Using
a three-phase batch reactor with coated steel panels, this
investigation studies the influence of carbon dioxide (CO2), present in the gas phase at conditions of high pressure and high
temperature (HPHT), on the degradation of an amine-cured epoxy novolac
(EN) coating. The combined effect of the gas, hydrocarbon, and seawater
phase compromises the coating and leads to underfilm corrosion. Consequently,
an understanding of the role of each of the phases is essential for
the effective design of superior epoxy-based coatings for HPHT applications
in the petroleum and other industries. Upon exposure to the three
phases individually, at a low pressure of N2, the EN network
remained unaffected and impervious. However, in the hydrocarbon-exposed
zone, a combination of para-xylene, representing
the hydrocarbon phase, and CO2 at HPHT initiated glass-transition
temperature depression with subsequent softening of the EN network.
This allowed the dissolved CO2 gas to diffuse into the
EN network, thereby generating pinholes at the coating surface. The
seawater-exposed zone, in the presence of CO2 at HPHT,
suffered from increased seawater ion diffusion, leading to blister
formation. Moreover, the most detrimental subzone for the EN network
was when CO2, para-xylene, and seawater
were synergistically interacting at its hydrocarbon–seawater
interface. This combination resulted in an increased chain motion
of the EN network, subsequently allowing CO2 and seawater
ions to diffuse into the EN network to the steel substrate, imposing
underfilm corrosion. In the absence of CO2, blisters were
formed at the interface subzone, but no corrosion was detected. The
results are of high relevance to the petroleum industry but also for
the protection of transport pipelines and process equipment in the
next-generation carbon capture and storage technologies.