Corrosion and Scale at Extreme Temperature and Pressure · 2018-05-07 · tomson.com Corrosion and...

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Corrosion and Scale at Extreme Temperature and Pressure

RPSEA 10121-4202-01

August 13, 2015

Ross Tomson, JD MES

President

Tomson Technologies

(formerly Brine Chemistry Solutions)

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Safety & Orientation

• Exits

• Restrooms

• Phone call area outside hallway down stairs

• No fire drills scheduled

• Food served in rear of room; can eat at tables

2

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Today’s Agenda

• Sign-In, Refreshments, and Breakfast Snacks• Project & Phase II Overview

– Ross Tomson, J.D., M.E.S. (Tomson Technologies)

• Scale and Inhibition at xHPHT Results– Chao Yan, Ph.D. (Tomson Technologies)

• Break• Workshop and Discussion

– Mason Tomson, Prof., Ph.D., P.E., (Tomson Technologies)– Paula Guraieb, MS (Tomson Technologies)– Chao Yan, Ph.D. (Tomson Technologies)

• Modeling Overview– Walter Chapman, Prof., Ph.D., (Rice University)– Ken Cox, ProfPrac., Ph.D., P.E. (Rice University)

• Lunch Break• Discussion

3

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Presentation Outline

• Project Overview and Timeline

• Project Motivation and Objectives

• Phase I Accomplishments

• Phase II Accomplishments

• Phase III Discussion

4

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Motivation and Objectives

• Motivation– A lack of data and models for corrosion and

scale at extreme temperature and pressure in ultra-deepwater reservoirs leads to uncertainty in predictions and operations.

• Objectives– Extend scientific understanding of corrosion and

scale to xHPHT conditions– Establish xHPHT lab test capabilities (250 °C;

24,000 psig)– Establish xHPHT test methods

• Scale and inhibitor testing• Corrosion and inhibitor testing• Core flood testing at reservoir HPHT conditions

– Reduce operational and maintenance cost– Mitigate environmental risk; improve safety– Increase production security in ultra deepwater– Create models rooted in experimental data

5

Source: LAMP 2015

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Phase & Task Overview

• Phase I (Year 1): – Tasks 1-4: Project Mgmt Plan; Tech. Status Assessment; Tech. Transfer; Reporting

– Task 5: Literature search on corrosion and scale at xHPHT

– Task 6: Develop methodology to study scale and corrosion at xHPHT and analyze with surface scanning instruments such as Vertical Scanning Interferometry (VSI)

– Task 7: Couple Task 6 results into viable models and experiments to validate• Preliminary assessment of EOS and Pitzer equation

– Task 8: Detail report and recommendation for Phase II research

• Phase II (Year 2 and 3)– Task 9 - Collection of supporting data and models

– Task 10 - A preliminary design of imaging equipment

– Task 11 - Equation of State Development

– Task 12 - Peer Review Workshop

– Task 13 - Final Technical Report

• Phase III (Post RPSEA funding)– Continuation of xHPHT corrosion and scale research for deepwater flow assurance

– Applied solutions to HPHT scale and corrosion

6

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Timeline

7

Last WPG Mtg

Today

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Knowledge Gap

Conventional O&G production

Deep water GOM

Future xHPHT

Current HT/HP production

Well known Unknown

Water depth > = 1,500 m

(~ 5,000 ft)

0 5 10 15 20 25 35

0 100 200 300 400 500

0 100 150 200 and complex brine 400

Pressure (psia x 1,000)

Temperature (°F)

TDS (mg/L x 1,000)

8

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Phase I Accomplishments

• Develop methodology to test corrosion and scale at xHPHT

• Successfully designed, built, and tested xHPHT flow-through apparatus for corrosion and scale– 24,000 psig– 250 °C– 300,000 mg/L TDS

• Fully custom HC-276 autoclave reactor designed and used

• Bruker vertical scanning interferometer (VSI)– Rapid/detailed surface analysis for

uniform and localized corrosion

9

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Phase I Accomplishments

• Successful initial mineral solubility

• Corrosion coupon (SS316, CS1018, CRA’s) testing at xHPHT

• Electrochemistry equipment customized and applied at xHPHT

• Surface analyses techniques developed

• Equation of state model development

I-825, 250 °C, 3 M NaCl solution, 60 psig CO2 Duration of experiment: 3 week

Reactor Head

Reference ElectrodeWorking Electrode

Counter Electrode

Electrochemistry probes used in autoclave

Before After

10

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Phase I Development

11

ICP

24,000 psig pump

xHPHT flow-through

HPHT column

VSILined tubing

Programmable Oven

HP Autoclave

Corr. Inhib. Assay

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Phase II Tasks

• Task 9 - Collection of supporting data and models – Subtask 9.1 – Validate species activity coefficients at various

HPHT and TDS conditions– Subtask 9.2 – Eliminate of pH measurement in HPHT solution

theory– Subtask 9.3 – Nucleation kinetics and inhibition of scale

formation– Subtask 9.4 – Investigate the thermal limit of scale inhibitors– Subtask 9.5 – Scale and corrosion inhibitor treatment

methodology

• Task 10 - A preliminary design of imaging equipment• Task 11 - Equation of State Model Development• Task 12 - Peer Review Workshop• Task 13 - Final Technical Report

12

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Phase II Tools Developed and Used

• Dynamic tube blocking – nucleation time determination

• Electrochemistry (LPR, CP, EIS)• Packed column solubility tests• Increased autoclave testing capability

(rotating cage, multiple setups) • Tubular corrosion coupon analysis• Core flooding apparatus

HC-276 Autoclave w/ Electrochem Probes

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Tubular

-50

50

Hei

ght

(μm

)

• VSI is powerful tool for surface characterization of both flat and curved coupons.• Various shaped coupons used in autoclave, glass-cell, and flow-through have been

analyzed using VSI.

