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b. Temperature
The temperature influences the conditions of protective iron carbonate layers. At temperature below 60oC, Hydrogen evolution acts a rate determinating step and carbonate scale does not form well. Carbonate scale governs corrosion rate at the range temperature of 60 - 100oC when protective films is formed. Such temperature is called as scaling temperature which is formulated as: Tscale= 2400/(6.7+0.6Log(fCO2)) ..(2) The effect of temperature of the diffusion coefficient is given by:
In the case of non-ideal gas, the total pressure must be corrected with CO2 fugacity which is formulated as: CO2=a.pCO2. (4) Where a is the fugacity coefficient
d Effects Of Flow
Flow induced corrosion is due to combination effects of mechanical and electrochemical forces. The flow results in thinner boundary layer which allows dissolved oxygen in water to corrode the surface more quickly. Higher flow will also increase the wall stress that can cause localized corrosion and surface damage.
mass transfer reaction. Then, solid state diffusion through the inner film can be formulated as: By eliminating the unknown interfacial concentration co and ci, from equations, the following equation is obtained for the corrosion rate of steel due to mixed species will become: In case when inner solid film does not form, Equation 7 can be neglected. Thus, Equation 8 will become: Where: Km is mass transfer coefficient of species I (m/s) is bulk concentration of species i (mol/m3) is the interfacial concentration of species i at outer scale/solution interface (mol/m3) is diffusion coefficient for dissolved species i (m2/s) is outer scale porosity is tortuosity factor is interfacial concentration of species i is the thickness of outer film sacle A is Arhrhenius constants Tk is temperature (Kelvin) cs is surface temperature The total corrosion rate equals to the sum of the corrosion caused by each species. Based on the description of the CO2 corrosion process, a schematic of the CO2 corrosion process is shown in Figure 1 below.
Scale Properties
The corrosion process happens via a direct heterogeneous solid state reaction at the steel surface which acts as a solid state diffusion barrier. The amount of scale retained on the metal surface depend on time, hydrodynamic stresses, chemical reaction, precipitation rate, change of mass scale removal of the outer scale. Empirically, competition growth between scale formation and scale damage is formulated: This equation is used to calculate the changes of the scale, thus the change in mass of the outer scale can be calculated.
Experiment Setup
Electrodes
A three-electrode set-up was used in all electrochemical experiments. A rotating cylinder electrode with a speed control unit was used as the working electrode. A platinum or graphite was used as a counter electrode. Glass cell was fitted with graphite electrodes as auxiliaries electrode and a Ag/AgCl as a reference electrode.
Specimen preparation
The working electrodes were carbon steels which have chemical compositions as can be seen in Table 1. It was used a cylinder rod of 1.2 cm2 in diameter and 1 cm thickness. Before immersion, the specimen surfaces were polished successively with 240, 400 and 600 grit SiC paper, rinsed with alcohol, and degreased using acetone. Some of the experiments were repeated in order to obtain the reproducible results.
Cell Solutions
The schematic of the experimental setup are shown in Figure 2. The experiments were performed both in flow and stagnant solutions condition. The total pressure was 1 bar, the glass cell was filled with 1 liter of distilled water and 3% wt NaCl which was stirred with magnetic stirrer. Then, CO2 gas was bubbled through the cell (at least one hour prior to experiments) in order to saturate and de-aerate the solution. Temperature was set using a hot plate. After the solution was prepared, the pH was measured to reach the pH set by using NaHCO3 as buffer solutions. Simulation of flow condition test was conducted using rotating cylinder electrode (RCE). A cylindrical working electrode was screwed onto an electrode holder at the center of the cell for rotating in the RCE. The Linear Polarization Resistance (LPR) technique was used to measure the polarization resistance, Rp, and the corrosion rate. The procedure is similar to that described in ASTM G 5-94 - Standard Reference Test Method for Making Potentiostatic and Potentiodynamic Polarization Measurements.
Conclusion
The mechanistic prediction models of CO2 corrosion have shown a satisfied model in calculating corrosion rate, predicting corrosion mechanism and simulating the growth of corrosion products. Using this prediction, the parameters influencing corrosion such as: rate of controlling step corrosion reaction, rate of ions dissolution in the solution can easily be observed and analyzing. Through studying CO2 corrosion mechanism, it can be concluded that CO2 corrosion produce a very thin films (1-5 m). The film properties such as: porosity, contour surface appearance and quality of the film change with time and influenced by solution compositions. The decrease of corrosion rate in the higher of pH is controlled by the film formation. The other factors affecting corrosion rate are the scale formation rate and the scale damage rate. The scale formation rate includes both the corrosion rate and precipitation rate have also role in corrosion mechanisms.
Acknowledgments
The authors are thankful to Universiti Teknologi PETRONAS for providing grant and facilities for the research.
References
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