoxy resin (40 mm ϕ) and used as a probe electrode for the corrosion monitoring in soil. SiO2 particles with 100 μm diameter were used as a simulated soil. An acrylic pipe with a flange was fixed vertically on the probe surface with a gasket sandwiched, and the silica powder was put into the acrylic pipe so that the height was 1 cm. Furthermore, 3% NaCl solution was poured until the soil surface was completely immersed (100%). The experimental cell was placed in a chamber set at 25 ℃ and 40% RHDuring drying, impedance at two frequencies, 10 kHz and 10 mHz was continuously measured. The solution resistance R sol and charge transfer resistance R ct were monitored by Z 10kHz and (Z 10mHz – Z 10kHz), respectively. The R sol increased with the drying time and reached a constant. The impedance measurement was terminated when the R sol became a constant. In this study, the reciprocal of R ct was used as an index of the corrosion rate.The corrosion rate reached a maximum after 1 ~ 3 hours from the start of the drying. It is considered that the increase in the corrosion rate was due to the decrease in the water content by drying. At the onset of the drying, the spaces among the particles were completely filled with 3% NaCl solution. In such a condition, the corrosion will be strongly suppressed because oxygen diffusion through the soil is very slow. As the drying progresses, the gas phase in soil increases and enhances the oxygen diffusion. Thus, the corrosion rate can increase. However, further drying decreases the solution phase and decreases the average corrosion rate because the anodic dissolution of Fe could be hindered. Finally, when the simulated soil was completely dried out, the 1/R ct became negligibly small.After the dry-up, ultrapure water was added to the soil, so that NaCl concentration became 3% and the cell was exposed to the 2nd drying. The tendency of the change in R ct -1 during the drying was the same as the first drying process. However, the maximum value of the R ct -1 seemed to increase by repeated drying. This may be attributed that the corrosion product formed in the drying process becomes an oxidant in the next drying process.

Corrosion risk assessment of geothermal reinjection wellbore in Xining Basin, China

A potential corrosion risk exists during the re-injection of geothermal water in Xining Basin of China due to air entering the well caused by it being open. In this paper, a series of corrosion experiments using metal coupons and geothermal waters was conducted to evaluate the corrosion risk for steels in different typical geothermal waters by dissolved air. A novel and comprehensive prediction model for O2 corrosion rate in reinjection wellbores was established, and a sensitivity analysis of factors influencing air corrosion risk in reinjection wellbores was carried out. The results show that the main corrosive components in the geothermal water from the Xining Basin are Cl−, SO42−, H+ and the O2 added, which can cause a uniform corrosion and a small amount of local corrosion on the surface of carbon steel. The main corrosion products are FeO(OH) and Fe3O4. A high O2 partial pressure and flow velocity, a moderate temperature and salinity, and low pH promote a high corrosion rate for carbon steel. When the geothermal water is injected with a small amount of air, only the deeper part of the wellbore with a high temperature and pressure will suffer a serious corrosion risk, while when a large amount of air is mixed with geothermal water and injected, a huge corrosion risk will be imposed on the entire wellbore. Anti-corrosion measures should be taken if air is added to a wellbore. Removing the O2 from the geothermal water is the most effective solution for carbon steel. In addition, the established corrosion rate prediction model can consider more influencing factors and specializes in the situation of a low O2 partial pressure, which can be used as an effective tool to assess the corrosion risk in reinjection wells.

Experimental Study on Corrosion of J55 Casing Steel and N80 Tubing Steel in High Pressure and High Temperature Solution Containing CO2 and NaCl

The downhole casing and tubing in thermal recovery wells are the main channels for fluid flow. The corrosion for casing and tubing in high pressure (5 MPa) and high temperature (200 °C) (HPHT) fluid can cause string failure due to wall thinning, deformation, and fracture. In order to study the corrosion characteristics of J55 casing steel and N80 tubing steel in HPHT environment containing CO2 and NaCl, corrosion and corrosion inhibition experiments were carried out using a rotating autoclave at a pressure of 5 MPa and 50–200 °C environment. Morphologies and compositions of corrosion products were analyzed by SEM and XRD. HPHT corrosion process was discussed by Arrhenius equation and the transition state equation. Results showed that the corrosion rates of the two materials increased with CO2 partial pressure while increased initially and then decreased with increasing temperature. In CO2–NaCl solution, the saturate NaCl decreased the CO2 corrosion rates at low temperature (inhibition) and increased CO2 corrosion rates at high temperature. Meanwhile, SEM results showed that the surfaces of CO2 corrosion became more dense and uniform at high temperature. The increase of NaCl leaded to pitting and high concentration NaCl solution causes granular products to appear on the CO2 corrosion surface. The carbon steel corrosion rate is mainly controlled by kinetic parameters of activation; the activation parameters were increased by the increase in temperature and NaCl concentration. Oil-soluble imidazoline acts as a good inhibitor for corrosion of J55 and N80 in this work.