CylindricalFlat

-200

160

Hei

ght

(μm

)

-40

30

Hei

ght

(μm

)

VSI Surface Capabilities

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Localized corrosion is the concern for CRAs at xHT

o VSI was developed as a powerful tool to detect localized pitting rapidly

0.652 mm/yr Uniform CR = 0.004 mm/yr

BCS PUBLICATION:Corrosion Science:Vol. 87, Oct 2014,

p. 383-391

Alloy I 825250 °C, 60 psig PCO2

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Avg. CR units

CR by VSI 0.299 mm/y

CR by WL 0.288 mm/y

Pre-test

Post-test

Ref. 05 06 07

Ref. 05 06 07

R: -5.84 um

R: -5.81 um

4.829 um 14.1483 8.2479

0.8454 um 8.4943 1.3884

Experimental Conditions:

• 250 °C, 3 M NaCl solution • 60 psig CO2 charged at 25 °C• pH 5 adjusted• 3 weeks

Corrosion Sci. Paper:VSI for Uniform Corrosion

Paper published with Bruker Corrosion Science: Vol. 87, Oct 2014, p. 383-391

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Phase II Highlighted Accomplishments

• Designed system to produce strictly anoxic (<< 1 ppb O2) brine at xHPHT – Fundamentally different results in

both scale and corrosion studies – Reservoirs naturally anoxic

• Mineral scale solubility at xHPHT in flow through apparatus – Extend prediction models and

understanding

• Thermal limit of inhibitors – Stability of inhibitors after long

term temperature exposure

~92 ppb dissolved O2<< 1 ppb dissolved O2

Synthesized Siderite powder anoxic vs. 92 ppb O2

17

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Phase II Highlighted Accomplishments

• Effect of scale formation on corrosion at xHPHT

– Kinetics– Protective film/corrosion product formation

• Realistic field brine importance at xHPHT– Downhole conditions– Production tubing

• Pitting evaluation of (CRAs) at xHPHT– Showed PREN as ineffective materials selection

guide at temperature and pressure– New Concept Defined: Repassivation Potential

• Corrosion and scale inhibitor thermal stability at xHPHT and realistic brine conditions

– Synergistic effects and importance of anoxic conditions

• Vertical Scanning Interferometry development

– Uniform and localized corrosion measurements

– Software development with Bruker

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Experimental Database

• Filling in knowledge gap of xHPHT corrosion and scale

• Database of experimental results from both corrosion and scale experiments– Data validation against the small number of papers

published

– Large prediction capability from database values

• Interconnection between corrosion products and scale formation

• Phase II goals– Experimentally obtain xHPHT scale and corrosion results

– Incorporate into modeling (EOS development)

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Autoclave

• G3, Ni718, I-825, L80, SS2507, G3, HC276, CS1018, CS 1010, 13 Cr

• Weight loss method: 5 temps, 10 alloys, 3 concentrations = 300 coupons corroded and analyzed

• LPR: 5 temps, 10 alloys, 3 concentrations = 300 coupons corroded and analyzed

• Cyclic polarization – 6 alloys, 2 temps, 2 concentrations, 2 polarization settings

• Electrochemical impedance spectroscopy (EIS)

• Imaged all coupons• SEM• XRD• VSI

200

10

20

30

40

50

60

70

80

90

100

10 20 30 40 50 60 70 80 90

Inte

nsi

ty

2-Theta

Exp

CaCO3

Fe3O4

Ankerite

FeCO3

-0.50

-0.45

-0.40

-0.35

-0.30

-0.25

-0.20

-0.15

-0.10

0.001 0.01 0.1 1 10 100

Po

ten

tial

vs.

sat

ura

ted

Ag/

AgC

l / V

Current density / A/m2

I 825_250 C_3M NaCl

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Experimental DatabaseFlow-through corrosion

• Simultaneous temperature and pressure conditions (up to 250 °C; 24,000 psig)– HC-276– C1010– SS316L

• Complex brine composition– ICP for ions of concern (e.g. Fe, Ca,

Mg, Sr)

• Ankerite studied– Ca(Fe,Mg,Mn)(CO3)2

– Strictly anoxic (<< 1 ppb O2)

• Surface imaging techniques – SEM– VSI

0

50

100

150

200

250

300

20 30 40 50 60

Inte

nsity

2Θ

ExperimentalSideriteAnkeriteCalcite

SEM of Synthesized Ankerite

21

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Packed column • In house synthesis of particles• Solubility at 150 °C and 5,000

psig to 24,000 psig – Calcite, Barite, Siderite,

Magnetite, FeS– Solubility at 250 °C and 5,000

psig to 24,000 psig

• Characterization of all solids – XRD,– SEM

• ICP analysis of all samples collected– Ions of concern for corrosion

and scale

Pump

Heating setup

Column

Cooling Stage

Back Pressure Regulator

Sampling

Pump (Chelating agent)

