Can Thermally Sprayed Aluminum (TSA) Mitigate Corrosion of Carbon Steel in Carbon Capture and Storage (CCS) Environments?

Paul, Shiladitya; Syrek-Gerstenkorn, Berenika

doi:10.1007/s11666-016-0504-7

Cited by 3 publications

(1 citation statement)

References 16 publications

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“…But in the presence of liquid water, CO2 forms corrosive carbonic acid. Hence to reduce corrosion of carbon steel in sea water thermally sprayed aluminum (TSA) has been used [13].New materials like refractory (e.g., W, Mo) silicide alloys and SiC composites are used to enhance the high temperature capability. Thermal spray coatings of Molybdenum followed by chemical vapor deposition of Silicon and Boron by pack cementation has been carried out to develop an aluminoboro silica surface for improved environmental resistance [14].In one study, detonation-gun-sprayed Ni-5Al coatings were applied on Ni based super alloy Inconel-718 and a comparative study of the high temperature hot corrosion behavior of bare and coated specimens were carried out.…”

Section: Introductionmentioning

confidence: 99%

HVOF Sprayed Mullite Coatings for Use In Extreme Environments

Bellie¹,

Suresh²,

Ragunath³

2020

JTSE

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Products used in industry and marine applications are exposed to extreme environments like high heat, humidity, acidic or alkaline or hyper saline environment, UV and IR radiation. Metals with good corrosion and oxidation resistance may be used but are restricted to Ni and Cr alloys, titanium and super alloys etc., which are costly and have their limitations. Hence ceramic coatings on low cost metals may be an answer to this problem. Ceramics are inherently chemically inert, high temperature resistant, corrosion and oxidation resistant. Flame spraying of ceramics is a good and reliable method for applying ceramic coatings on metallic substrates with good bond strength (> 80 MPa) and 1% porosity. In this work, HVOF technique is applied to obtain 100 microns thick mullite coatings on MS substrates with a NiCr bond coat. Mullite has a high oxidation and corrosion resistance. It is chemically inert. It has high temperature resistance even at 2000 C. These properties are ideal for industrial components exposed to salty environments. Characterization studies like XRD, SEM/EDS, Corrosion tests using polarization technique, coating thickness and surface roughness have been studied and reported. A corrosion rate of 1.55 mm/ year has been achieved in a sea water environment.

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Section: Introductionmentioning

confidence: 99%

HVOF Sprayed Mullite Coatings for Use In Extreme Environments

Bellie¹,

Suresh²,

Ragunath³

2020

JTSE

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Feasibility Study of High-Velocity Oxy-fuel (HVOF) Sprayed Cermet and Alloy Coatings for Geothermal Applications

Zhang

Tabecki²,

Bennett³

et al. 2023

J Therm Spray Tech

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Geothermal is one of the least utilized renewable energy sources due to high investment costs and long development cycle. A major cost for geothermal operations is drilling, where the cost is dependent on drilling depth, tripping times, environments, etc. These costs can increase significantly for greater drilling depths, harsher environments, component failures, etc. During drilling, hammers break the rock through repetitive impact and cuttings are removed via a high-velocity stream. Component lifetime can be extended by selecting appropriate coatings resulting in reduced lost time and improved drilling efficiency. High-velocity oxygen fuel (HVOF) spraying is one of the most popular technique to deposit thick, dense and highly adherent coatings. This paper discusses the characteristics of cermet and alloy coatings using liquid-fueled HVOF spraying technique and their performance in simulated geothermal drilling environment. Properties of the deposited cermet (WC-CoCr, CrC-NiCr) and alloy (Ni self-fluxing, Fe-based amorphous) coatings in terms of surface roughness, thickness, porosity, hardness, adhesion strength, and erosion–corrosion resistance have been studied, and their performance are compared with selected benchmarking steel used in geothermal drilling. Based on the findings of this study, recommendations are made on the type of HVOF coatings that can potentially be used in geothermal applications.

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Mitigating CO2 Corrosion of Natural Gas Steel Pipelines by Thermal Spray Aluminum Coatings

2021

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Internal pipeline corrosion due to CO2 is a major challenge facing the oil and gas industry. To protect the pipelines and equipment from the ravages of CO2 corrosion, novel sacrificial coatings can be used. The objective of this study was to investigate the corrosion behavior of Al-based alloys as sacrificial coatings to protect pipelines in a CO2-saturated aqueous electrolyte (3.5 wt.% NaCl) at 4 bar CO2 partial pressure (3 barg) and 40 oC. The corrosion resistance of Al-based alloys and thermal spray coatings was evaluated in an electrochemical reaction autoclave using electrochemical methods (potentiodynamic polarization, linear polarization resistance, and electrochemical impedance spectroscopy). Post-corrosion surface characterization was performed by scanning electron microscopy equipped with energy dispersive X-ray spectroscopy. The obtained data show Al-based alloys demonstrated promising protection against CO2 corrosion with no breakaway degradation issues.

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Can Thermally Sprayed Aluminum (TSA) Mitigate Corrosion of Carbon Steel in Carbon Capture and Storage (CCS) Environments?

Cited by 3 publications

References 16 publications

HVOF Sprayed Mullite Coatings for Use In Extreme Environments

HVOF Sprayed Mullite Coatings for Use In Extreme Environments

Feasibility Study of High-Velocity Oxy-fuel (HVOF) Sprayed Cermet and Alloy Coatings for Geothermal Applications

Mitigating CO2 Corrosion of Natural Gas Steel Pipelines by Thermal Spray Aluminum Coatings

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