Doctor of Philosophy (PhD), Ohio University, 2020, Chemical Engineering (Engineering and Technology)
A systematic investigation of pitting failure of mild steel in marginally sour environments was performed with the objective of understanding and predicting the occurrence of localized corrosion. While localized corrosion can happen due to a variety of reasons, recent work has shown that mild steel was particularly susceptible to pitting in environments containing traces of H2S (ppm level in the gas phase, which equates to ppb level of dissolved O2 in the liquid phase) of H2S. Relevant research works related to localized corrosion of mild steel exposed to O2, CO2 and H2S containing aqueous environments were carefully reviewed and a critical comparison was performed, identifying experimental methodologies, common mechanisms and gaps in understanding. A comprehensive parametric study was conducted to identify the operating parameters controlling the occurrence of localized corrosion in marginally sour environments. As a result, pitting was found to occur under the following conditions: 0 mbar < pH2S < 0.15 mbar, pCO2 > 0 bar, temperature < 60C, bulk pH < 6, on X65 mild steel (not on pure iron), in NaCl concentrations of 0, 1, and 10 wt.%, with 3 ppb(w) < [O2]aq < 40 ppb(w). Surface analysis (FIB-TEM-SAED-PED) identified a typically 200 nm thick, porous, detached, and partially oxidized amorphous mackinawite layer precipitated within a Fe3C network. The role of O2 was further investigated to explain the unexpected presence of oxides in the corrosion product layer. Initially, FeS was thought to have been oxidized during the post processing analysis. However, in situ Raman microscopy later showed that oxygen ingress during the experiment was the origin of iron oxide formation. In addition, when [O2]aq < 3 ppb(w), neither corrosion product precipitation nor pitting was observed on the steel surface in any conditions tested, while the uniform corrosion rate remained low. In this case, the protectiveness was due to the presence of a very thin FeS chemisorbed layer. In the p (open full item for complete abstract)
Committee: Marc Singer (Advisor)
Subjects: Chemical Engineering; Materials Science