22

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• Tube blocking setup: scale nucleation and induction time – Scale nucleation at xHPHT

(180°C data and 250°C) • Barite, calcite, celestite,

anhydrite, hemihydrate

– Titanium setup for zero iron background

• Siderite, FexOy

• Ion concentration with time analysis– ICP data for all samples

(sampled 10 times over 2 hour test duration)

– Inhibitor return curve

• Nucleation time • Various field based inhibitor

concentrations • Varying temperature (100°C to

250°C) and pressure conditions• Direct injection inhibitor

performance– Sulphonated polycarboxylic acid

(SPCA)– Polyvinyl sulphonate (PVS)– Carboxymethyl Inulin (CMI) – Maleic acid copolymer (MAC)– Polyacrylic acid (PAA)– Polyacrylamide (PAM)– BHPMP– Sodium citrate

23

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• Inhibitor screening: – Thermal aging cell (at up to 250 °C;

3 M NaCl; 24 hours)– Glass cell tests inhibitors:

• 1-(para-toluenesulfonyl)-imidazole• 1-benzyl-imidazole• 2-benzyl-imidazoline + Tween 80• 2-methyl-imidazoline + Tween 80• Cocodimethylbenzalkonium chloride• WPG member inhibitor A • WPG member inhibitor B

• Performance based assessment of inhibitors after aging

Thermal aging cell with Teflon sleeve

Three-electrode glass cell

24

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Publications

• Journal Corrosion Science – VSI application in corrosion – Vol.

87, Oct 2014, pp: 383 - 391– Pitting evaluation of CRAs at

xHPHT (submitted)

• NACE– Localized corrosion of CRAs at

xHPHT in autoclave (2015 #5620)– Solubility of FeCO3 at xHPHT (2015

#5623)– Uniform corrosion of CRAs at

xHPHT in autoclave ( 2014 # 3978)– Solubility of CaCO3 at xHPHT ( 2014

#4360)

• SPE– FeCO3 precipitation kinetics (SPE

2015)

• OTC– Mineral scaling kinetics and

inhibition (2015 #25126)– Corrosion of CRAs at xHPHT in

flow-through (2014 #25193)

• Journal of Chemical Engineering – (Rice) Examining the Consistency

of Water Content Data in Alkanes Using the Perturbed-Chain Form of the Statistical Associating Fluid Theory Equation of State

• Journal of Chemical Physics– (Rice) Isolating the non-polar

contributions to the intermolecular potential for water-alkane interactions

• Several other pending publications

25

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Future Planning: Phase III

• Why– Upcoming production from xHPHT deepwater– Continued industry need for xHPHT applied research– No startup time for continued research and development– Demonstrated expertise in xHPHT scale and corrosion research

• When– RPSEA funding ends at the end of August 2015

• Who– Government funding– Production companies– Service companies

• Outcomes & Benefits – Accurate xHPHT predictive modelling based on experimental data – Inhibitor screening, development, and testing– Materials selection database (CRAs, pitting tendencies)– Applicable research in xHPHT areas of interest

26

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Proposed Structure

Steering Committee

- Two industrial members

- Ross Tomson (President)

- Paula Guraieb (VP)

xHPHT Scale Kinetics and Thermodynamics

xHPHT Corrosion processes and interplay with scale

Inhibitor screening, development, and testing

Materials Selection

Industry applied software development

Iron thermodynamic, kinetics and inhibition

Technical Support to Members

Industrial Members

Dedicated Ph.D. Research Scientists

27

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Budget Cost Share and Total Cost Budget

• Total Project Cost is now met – Full written report to follow at the end of August.

• Cost Share provided at above 20% required level

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Budget: Technology Transfer

• Technology transfer resources well above requirements, allowing more dissemination of project information, feedback, publication, and reporting.

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Acknowledgements

• James Pappas, President RPSEA

• Bill Fincham, NETL / DOE

• Roy Long, NETL / DOE

• Working project group members:

• Anadarko• Apache• Aramco• Baker Hughes• BP• Chevron• Clariant• ConocoPhillips• Dow• ExxonMobil• GE

• Halliburton• OneSubsea• Nalco Champion• Oxy• Petrobras• Schlumberger• Science Deployed• Siemens• Shell• Statoil• Total

30

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Teams

Tomson Technologies• Mason B. Tomson, Prof., Ph.D., P.E.• Ross C. Tomson, J.D., M.E.S.• Paula Guraieb, M.S.• Disha Jain, Ph.D.• Chao Yan, Ph.D.• Shane Graham, B.S.

Rice University• Walter G. Chapman, Prof., Ph.D.• Kenneth R. Cox, ProfPrac, Ph.D., P.E.• Essmaiil Djamali, Ph.D.• Dilip N. Asthagiri, Ph.D.• Artee Bansal, Ph.D. candidate• Wael Ahmed, Ph.D. candidate• Mason B. Tomson, Ph.D., P.E.• Ross C. Tomson, JD MES

31

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Contacts

Ross Tomson

President, Tomson Tech.

[email protected]

(713) 487-5813

Paula Guraieb

Vice President, Tomson Tech.

