Key Takeaways & Executive Findings
- •• • Individual impurity effects (H2O, H2S, O2, SO2, N2O, N2, H2, CH4) and operating parameters on corrosion mechanisms are basically clarified, but synergistic mechanisms of mixed gases remain unresolved, lacking quantitative description. This gap prevents accurate prediction under real multicomponent conditions, risking pipeline integrity and economic losses. • • Current corrosion prediction models are limited in applicability to corrosion conditions, morphological matching, and comprehensiveness of factors. They cannot fully meet prediction needs, leading to either over-conservative designs or unexpected failures, with significant cost implications for CCUS projects. • • Comprehensive mechanistic models are a feasible direction for accurate prediction, but numerical analysis of aqueous phase precipitation, water chemical reactions, electrochemical corrosion reactions, and product film growth still has multifaceted limitations. Accelerating development of these sub-models is critical for reliable prediction. • • Experimental reliability is insufficient, particularly for precise metering and replenishment of corrosive media under low water content and multicomponent impurity synergy. This undermines the validation and calibration of prediction models, necessitating improved experimental methods to support accurate corrosion prediction. • • Field application of prediction models remains challenging due to irrational model use and difficulty in accurately extracting field data. Understanding model parameter physical meanings, applicability boundaries, and ensuring reasonable input parameters are essential for practical deployment.
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Abstract
Pipeline transport is the core of large-scale CO2 delivery in CCUS projects, and supercritical pipeline transport is the most economical and feasible method. However, inherent multicomponent impurities and complex aqueous phase precipitation make corrosion control difficult and costly. This review assesses corrosion mechanisms and prediction technologies for supercritical CO2 transport pipelines, focusing on numerical analysis, supporting experiments, and field application within comprehensive mechanistic models. Current understanding has clarified the effects of individual impurities (H2O, H2S, O2, SO2, N2O, N2, H2, CH4) and operating parameters, but synergistic mechanisms of mixed gases remain unresolved, lacking systematic quantitative description. Existing prediction models are limited in applicability to corrosion conditions, morphological matching, and comprehensiveness of factors. Experimental methods suffer from insufficient reliability, particularly in precise metering and replenishment of corrosive media under low water content and multicomponent impurity synergy. Field application faces challenges in rational model use and accurate extraction of field data. Future directions include: deepening research on synergistic effects of impurity gases and quantifying them via theoretical analysis to establish mapping between impurity concentration and corrosion rate; accelerating development of aqueous phase precipitation and distribution models, multicomponent impurity water chemistry models, thermodynamic and kinetic models for multicomponent reactions, and competitive formation/growth models for multiple product films; strengthening experimental techniques for precise metering and replenishment under low water and multicomponent synergy; and improving field application by understanding model parameter physical meanings, applicability boundaries, and ensuring reasonable input parameters and accurate field data extraction.
1. Introduction
Supercritical CO2 pipeline transport is the most economical and feasible method for large-scale CO2 delivery in CCUS projects. However, the inherent presence of multicomponent impurities and the complexity of aqueous phase precipitation make corrosion prevention and control difficult and costly. Accurate corrosion prediction is therefore of great significance for safe pipeline operation. Existing commercial approaches have stalled due to inadequate understanding of synergistic effects among impurities and limitations in prediction models, which often fail to match real corrosion conditions and morphologies.
This study provides a comprehensive review of corrosion mechanisms and prediction technologies for supercritical CO2 transport pipelines. It specifically addresses the bottleneck of multicomponent impurity synergy by analyzing the entire process of comprehensive mechanistic models, including numerical analysis, supporting experiments, and field application. The work identifies current limitations and proposes future research directions to advance accurate corrosion prediction, thereby enhancing pipeline safety and economic viability.
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LI Fagen, CAO Yuguang, ZHEN Ying, LI Xuanpeng, HUANG Jufeng (2026). Research Progress and Problem Analysis on Corrosion Prediction of Supercritical CO2 Transport Pipelines. Surface Technology (表面技术). https://doi.org/10.16490/j.cnki.issn.1001-3660.2026.10.001
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Frequently Asked Questions
What are the primary limitations of current corrosion prediction models for supercritical CO2 pipelines?
Current models are limited in applicability to corrosion conditions, morphological matching, and comprehensiveness of factors. They cannot fully meet prediction needs, leading to either over-conservative designs or unexpected failures. Specifically, they lack accurate sub-models for aqueous phase precipitation, multicomponent water chemistry, thermodynamic and kinetic reactions, and competitive product film formation.
How do multicomponent impurities affect corrosion mechanisms compared to individual impurities?
Individual impurity effects (H2O, H2S, O2, SO2, N2O, N2, H2, CH4) and operating parameters are basically clarified, but synergistic mechanisms of mixed gases remain unresolved. The presence of multiple impurities can lead to complex interactions that alter water solubility, corrosion reaction mechanisms, and corrosion morphologies, which are not yet systematically quantified.
What experimental challenges hinder accurate corrosion prediction?
Experimental reliability is insufficient, particularly for precise metering and replenishment of corrosive media under low water content and multicomponent impurity synergy. This undermines the validation and calibration of prediction models, as it is difficult to maintain consistent and controlled conditions that mimic real pipeline environments.
What are the key future research directions to improve corrosion prediction?
Future work should focus on: (1) deepening research on synergistic effects of impurity gases and quantifying them via theoretical analysis to establish mapping between impurity concentration and corrosion rate; (2) accelerating development of aqueous phase precipitation and distribution models, multicomponent impurity water chemistry models, thermodynamic and kinetic models for multicomponent reactions, and competitive formation/growth models for multiple product films; (3) strengthening experimental techniques for precise metering and replenishment under low water and multicomponent synergy; and (4) improving field application by understanding model parameter physical meanings, applicability boundaries, and ensuring reasonable input parameters and accurate field data extraction.
Why is field application of prediction models still challenging?
Field application remains challenging due to irrational model use and difficulty in accurately extracting field data. Models may be applied outside their applicability boundaries, and input parameters may not be reasonable. Understanding the physical meaning of model parameters and ensuring accurate field data extraction are essential for reliable predictions.
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