Designing an Aqueous Corrosion Rig for Testing under Dynamic Supercritical-CO2/H2O Conditions

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The most problematic corrosion in oil and gas production is caused by CO2 in combination with produced water. Under extreme pressures and temperatures, the CO2 combined with water forms a supercritical (SC) phase, resulting in accelerated cathodic reactions. This project thus aims to study the influence of SC CO2, and other trace gases such as O2 and NO2, on the corrosion behavior of various materials by designing a corrosion rig facility under dynamic SC-CO2 conditions. In designing this rig, a number of factors have been considered including: existing rig design comparisons, cost of components, and health/safety implications. This rig provides up to 100°C and 100 bar. To measure corrosion rate, it has an electrochemical workstation as well as a pH meter (measuring hydrogen-ion activity). It is expected to provide basic material’s corrosion information which will be used in predicting corrosion in fields including deep oil and gas fields. The autoclave includes: two gas cylinder, a series of valves, booster pump, autoclave, tanks, and an exhaust system. The developed rig design fulfils the aim and objectives mentioned above. It is capable of studying the aqueous corrosion under dynamic supercritical CO2 conditions including the influence of O2, SO2, and NO2. Rig parameters were met including (temperature, pressure, dynamic condition) and specific components to build up the rig has been concluded. All risks associated with installing and operating the rig has been investigated, addressed and specific controls has been suggested to avoid such risks and how to handle them if and when occurred.