[email protected]

(713) 487-5813

Bill Fincham

Project Manager, NETL

[email protected]

(304) 285-4268

James Pappas

President, RPSEA

[email protected]

(281) 313-9555

32

mailto:[email protected]




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RPSEA Working Project Group

Scale and Corrosion at Extreme Temperature and Pressure

Chao Yan, PhD

August 13, 2015

1

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o Development and design of dissolved oxygen (DO) removal apparatus for strictly anoxic condition (<< 1 ppb O2)

o Subtask 9.1 – Validate species activity coefficients at various HPHT and TDS conditions

o Subtask 9.2 – Eliminate of pH measurement in HPHT solution theory

o Subtask 9.3 – Nucleation kinetics and inhibition of scale formation

o Subtask 9.4 – Investigate the thermal limit of scale and corrosion inhibitors

o Subtask 9.5 – Scale inhibitor treatment methodology

Phase II - Statement of Work

22

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Executive Summaryo Strictly anoxic condition (<< 1 ppb O2) has been established

– Developed and designed apparatus to remove dissolved O2 (DO)– The tested DO concentration is far less than 1 ppb – Ankerite (CaMg0.27Fe0.73(CO3)2) instead of magnetite (Fe3O4) formed at 200 °C under strictly

anoxic condition in real brine

o Solubility of iron sulfide (Troilite, FeS) was studied at xHPHT– Hard to study– Limited studies

o Nucleation kinetics studies of various scales and their inhibition– Carboxyl ethyl inulin shows better inhibition efficiency toward ferrous carbonate at 100 °C– Sulphonated polycarboxylic acid (SPCA) shows good inhibition efficiency toward iron oxides at

250 °C– Formation of Fe-SPCA complex

o Studies of thermal limit of scale inhibitors toward BaSO4, CaCO3 and SrSO4

– Polyvinyl sulphonate (PVS), Maleic acid copolymer (MAC) and SPCA show nearly 100% inhibition of all scales at 180 °C

– Their inhibition efficiency toward BaSO4 and SrSO4 decreased dramatically at 250 °C– Prevent majority of CaCO3 formation at 250 °C

o Inhibitor core flooding apparatus has been designed, customized and validated for inhibitor squeeze simulation

3

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44

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o Downhole condition is strictly anoxic (<< 1 ppb O2)

o Study of scale nucleation kinetics and inhibition

• 10 ppb of O2 oxidize 70 ppb of Fe2+ → 134 ppb of Fe(OH)3, colloid

o Scale inhibitor evaluation at high temperature

• Oxidation of scale inhibitors

o Impact on corrosion passive layer formation at high

temperature

5

Importance of Strictly Anoxic Condition

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Design and Setup for DO Removal Apparatus

6

o DO removal at ambient condition for both water and brine o No need for pretreatment such as evacuating and spargingo Environmentally friendlyo Fast treatment for large volumeo Continuous supply of anoxic solutiono Easy to setup and cost less compared with membrane setup

o Evacuating and sparging• ~ 100 ppb limit

o Membrane method• Expensive

o Catalyst method• For lab use

40 ppb

30 ppb

25 ppb

20 ppb

15 ppb

10 ppb

5 ppb

0 ppb

<< 1 ppb

Feed solution

Pump

O2

Removal stage

Gas injection

Test O2

levelsAnoxic water

storage

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Formation of Ankerite at Strictly Anoxic Condition

7

XRD suggested composition ICP solid analysis

CaMg0.27Fe0.73(CO3)2 CaMg0.63Fe0.37(CO3)2

0

50

100

150

200

250

300

20 30 40 50 60

Inte

nsity

2Θ

ExperimentalSideriteAnkeriteCalcite

oFlow-through corrosion testoHigh temperatureoStrictly anoxic conditionoField brine composition

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Siderite Solids Produced Under Various DO Concentration

1. << 1 ppb dissolved O2

2. ~92 ppb dissolved O2

3. ~8 ppm dissolved O2

1.

2. 3.

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99

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Introduction - FeS

10

Iron sulfide o No gas phase of H2S present in the experimento Performed in fume hood with H2S monitorso Present in several crystalline forms with different solubilityo Phase composition can change with time and history of thermal treatment

H.A. Nasr-El-Din and A.Y. Al-Humaidan, “Iron sulfide scale: formation, removal and prevention”, SPE 68315, 2001

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Solubility Studies Using Flow-Through Apparatus

o Lack of mineral solubility data to accurately predict scale formation at xHPHT (up to 250 °C and 24,000 psig)

o Solubility of calcite (CaCO3), siderite (FeCO3) and magnetite (Fe3O4) has been investigated

o Highly customized with all wetted parts made of PTFE coated Hastelloy C-276 to resist corrosion at these conditions

o Modified to allow for strictly anoxic sample collection

11

Anoxic brine storage

Pump

Heating

setupColumn

Cooling

Stage

Back

Pressure

Regulator

Anoxic

sampling

Pump

(Chelating agent)

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0

200

400

600

800

1000

1200

1400

20 30 40 50 60 70 80

Inte

nsi

ty

2 Theta

Experimental data

Troilite PDF 01-089-3039

Fe0.99C0.01 PDF 00-044-1291

Characterization of Packed Troilite Before Experiments

12

SEM image of troilite (FeS) with sharp edges and smooth surface before experiment

XRD spectrum of troilite (FeS) before experimento Black line shows the experimental datao Red circles show the standard troilite structure

(PDF# 01-089-3039)