Corrosion of carbon steel in formic acid as an organic pollutant under the influence of concentration cell

The presence of contaminants in water even in small amounts can cause considerablecorrosion damages of metals. This is due to free corrosion effect or the formation ofconcentration cell of pollutants resulting in a galvanic effect. The current work was devotedto study the effect of formic acid (CH2O2) as an organic pollutant on the corrosion rate ofcarbon steel under different operating conditions. It includes an investigation of galvaniccorrosion caused by the establishment of concentration cell of formic acid under differentoperating conditions. The ranges of operating parameters were formic acid concentration of10-4 - 10-5 M and temperature of 32 - 50 °C. The results showed that increasing formic acidconcentration to 10-4 M leads to an increase in the corrosion rate by up to 7.6 times that inthe water of 0.1N NaCl. In addition, the corrosion rate in each terminal in concentrationcell also increased by up to 2.3 times. Pumping of air in formic acid solution led to aconsiderable increase in the corrosion rates and enhances the concentration cell effectwhich increases the galvanic currents. High increase of corrosion rate was noticed bypumping the air at high temperature reaching up to 4 times depending on temperature. Ingeneral, the galvanic currents were high initially and decreased with time due to theformation of corrosion product layer. The increase in temperature from 25 to 50 oC causedan increase in the galvanic corrosion rate reached up to 2 times in formic acid solution. Inaddition, the galvanic currents were noticed to decrease with temperature while thecorrosion rate of each terminal was increased.

Improving atmospheric corrosion prediction through key environmental factor identification by random forest-based model

Atmospheric corrosion prediction models were constructed based on the corrosion rates of carbon steel and 12 environmental factors from long-term exposure tests. Prior to support vector regression (SVR) modelling, the dimensionality of the dataset was reduced by a hybrid method combining random forest (RF) and Spearman correlation analyses, compared with maximal information coefficient (MIC) and principal component analysis (PCA). Using key environmental factors identified by the hybrid method as input parameters, the SVR model presented higher accuracy than those with dimensionality reduction by MIC and PCA. The dimensionality reduction also significantly improved the accuracy and generalizability of the SVR model.

Biomass Extraction as Green Corrosion Inhibitor for Low Carbon Steel in Hydrochloric Acid Solution

Corrosion is a degradation of metals quality caused by a chemical reaction between a metal and its ambient. The use of a green inhibitor is a natural method to control the corrosion rate of the metal. The objective of this research is to count the efficiency of the green inhibitor from biomass of tea and coffee extract, to find which variable that affect the most of corrosion rate of carbon steel, to determine the best concentration of extracts to control the corrosion rate of carbon steel. The extraction methods are the use method with a solvent ratio 1:4 of ethanol : aqua dest. Weight loss method is used to determine the rate of corrosion with 0,5g/L, 1g/L, and 1,5 g/L variance of inhibitor concentrations and 3, 6, 9, and 12 days immersed times. The lowest corrosion rate is 61,27 mpy at 1,5 g/l of tea extract inhibitor solution with 9 days immersed times and the highest efficiency is 79,02% at 1,5 g/l of tea extract inhibitor solution with 12 days of immersed times.

Modeling the corrosion rate of carbon steel in carbonated mixtures of MDEA-based solutions using artificial neural network

Amine-based CO2 absorption process has the benefit of purifying produced natural gas and reducing greenhouse gas emissions; however, it is associated with corrosion issues. This work aims to develop a corrosion prediction model for carbon steel in methyldiethanolamine (MDEA)-based binary mixtures with monoethanolamine (MEA), diethanolamine (DEA), or piperazine (PZ) at various concentrations using artificial neural network (ANN). Experimental studies of Q345R steel are performed, and corrosion rate data obtained by weight loss method is used to create a database for training and testing of the ANN model. A backpropagation (BP) multilayer perceptron (MLP) network with three layers is proposed. The number of input variables for the input layer is optimized after performing a correlation analysis. Effect of neuron quantity in the hidden layer on ANN model performance is studied; increasing the neuron quantity in the hidden layer is found to enhance the training accuracy and reduce the testing accuracy. A new index, max absolute relative deviation (MARD), is introduced to quantify the performance of the ANN model. The developed 5-8-1 type ANN model is able to give a MARD of 8.66 %. The same corrosion rate database is used to develop the SVM model, in which radial basis function (RBF) is used as the kernel function, and K-fold cross-validation technique is applied to select the optimal model values. A comparison of performance in both training and testing shows that the ANN model outperforms the SVM model.

Preparation of Cu-MOFs and its corrosion inhibition effect for carbon steel in hydrochloric acid solution

Cu-based metal–organic framework materials (Cu-MOFs) were synthesized by reacting copper nitrate trihydrate with 5-methyl-2-thiophenecarboxylic acid in the presence of 4,4-bipyridyl via the solvothermal method, and the structure of the resulting materials was characterized. The experimental results showed that Cu-MOFs could significantly reduce the corrosion rate of carbon steel and protect it from corrosion. Increasing the concentration of Cu-MOFs in the test solution increased inhibition efficiency, which reached 82.42% at 50 mg/L Cu-MOFs. Our findings confirmed that the synthesized Cu-MOFs could adsorb into and cover the surface of carbon steel to form a dense protective film that inhibits its corrosion.