Corrosion Behavior of Hot-dip Aluminum Coating in “High Temperature-salt Deposited-CO2/O2” Multi-degree Coupling Environment

doi:10.11902/1005.4537.2022.229

Journal of Chinese Society for Corrosion and protection

2023, Vol. 43

Issue (3): 569-577 DOI: 10.11902/1005.4537.2022.229

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Corrosion Behavior of Hot-dip Aluminum Coating in “High Temperature-salt Deposited-CO₂/O₂” Multi-degree Coupling Environment

CHEN Qingguo¹, TANG Quanhong¹, QIN Zhenjie¹, LI Yifan², LI Lei³, LI Xuanpeng³(

), YUAN Juntao³, SU Hang³, FU Anqing³

^1.PetroChina Tarim Oilfield Company, Korla 841000, China
^2.The 12th Oil Production Plant of China National Petroleum Corporation Changqing Oilfield Company, Xi'an 710014, China
^3.State Key Laboratory for Performance and Structural Safety for Petroleum Tubular Goods and Equipment Materials, CNPC Tubular Goods Research Institute, Xi'an 710077, China

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Abstract

The applicability of hot-dip aluminum (HDA) coating in oilfield reboiler tube bundles is studied by means of micro-morphological observation, polarization curve test, and 240 ℃-salt deposited-CO₂/O₂ multi-degree coupling environment simulation testing in this work. The HDA sample is mainly composed of pure Al outer layer and tongue-shaped Fe₂Al₅ inner alloy layer, and the thickness is between 150 and 200 μm. The polarization curves, which measured at 30 ℃ in simulated oilfield water, show that the corrosion current density of the HDA sample is about 300 times lower than that of 20#, and display excellent corrosion resistance. The simulated results at high-temperature-high-pressure environment show that the uniform corrosion rate of 20# steel in extreme environment is 0.68±0.04 mm/a, the maximum pitting depth is 70.5 μm in 240 ℃-salt deposited-CO₂/O₂ multi-degree coupling environment. In addition, the corrosion scales formed on the surface are consisted Fe₃O₄ and Fe₂O₃, and some cracks can be detected in the scales. However, the corrosion rate of the hot-dip aluminum coating is 0.08±0.02 mm/a, the corrosion mainly occurs in the pure Al layer, and the corresponding corrosion scale is Al(OH)₃ after simulated testing. The comprehensive results show that the hot-dip aluminum coating exhibits excellent anti-corrosion performance under this complex environment.

Key words: hot-dip aluminum coating 20# steel heat exchanger tube bundles electrochemical testing high-temperature-high-pressure simulation test

Received: 13 July 2022 32134.14.1005.4537.2022.229

ZTFLH:

TG174.4

Fund: National Natural Science Foundation of China(21908250);Ningbo Science and Technology Innovation 2025 Major Special Project(2020Z108)

Corresponding Authors: LI Xuanpeng, E-mail: lixuanpeng127@cnpc.com.cn

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	CHEN Qingguo
	TANG Quanhong
	QIN Zhenjie
	LI Yifan
	LI Lei
	LI Xuanpeng
	YUAN Juntao
	SU Hang
	FU Anqing

Cite this article:

CHEN Qingguo, TANG Quanhong, QIN Zhenjie, LI Yifan, LI Lei, LI Xuanpeng, YUAN Juntao, SU Hang, FU Anqing. Corrosion Behavior of Hot-dip Aluminum Coating in “High Temperature-salt Deposited-CO₂/O₂” Multi-degree Coupling Environment. Journal of Chinese Society for Corrosion and protection, 2023, 43(3): 569-577.

URL:

https://www.jcscp.org/EN/10.11902/1005.4537.2022.229 OR https://www.jcscp.org/EN/Y2023/V43/I3/569

Fig.1 Cross-sectional image of 20# steel sample with HDA coating

Fig.2 Cross-sectional image (a) of HDA coating, and corresponding EDS element mappings of C (b), O (c), Al (d) and Fe (e)

Fig.3 XRD patterns of HDA coating (a) and 20# steel (b) before/after and after high-temperature-high-pressure simulation test, respectively

Fig.4 Polarization curves of 20# steel and HDA coating

Table 1 Fitting electrochemical parameters for 20# steel and HDA coating

Fig.5 Macro-morphologies of 20# steel before (a) and after (b) removing corrosion scale, morphology of maximum pit (c)

Fig.6 General view (a) and locally enlarged image (b) of 20# steel after high-temperature-high-pressure simulation test

Fig.7 Cross-section image (a) and locally enlarged image (b) of 20# steel after high-temperature-high-pressure simulation test

Fig.8 Cross-sectional image (a) of 20# steel after high-temperature-high-pressure simulation test, and EDS element mappings of C (b), O (c) and Fe (d)

Fig.9 Macro-morphology (a), micro-morphology (b) and locally enlarged view (c) of the corrosion scale formed on HDA coating after corrosion test

Fig.10 Cross-sectional morphology (a) and locally enlarged view (b) of HDA coating after corrosion test

Fig.11 Cross-sectional image (a) of HDA coating after corrosion test, and corresponding EDS element mappings of C (b), O (c), Al (d) and Fe (e)

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