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Erosion and Corrosion Mechanism and Control Method of Energy and...
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Erosion and Corrosion Mechanism and Control Method of Energy and Chemical Equipment

A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Chemical Processes and Systems".

Deadline for manuscript submissions: closed (20 June 2024) | Viewed by 15047

Special Issue Editors

Prof. Dr. Dezhi Zeng

E-Mail Website
Guest Editor
Petroleum Engineering School, Southwest Petroleum University, Chengdu 610500, China
Interests: oil and gas field corrosion and protection; wellbore integrity; oil pipe mechanics and environmental behavior
Dr. Liuxi Cai

E-Mail Website
Guest Editor
School of Chemical Engineering and Technology, Xi'an Jiaotong University, Xi'an 710049, China
Interests: erosion and corrosion mechanism; fault diagnosis; energy and chemical equipment; multiphase flow; heat transfer and cooling technology
Prof. Dr. Zhiguo Wang

E-Mail Website
Guest Editor
School of Mechanical Engineering, Xi’an Shiyou University, Xi’an 710065, China
Interests: erosion, corrosion and control method in multiphase flow of petroleum engineering; new energy and chemical equipment; energy saving

Special Issue Information

Dear Colleagues,

In the energy and chemical industry, many cases of equipment failure are caused by solid particle erosion and working fluid corrosion, which have a huge impact on the service economy and operational safety of the equipment. Erosion damage from particles to equipment involves many disciplines such as aerodynamics, multiphase flow, and material mechanics. The corrosion of fluid medium in equipment mainly involves chemical corrosion, electrochemical corrosion and other types of corrosion (such as high-temperature oxidation corrosion, fatigue corrosion, etc.). To tackle the problem of erosion and the corrosion failure of engineering equipment, it is necessary to first study and reveal the mechanism and key influencing factors of erosion and corrosion, and only on this basis can effective control measures be proposed.

This Special Issue, entitled “Erosion and Corrosion Mechanism and Control Method of Energy and Chemical Equipment”, seeks high-quality articles that focus on the erosion and corrosion mechanism and control method of energy and chemical equipment. Topics include, but are not limited to:

  • Erosion and/or corrosion mechanisms of energy and chemical equipment;
  • The development of anti-erosion and/or corrosion-resistant materials and coatings;
  • Testing and monitoring technology for erosion and/or corrosion;
  • Structure and process optimization methods for erosion and corrosion mitigation;
  • Hydrogen corrosion and hydrogen damage.

Prof. Dr. Dezhi Zeng
Dr. Liuxi Cai
Prof. Dr. Zhiguo Wang
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Processes is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • multiphase flow
  • solid particle erosion
  • turbine erosion
  • anti-erosion coating
  • corrosion of pressure vessel
  • corrosion in oil and gas engineering
  • marine corrosion
  • hydrogen corrosion
  • energy and chemical equipment damage

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Published Papers (6 papers)