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Experimental details

13

Reaction: 𝐹𝑒𝑆(𝑠) +𝐻+ → 𝐹𝑒2+ +𝐻𝑆−

Solubility product (Ksp) defined as: 𝐾𝑠𝑝,𝐹𝑒𝑆 = 𝑚𝐹𝑒2+𝛾𝐹𝑒2+𝑚𝐻𝑆−𝛾𝐻𝑆− 𝑎𝐻+

𝑝𝐾𝑠𝑝 = −𝑙𝑜𝑔10(𝐾𝑠𝑝,𝐹𝑒𝑆) = −𝑙𝑜𝑔10(𝑚𝐹𝑒2+𝛾𝐹𝑒2+𝑚𝐻𝑆−𝛾𝐻𝑆−/𝑎𝐻+)

Note: secondary dissociation constant K2 for H2S is not accurately defined

o 1 M or 3M NaCl, 5 mM sodium citrate and 5 mM citric acid was used asfeed solution under strictly anoxic conditions (<< 1 ppb O2)

o Retention time of 181 min (0.02 ml/min) in the packed column waschosen

o Sample was analyzed using inductively coupled plasma (ICP) for totaliron concentration

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y = -3E-05x + 1.9588R² = 0.9909

y = -3E-05x + 3.688R² = 1

0.00

0.50

1.00

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2.00

2.50

3.00

3.50

4.00

0 5,000 10,000 15,000 20,000 25,000 30,000

pK

sp

Pressure (psig)

100C-1M NaCl

pKsp (this study)pKsp predictedLinear (pKsp (this study))

14

Troilite Solubility at 100 °C – 1 and 3 M NaCl

Max. ΔSI=1.74

y = -1E-05x + 1.7752R² = 0.9957

y = -3E-05x + 3.6891R² = 1

0.00

0.50

1.00

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3.50

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0 5,000 10,000 15,000 20,000 25,000 30,000

pK

sp

Pressure (psig)

100C-3M NaClpKsp (this study)pKsp predictedLinear (pKsp (this study))

Max. ΔSI=1.85

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y = -4E-05x + 3.1871R² = 0.8793

y = -3E-05x + 4.4628R² = 1

1.00

1.50

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0 5,000 10,000 15,000 20,000 25,000 30,000

pK

sp

Pressure (psig)


15


Max. ΔSI= 1.65

y = -5E-05x + 3.408R² = 0.9412

y = -3E-05x + 4.4592R² = 1

1.00

1.50

2.00

2.50

3.00

3.50

4.00

4.50

5.00

0 5,000 10,000 15,000 20,000 25,000 30,000

pK

sp

Pressure (psig)


Max. ΔSI=1.51

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y = -6E-05x + 5.2105R² = 1

y = -3E-05x + 5.581R² = 0.9999

2

2.5

3

3.5

4

4.5

5

5.5

6

0 5,000 10,000 15,000 20,000 25,000 30,000

pK

sp

Pressure (psig)


16


Max. ΔSI=1.01

y = -6E-05x + 5.7337R² = 0.9565

y = -3E-05x + 5.5818R² = 1

2

2.5

3

3.5

4

4.5

5

5.5

6

0 5,000 10,000 15,000 20,000 25,000 30,000

pK

sp

Pressure (psig)


Max. ΔSI=0.74

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0

100

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20 30 40 50 60 70 80

Inte

nsi

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2 Theta

Experimental data

Troilite (FeS) PDF 01-089-3039

Pyrrhotite (Fe11S12) PDF 04-017-9146

NaCl PDF 01-071-4661

o XRD of packed solids after 250 °C experimento Both troilite (red dots) and pyrrhotite (blue squares)

phases are showno NaCl (yellow diamonds) are also present

Characterization of Packed Solids After Experiments

17

Weight percentage in solid after experiment

~75.1% Troilite~24.9% Pyrrhotite

Troilite (75.1%)

Pyrrhotite(24.9%)

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Characterization of Packed Solids After Experiments

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Summary of Iron Sulfide Solubility Study

o First experimental study of FeS solubility under xHPHT up to250 °C and 24,000 psig in 1 M and 3 M NaCl for modeldevelopment

o Safe method for studying sulfide species

o Strictly anoxic condition (<< 1 ppb O2) has been used toperform solubility experiments

• Feed solution preparation

• Sample collection

o Reliable flow–through apparatus has been used forsolubility studies under xHPHT and can be extended forother scale research

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2020

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Core Flooding Apparatus

21

o Temperature

• Up to 250 °C

o Pressure

• Up to 15,000 psig

o Flexible core size

o Flexible flow rate

o Multiphase core flooding

capabilities

o Permeability monitoring

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Measurement of Core Pore Volume

22

0

0.1

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0.9

1

1.1

0 1 2 3 4 5 6

Ct/

C0

V (ml)

Sr Ba Ca Mg K

3.25 ml at 50%

0

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0.9

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0 10 20 30 40

Bo

ron

co

nce

ntr

atio

n (

Ct/

C0)

V (ml)

14.95 ml at 50%

Cation breakthrough curve for determination of the system volume (no core packed)

Boron tracer breakthrough curve for determination of packed system volume (with core)

Core pore volume is 11.7 ml

70 °C, 6,000 psig, field brine composition, limestone core

tomson.com

Inhibitor Adsorption and Ca Release Curves

23

0

0.2

0.4

0.6

0.8

1

1.2

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6

Inh

ibit

or

con

cen

trat

ion

in e

fflu

ent

as

NTM

P (

C/C

o)

Inhibitor Injected PV (1 PV=11.7 ml)

