• Energy Research

Laboratory corrosion and scaling testing of metallic materials exposed in high temperature and pressure environments generally involves complex, multi-instrument measurement setups. Here, we present a setup including an autoclave that is instrumented for in-situ electrochemical testing and that contains a ZrO2-based solid-state pH electrode and devices for temperature control and solution stirring. We show results highlighting the importance of adequate pre-calibration of the pH measurement, due to the hysteresis depending on temperature sweep. Additionally, we illustrate how interfacing the autoclave and the electrochemical cell to measuring and controlling instruments, using different data communication interfaces, can create ground loops. These ground loop interferences can introduce significant errors in the measurement, such as a potential shift of >100 mV. In complex, multi-instrument setups, a complete understanding of ground loops may often be difficult. Thus, we recommend systematic checks to identify the ground loops and we propose measures to avoid them. Measurement, 155 ISSN:0263-2241 ISSN:1873-412X

Materials and Structures, 51 (1) ISSN:1359-5997 ISSN:1871-6873

AbstractOne of the main challenges associated with the operation and maintenance of binary geothermal power plants is the degradation of construction materials. In this sense, it is crucial to apply appropriate preventive maintenance in critical components (such as the wellheads, heat exchangers, or pipes), while reducing shutdown times. Based on electrochemical measurements performed in an autoclave corrosion testing setup, we studied the corrosion mechanism of API L80 steel grade as a function of operational and/or maintenance procedures. We used a test fluid representative for a site in Switzerland, but the main observations made may be applicable in a wider context. We found that changes in the fluid temperature (from 200 to 100 °C) or temporary oxygen ingress significantly influenced the corrosion behavior of this carbon steel and increased its corrosion rate (from approx. 20 µm/year to > 120 µm/year). After a few days, the corrosion rate was found to decrease and stabilize around values of 50–70 µm/year, as a result of a porous corrosion product layer formed on the metal surface (approx. 250 µm thick). Electrochemical impedance spectroscopy indicated an increase in capacitance of the double layer over time, most likely due to an increase in the effective surface area of the steel sample, as a consequence of surface roughening due to corrosion. The results from this study may be implemented in the design and operation of future power plants in Switzerland and elsewhere to ensure reliable and cost-effective energy production from geothermal resources.

Various electrochemical techniques exist to study corrosion processes locally. Generally, sample preparation is required to ensure smooth surfaces, which may limit the applicability of experimental findings to engineering conditions. To overcome these limitations, we use a probe with a soft porous diaphragm that establishes electrolytic connection to unprepared metal surfaces. We develop a setup that combines this probe with a robotic device to ensure reproducible probe positioning. Results illustrate that through adjusting the force at the soft probe, the contact area can be modified. The robotic device can position the probe on non-flat, complex-shaped samples such as cylindrical, corrugated bars (reinforcing steel). As the porous diaphragm tends to become contaminated in the course of subsequent measurements, an automated probe cleaning procedure is implemented. Finally, automation of the measurements can allow for high-throughput local characterization, to deliver local characterization data suitable for statistical and spatial analysis. Measurement, 201 ISSN:0263-2241 ISSN:1873-412X

AbstractCathodic protection was introduced two centuries ago and since has found widespread application in protecting structures such as pipelines, offshore installations, and bridges from corrosion. Despite its extensive use, the fundamental working mechanism of cathodic protection remains debated, particularly for metals in porous media such as soil. Here, we use in-situ and ex-situ characterisation techniques coupled with electrochemical measurements to characterise the spatio-temporal changes occurring at the steel-electrolyte interface. We show that upon cathodic protection, the interfacial electrolyte undergoes alkalinisation and deoxygenation, and that depending on polarisation conditions, an iron oxide film can simultaneously form on the steel surface. We further demonstrate that these changes in interfacial electrolyte chemistry and steel surface state result in altered anodic and cathodic reactions and their kinetics. We propose a mechanism of cathodic protection that integrates previous theories, based on both concentration and activation polarisation, complimentarily. We discuss the implications of this study in enhancing corrosion protection technologies and the safe, economical, and environmentally friendly operation of critical steel-based infrastructures.

Carbonation of concrete is generally assumed to lead to reinforcing steel corrosion. This mindset has long dictated the research priorities surrounding the developments towards new, low-emission binders. Here, by reviewing documented practical experience and scientific literature, we show that this widely held view is too simplistic. In fact, there are many cases from engineering practice where carbonation of the cementitious matrix surrounding the steel did not lead to noticeable corrosion or to corrosion-related damage at the level of a structure. The influencing factors that can, however, lead to considerable corrosion damage are identified as the moisture state, the microstructure of the carbonated concrete, various species that may be present – even in minor amounts – in the concrete pore solution, and the cover depth. The circumstance that a reduced pH alone is not sufficient to lead to significant steel corrosion in concrete seriously challenges the established approach of assessing the durability performance based on carbonation testing and modeling. At the same time, this circumstance offers great opportunities for reducing the environmental impact of concrete structures with low-emission binders. To realize these opportunities, the focus in research and engineering should shift from studying carbonation to studying corrosion of steel in carbonated concrete.

AbstractBy means of numerical modeling and experimental measurements, this work addresses the longstanding controversy of whether or not IR (ohmic) drops need to be considered in on-potential catho...