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Research

12 pages, 4469 KiB  
Article
Erosion Resistance of Casing with Resin and Metallic Coatings in Liquid–Solid Two-Phase Flow
by Lixia Zhu, Jinheng Luo, Chencheng Huang, Lang Zhou, Lifeng Li, Yibo Li and Zhiguo Wang
Processes 2024, 12(4), 790; https://doi.org/10.3390/pr12040790 - 14 Apr 2024
Cited by 1 | Viewed by 1015
Abstract
Protective coatings are typically applied to enhance their resistance to corrosion. There is considerable research on the corrosion resistance of coated casings. However, few research studies have focused on the erosion resistance on coated casings. In this work, the erosion resistance of resin- [...] Read more.
Protective coatings are typically applied to enhance their resistance to corrosion. There is considerable research on the corrosion resistance of coated casings. However, few research studies have focused on the erosion resistance on coated casings. In this work, the erosion resistance of resin- and metallic-coated casings in liquid–solid two-phase fluids were investigated using a self-made erosion facility. The results show that the resin coating tends to peel off the material base in the form of brittle spalling or coating bulge in the high-speed sand-carrying liquid. Both resin and metallic coatings were broken through within 20 min in a liquid–solid two-phase flow environment. Compared to resin coatings, metallic coatings exhibit weaker erosion resistance in similar liquid–solid flow. Through the analysis of experimental results and fitted curves, empirical constants for materials and sand content influencing factors were determined using non-dimensional processing. The erosion prediction model of metallic coatings and resin coatings was established based on the ECRC/Zhang model with the change in flow rate, angle, and sand content. This research contributes to a better understanding of the erosion resistance performance of casings used in oil and gas fields, thereby contributing to potential improvements in their production. Full article
(This article belongs to the Special Issue Erosion and Corrosion Mechanism and Control Method of Energy and Chemical Equipment)
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23 pages, 22400 KiB  
Article
Multiscale CFD Simulation of Multiphase Erosion Process in a Connecting Pipe of Industrial Polycrystalline Silicon Unit
by Sheng Chen, Jiarui Shi, Jun Yuan, Meng He, Yongquan Li, Liyun Zhu, Juanbo Liu, Jiangyun Wang and Guoshan Xie
Processes 2023, 11(8), 2510; https://doi.org/10.3390/pr11082510 - 21 Aug 2023
Viewed by 1829
Abstract
Severe erosion phenomena often occur in industrial polycrystalline silicon units, leading to hydrogen leakage accidents and affecting long-term operation. It is favorable to use a computational fluid dynamics (CFD) simulation with the dense discrete phase model (DDPM) and the sub-grid energy-minimization multi-scale (EMMS) [...] Read more.
Severe erosion phenomena often occur in industrial polycrystalline silicon units, leading to hydrogen leakage accidents and affecting long-term operation. It is favorable to use a computational fluid dynamics (CFD) simulation with the dense discrete phase model (DDPM) and the sub-grid energy-minimization multi-scale (EMMS) drag model to improve the prediction accuracy of complex multiphase erosion phenomena in a connecting pipe of an industrial polycrystalline silicon unit. Furthermore, the effect of droplet the specularity coefficient on boundary conditions is thoroughly considered. The predicted erosion behaviors are consistent with industrial data. The effects of operations parameters were discussed with three-dimensional CFD simulation, including droplet size and hydrogen volume fraction on erosion behaviors. The results indicated that the non-uniform multiphase erosion flow behavior near the wall can be simulated accurately with the EMMS drag model in a coarse mesh. A suitable droplet specularity coefficient such as 0.5 can also improve the accuracy of erosion position. Small liquid droplets, such as those of 30 μm size, will follow the gas phase better and have a lower erosion rate. The inertia effect of large droplets, such as those of 150 μm size, plays a dominant role, resulting in obvious erosion on the elbow walls. The erosion range and thinning rate enlarge with the increase in hydrogen volume fraction. A few silicon solid particles, such as 0.01% volume fraction, change local flow behaviors and probably cause the variation of local erosion positions. The process of erosion deformation first circumferentially extended and then accelerated at the local center position deeper. Full article
(This article belongs to the Special Issue Erosion and Corrosion Mechanism and Control Method of Energy and Chemical Equipment)
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17 pages, 6761 KiB  
Article
Analysis of Regulating Valve Stem Fracture in a Petrochemical Plant
by Fuping Guo, Yunrong Lyu, Zhihong Duan, Zhiqing Fan, Weiming Li and Falin Chen
Processes 2023, 11(4), 1106; https://doi.org/10.3390/pr11041106 - 4 Apr 2023
Viewed by 2965
Abstract
This paper investigates the failure of a regulating valve stem in a petrochemical plant, which was mainly caused by vibration fatigue under small opening conditions. The fractured valve stem was analyzed using macroscopic analysis, chemical composition analysis, mechanical property analysis, metallographic analysis, fracture [...] Read more.
This paper investigates the failure of a regulating valve stem in a petrochemical plant, which was mainly caused by vibration fatigue under small opening conditions. The fractured valve stem was analyzed using macroscopic analysis, chemical composition analysis, mechanical property analysis, metallographic analysis, fracture surface observation, and energy spectrum analysis. Additionally, fluid-structure interaction (FSI) modal analysis was used to investigate the failure of the regulating valve. The results indicate that the valve opening had a direct impact on the vibration of the valve body, which, when operated at small openings, led to fatigue fracture at the step of variable cross-section. The paper suggests a smooth transition treatment be performed at the variable cross-section of the valve stem to avoid stress concentration. Although this study is limited to a specific case, it provides valuable insights for the failure analysis of valves operating at small openings. Full article
(This article belongs to the Special Issue Erosion and Corrosion Mechanism and Control Method of Energy and Chemical Equipment)