Experimental

Predicted

10% NTMP pill with pH 4.48

Inhibitor adsorption Curve Ca released from core dissolution during inhibitor injection

0

500

1000

1500

2000

2500

3000

3500

4000

0 1 2 3 4

Cal

ciu

m c

on

cen

trat

ion

in t

he

eff

lue

nt

(mg/

L)

Core PV (1 PV=11.7 mL)

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Inhibitor Return Profile

24

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

0.10

1.00

10.00

100.00

1000.00

10000.00

100000.00

1000000.00

0 200 400 600 800 1000 1200

NTM

P m

ass

bal

ance

(%

)

Inh

ibit

or

con

cen

trat

ion

as

NTM

P a

ctiv

e (

mg

/L)

PV (1PV=11.7 ml)

75% NTMP returned in first 3 PV83% NTMP returned in 20 PV86% NTMP returned after 1000 PV

tomson.com

Core Dissolution

25

Pill injection

BA C B

5

1

2

3

4

6

0.00

0.05

0.10

0.15

0.20

0.25

0.30

1 2 3 4 5 6Inh

ibit

ion

co

nce

ntr

atio

n a

s N

TMP

(m

g/g

co

re)

Core section

o Inhibitor concentration normalized per g of core o Inhibitor was evenly distributed throughout core material after the experiment

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Summary of Core Flooding Tests

• A reliable core flooding apparatus has been developed and validated under HPHT

• Inhibitor adsorption and Ca released during inhibitor injection has been successfully monitored

• Inhibitor flowback curve showed typical return profile for phosphonate inhibitor in limestone core

• Core dissolution tests showed the inhibitor distribution in core material

26

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2727

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Motivation

• Develop reliable apparatus to study scale nucleation kinetics and inhibition– Reduce background contamination from corrosion under xHT

• No effective inhibition of FeCO3– Wells with high risk of siderite

• Study of iron oxides (Fe2O3, Fe3O4) inhibition– Limited research– Limited knowledge of inhibition mechanism

• Understanding the formation of Fe-inhibitor complex (pseudo-scale)

28

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Experimental Setup

29

oTemperature - up to 250 °CoPressure – up to 24,000 psigoStrictly anoxic brine - << 1 ppb DOoTitanium setup for zero Fe background

Pump B

Anions

(anoxic)

Pump A

Cations

(anoxic)

Pump C

Inhibitor

(anoxic)

Oven

Cooling

Coil

Back Pressure

Regulator

Anoxic

sampling

Pump D

Chelating agent

Pressure

transducer

Reaction

Coil

Ti frit

tomson.com

0

20

40

60

80

100

120

140

0 20 40 60 80 100 120 140

Co

nce

ntr

ati

on

(m

g/L

)

Time (min)

Fe from Ti tubing

Ti from Ti tubing

Fe from HC-276

Ni from HC-276

Cr from HC-276

Mo from HC-276

Titanium setup to prevent Fe contamination

30

o HC-276 inert under 200 °C

o Corrosion occurred after 6 month of continuous usage at 250 °C

o Pure titanium provides zero Fe background

tomson.com

0

0.2

0.4

0.6

0.8

1

0 10 20 30 40 50 60 70

Fet/

Fe0

Time (min)

control 10 ppm SPCA 10 ppm PVS 10 ppm CMI

10 ppm Citrate 10 ppm PAA 10 ppm SPAA

Siderite (FeCO3)Inhibition at 100 °C

31

1 M NaCl, T=100 °C, P=600 psig, SI=0.4, pH=5.2, R (Fe2+/HCO3-)=1/2

o No differential pressure change observed in this 1 hour period

o Indicates the formation of small particles that do not block tubing.

tomson.com

0

0.2

0.4

0.6

0.8

1

0 20 40 60 80 100 120 140

Fet/

Fe0

Time (min)

0 ppm SPCA 1 ppm SPCA 10 ppm SPCA 50 ppm SPCA 316 ppm SPCA

32

Fe2O3/Fe3O4 Nucleation and Inhibition at 250 °C (SPCA)

1 M NaCl, T=250 °C, P=600 psig, SI=0.4, pH=5.7, R (Fe2+/HCO3-)=1/2

o SPCA, PVS and MAC were evaluated in Phase II

o Previous results show SPCA had inhibition on Fe2O3/Fe3O4

o Concentration effects of SPCA were studied

tomson.com33

Fe2O3/Fe3O4 Nucleation and Inhibition at 250 °C

Clean Ti frit 0.4 SI + 10 ppm SPCA

0.2 µm pore size

1 M NaCl, T=250 °C, P=600 psig, pH=5.7, R (Fe2+/HCO3-)=1/2, 10 ppm SPCA

tomson.com

0

200

400

600

800

1000

1200

1400

1600

1800

20 30 40 50 60 70 80

Inte

nsi

ty

2ɵ

exp-0.4SI

Ti-hexagonal

Fe2O3

Fe3O4

FeCO3

Fe2O3

Fe3O4

FeCO3

Ti-hexagonal

Exp-0.4 SI

34

Fe2O3/Fe3O4 Nucleation and Inhibition at 250 °C

1 M NaCl, T=250 °C, P=600 psig, SI=0.4, pH=5.7, R (Fe2+/HCO3-)=1/2, 10 ppm SPCA

XRD of Ti frit after nucleation test

EDX of particles after nucleation test

tomson.com

Summary of Nucleation Kinetics and Inhibition

35

o Field conditions can be simulated experimentally for nucleation and inhibition of various scales up to 250 °C

o Fe scale species have been studied under strictly anoxic conditions (<< 1 ppb O2)

o Validation of predicted inhibitor dosage and MIC o Further study of Fe-SPCA complex

• Solubility• Inhibitor release

o A reliable apparatus has been developed and customized to perform nucleation, growth and inhibition study of scales with nearly zero background.

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3636

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Method development

o Inhibitor thermal limit testing• Injection in situ at HPHT vs. pretreatment of

inhibitors

• Field dosage of inhibitor (0.2-0.5 gpt)

o Test inhibitors under xHPHT, HTDS and strictly anoxic conditions

o Long term testing• Existing inhibitors used at HPHT wells

• Stability of squeezed inhibitor

37

tomson.com

Summary of Scale Inhibitor Thermal Limit Results

o Commercially available inhibitors based on PVS, PAA, MAC,

BHPMP and SPCA were tested

• 3 scale species, 2 temperatures, 5 inhibitor chemistries

• Results for over 30 different conditions

o PVS, MAC and SPCA showed better inhibition of barite, calcite

and celestite at 180 °C than PAA and BHPMP

o Inhibition efficiency of SPCA, PVS and MAC toward barite and

celestite decreased significantly at 250 °C

• Inhibition of majority of calcite formation

38

tomson.com

Corrosion Inhibitor Thermal Limit

o Equipment used

• Glass cell ; LPR

• Thermal aging cell

• HT autoclave setup ; LPR

o Inhibitors tested

• Generic inhibitors (Phase II)

• Commercial inhibitors provided by WPG

Three-electrode glass cell

Thermal aging cell with Teflon sleeve Three-electrode autoclave setup

39

tomson.com

Corrosion Inhibitor Results

o Inhibitors were thermally aged for 24 hours at 250°C, then tested in glass cell test at room T and P• Carbon steel C 1018, 3 M NaCl solution, pH 5.0, CO2 saturated

0.001

0.01

0.1

1

0 5 10 15 20 25 30

Co

rro

sio

n r

ate

me

asu

red

by

LPR

/

mm

/yr

(B =

26

)

Test duration / hour

inhibitor B_orig.

inhibitor B_thermal aged

0.001

0.01

0.1

1

0 5 10 15 20 25 30

Co

rro

sio

n r

ate

me

asu

red

by

LPR

/

mm

/yr

(B =

26

)

Test duration / hour

Inhibitor A_Orig.

inhibitor A_Thermal aged

• Inhibitors’ performance was not affected by 24 hours thermal aging• Need more information on chemistry of inhibitors in order to study

the mechanisms

40

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Thermal Limit Future Work

41

o Thermal limit investigation for scale inhibitors with field brinecomposition of interest at broad range of temperature (up to 250 °C)and ionic strength (up to 360,000 mg/L) targeting various types ofscales (metal-CO3, SO4, S, Ox’s) under strictly anoxic condition

o Inhibition efficiency studies with simulated field conditions• Mixed scale and corrosion inhibitors• Inhibitors mixed with other additives

o Additional commercial corrosion inhibitors will be tested in the

future with realistic brine at xHPHT conditions

• Effect of calcite scaling index on inhibition

• Effect of scale inhibitor

o More corrosion inhibitors needed from WPG for future test and

investigation

tomson.com

Phase III Plan

• Use existing experimental apparatus design and expertise in xHPHT research to continue expanding database for scale and corrosion

• Expand on Fe studies under strictly anoxic (<< 1 ppb O2) conditions

• Based on WPG workshop results, align research to meet industry needs in HPHT development

• Scale and corrosion inhibitor evaluation and thermal stability at HPHT

• Expand material selection guide based on experimental corrosion results

• Technical support to WPG members

42

tomson.com

Acknowledgements

• James Pappas, President RPSEA

• Bill Fincham, NETL / DOE

• Roy Long, NETL / DOE

• Working project group members:

• Anadarko• Apache• Aramco• Baker Hughes• BP• Chevron• Clariant• ConocoPhillips• Dow• ExxonMobil• GE

• Halliburton• OneSubsea• Nalco Champion• Oxy• Petrobras• Schlumberger• Science Deployed• Siemens• Shell• Statoil• Total

43

tomson.com

Thank you!

44

Discussionand

Suggestions

Artee Bansal, Essmaiil Djamali, Dilip N. Asthagiri, Kenneth R. Cox and Walter G. Chapman

Chemical & Biomolecular Engineering Rice University, Houston, Texas

Phase II xHPHT Modeling Overview

Corrosion and Scale A multi-scale approach for a multi-scale problem

High T (150 C—300 C)High P (1000 bars)

xHTHP

Corrosion and Scale The system

TDS > 300,000 mg/LMultiple components

Multiple PhasesSolid/liquid/gas

Corrosion and Scale The challenges

Solution Chemistry & SpeciationO—H bond strength: ~111 kcal/mole

Molecular level: Quantum & Classical

Phase EquilibriaMultiple components at xHTHP

Meso-scale: Molecular EoS

Ca2+—water binding energy: ~59 kcal/mole

Surface ChemistryFe—> Fe2+ + 2 e-

Atomic level: Quantum

Corrosion and Scale Data & Experimental challenges

• Google scholar hits (excluded “include citations” and “include patents”) • Calcium sulfate solubility in brine: ~29,200