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16 pages, 7336 KiB  
Article
Primary Corrosion Cause of P110S Steel Tubing Corrosion Thinning in CO2–H2S Well and Its Remaining Life Prediction
by Wu Long, Xi Wang, Huan Hu, Wei Lu, Lian Liu, Miaopeng Zhou, Sirui Cao and Xiaowen Chen
Processes 2023, 11(2), 333; https://doi.org/10.3390/pr11020333 - 19 Jan 2023
Cited by 2 | Viewed by 1921
Abstract
To investigate the tube thinning of gas wells in the northwestern oilfield, the failed tubing was analyzed by using material property testing, SEM, EDS, and XRD. A novel model that was specific to the service life of tubing in terms of the wall [...] Read more.
To investigate the tube thinning of gas wells in the northwestern oilfield, the failed tubing was analyzed by using material property testing, SEM, EDS, and XRD. A novel model that was specific to the service life of tubing in terms of the wall thickness of tubing was established. The model is based on the circumferential stress of tubing. The safety factor against internal pressure and corrosion rate are considered in the model. Our results make clear that the chemical composition, non-metallic inclusion, hardness, and tensile strength of the pipe meet the requirements of relevant standards. The corrosion products on the inner and outer wall of the tubing are mainly FeCO3 and BaSO4, while CaCO3 exists in the outer wall. Additionally, we prove that the corrosion process of the failed tubing is CO2 corrosion. The tubing under the packer suffers from water-accumulation corrosion, and the tubing above the packer suffers from water-carrying corrosion. It is observed that the failed tubing arises under-deposit corrosion in local areas. According to the model calculation, the safe service life of tubing above the packer is 20.6 years. However, the safe service life of tubing below the packer is only 4.9 years. Full article
(This article belongs to the Special Issue Erosion and Corrosion Mechanism and Control Method of Energy and Chemical Equipment)
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16 pages, 6002 KiB  
Article
Design of Multifunctional and Efficient Water-Based Annulus Protection Fluid for HTHP Sour Gas Wells
by Qilin Liu, Xue Han, Jian Cao, Lang Du, Ning Jia, Rong Zheng, Wen Chen and Dezhi Zeng
Processes 2023, 11(1), 171; https://doi.org/10.3390/pr11010171 - 5 Jan 2023
Cited by 3 | Viewed by 2009
Abstract
In order to solve the corrosion problem of production string in the process of acidizing for the purpose of production, a new water-based annular protective fluid suitable for HTHP acid gas, including H2S-CO2 wells, was developed. Firstly, an appropriate deoxidizer, [...] Read more.
In order to solve the corrosion problem of production string in the process of acidizing for the purpose of production, a new water-based annular protective fluid suitable for HTHP acid gas, including H2S-CO2 wells, was developed. Firstly, an appropriate deoxidizer, bactericide, and corrosion inhibitor shall be selected according to the production string of acid gas. In addition, the synergism between additives is evaluated. Then, by designing the additive ratio, the optimal formulation of the water-based annular protective fluid is determined. Finally, a high-temperature autoclave was used to evaluate the protective performance of the water-based annular protective liquid. The results showed that it is recommended to use water-based annular protective liquids prepared with clear water that comes easily from nature (rivers, etc.), which consist of a corrosion inhibitor, CT2-19C (30,000 ppm), BN-45 bactericide (2 g/L), and anhydrous sodium sulfite (3 g/L). The density of the water-based annulus protection liquid is 1.02 g/cm3, and the freezing point is −2.01 °C. The dissolved oxygen content of water-based annulus protection fluids prepared with clear water in formation water shall be controlled within 0.3 ppm. The corrosion inhibition rate of water-based annular protective fluid in the liquid phase is higher than 90%, and the corrosion rate of P110SS steel in the gas–liquid phase is lower than the oilfield corrosion control index (0.076 mm/y). Full article
(This article belongs to the Special Issue Erosion and Corrosion Mechanism and Control Method of Energy and Chemical Equipment)
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19 pages, 17465 KiB  
Article
How to Choose the Suitable Steel of Wellhead, Wellbore, and Downhole Tools for Acid Gas Reinjection Flooding
by Yudi Geng, Zhendong Liu, Wenguang Zeng, Yibo Feng, Baodong Ding, Wenxia Li and Qinying Wang
Processes 2022, 10(12), 2685; https://doi.org/10.3390/pr10122685 - 13 Dec 2022
Cited by 1 | Viewed by 4324
Abstract
The material selection of injection gas wells in acid gas flooding is the bottleneck of the successful implementation of the technical scheme. Through standard and literature research, the materials of the wellhead, wellbore, and packer for reinjection well in acid gas flooding are [...] Read more.
The material selection of injection gas wells in acid gas flooding is the bottleneck of the successful implementation of the technical scheme. Through standard and literature research, the materials of the wellhead, wellbore, and packer for reinjection well in acid gas flooding are preliminarily established, and then the suitable materials are further screened by using the weight-loss and surface characterization method. Finally, a new type of packer is designed to optimize the wellbore material. The results show that 35CrMo (CR = 0.0589 mm/y) steel is used for wellhead materials, 625 alloy steel is selected as the sealing surface, and 625 or 825 alloys (with CR ≤ 0.0055 mm/y) steel is used for wellhead sealing material. The main material of the packer is 718 Alloy (with CR ≤ 0.0021 mm/y). The cost of T95 steel within 20 years (1263 ten thousand yuan) of service is much smaller than that of G3 alloy (1771 ten thousand yuan), but after 30 years of service, its cost is close to that of G3 alloy. A kind of downhole packer for acid gas reinjection is designed. Among them, G3 alloy steel tubing is used between the packer and the relief valve, T95 steel tubing is selected above the packer and below the safety valve, and the packer is set in the G3 steel tubing. The serious pitting corrosion of T95 steel in the liquid phase environment is due to the uneven deposition of FeS and FeCO3 on the steel surface. Full article
(This article belongs to the Special Issue Erosion and Corrosion Mechanism and Control Method of Energy and Chemical Equipment)
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