- “high temperature” & “high pressure”: ~13,200- “high temperature” & “high pressure” & “predict”: ~4730- “extreme temperature” & “extreme pressure”: ~10

• Barium sulfate solubility in brine: ~17,200- “high temperature” & “high pressure”: ~4060- “high temperature” & “high pressure” & “predict”: ~1170- “extreme temperature” & “extreme pressure”: ~5

➡ (Useful!) Solution thermodynamics data under xHTHP is scarce➡Regression models are essential tools in the engineer’s toolkit ➡But reliance on regression-based models outside the legitimate range

of applicability is unwise

Corrosion and Scale Aim: Single predictive EoS model

➡Develop an accurate, predictive model that shows fidelity to the underlying physics and has only a small number of adjustable parameters➡ Ideally the model parameters should be derivable from an even more basic

approach, such as atomistic simulations

Multi-scale problem;multi-scale solutionSolution Chemistry & Speciation

O—H bond strength: ~111 kcal/mole


Phase EquilibriaMultiple components at xHTHP


Ca2+—water binding energy: ~59 kcal/mole

Unifying theme in our modeling approach

− 50

− 40

− 30

− 20

− 10

0

Solv

ent

forc

e(k

cal/

mol

/A)

2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0r (A)

Non-specific

Na+ (aq)K+ (aq)F− (aq)Cl− (aq)

➡Ion-specific effects are short-ranged➡Our continuum, meso-scale EoS, and atomistic modeling efforts exploit

this observation

Overview of modeling

Molecular scale approach to understand, predict, and mitigate scaling and corrosion under HTHP conditions

MolecularThermodynamic

Framework

Standard State Properties of

Solution Species

Free Energy Models

Atomic/molecular scale information

Unified model of electrolytes

• Model to predict HTHP solutionproperties




Framework


Solution Species

Free Energy Models



• Electrolyte solution thermodynamicsincorporating molecular-scaleinformation

Statistical Associating Fluid Theory (SAFT)-EOS

-

+-

+



• Molecular scale simulations to obtainfine-grained information on ion-waterinteraction and chemistry


Framework


Solution Species

Free Energy Models




Atomistic simulations

Modeling challenges that we addressed

Ion Solvation

Mixed SaltsMultiphase High temperature & high pressure

Speciation

Ca2+ SO42- HSO4

- H+ OH- CaSO4o

Mixed Solvents

Ion Solvation

• Incorporated information from molecular dynamics simulations into the SAFT-EoS• Incorporated multi-body effects into the SAFT-EoS• Quasichemical theory to rationalize the unified model and other continuum models

(including Pitzer-type formulations)➡These fundamental developments are essential stepping stones to have a

minimally parameterized EoS for xHTHP application


Framework


Solution Species

Free Energy Models





Chapman, Jackson, and Gubbins, Mol. Phys. 65, 1057 (1988).

13

SAFT model for electrolytesSAFT- EoS

Chapman, Jackson, and Gubbins, Mol. Phys. 65, 1057 (1988).

14

SAFT model for electrolytesSAFT- Association Contribution

qA1 qB2

A B

r12

• Short- range directional interactions included• Chemical equilibrium theory => can account for speciation

15

Perturbed Chain-SAFT Non Primitive model

Short-Range Forces Hydrogen bonding Ion-Solvent AssociationCoulombicInteractions

Short Range Long Range

Gross, J. & Sadowski, G. ,Ind. Eng. Chem. Res. 40, 1244–1260 (2001).

Blum, L. & Wei, D. Q. ,J. Chem. Phys. 87, 555 (1987).

Long range: Integral equation theory (MSA) with explicit account of molecular solvent

Short range: PC-SAFT with modified ion-solvent association

SAFT model for electrolytes

16Bansal et al. (In preparation)

SAFT model for electrolytes

Ion-Solvent Association

• Naturally applicable to mixed solvent and electrolyte systems

• Ions are modeled with spherically symmetric interactions

• Solvent with directional interactions

• Equilibrium distribution (speciation) of various

species can be well estimated

• Approach allows us to calculate other properties,

such as dielectric constants (right)

Advantages of our approach

Dielectric constant of water in aqueous NaCl solution at 298.15 K

Fundamental contributions

SAFT model for electrolytesActivity coefficient for alkali halides at 298.15 K

• Only three salt specific parameters required for modeling • Deviations in the activity coefficient values for cation with larger size• Exploring reasons for deficiency for larger cations using Monte Carlo simulations

Bansal et al. (In preparation)

Insights from molecular dynamics simulations Short-range contributions to ion hydration

IonInner shell

• With increasing temperature, it is easier to evacuate the inner hydration shell around the anion than the cation

• Suggests Na+ holds on to its shell of waters more tightly than Cl-• Fit ion specific parameters in the SAFT EOS model to match distribution of

coordination states for Na+

SAFT EOS density prediction

• Agreement is better than what has been reported in the literature for a model with as few parameters


• SAFT EOS parameters for Na+ (developed using NaCl as reference) are transferrable to another electrolyte (NaBr)

SAFT EOS density prediction


Multi-body effects & SAFT-EoSExtension to a general theory for solvation

Mixture of patchy and spherically symmetric molecules

• In previous approach medium effects are neglected • But multi-body correlations become important at high densities and low solute

concentrations (infinite dilution)• We incorporated medium effects by better accounting of real reference

fluid behavior• The free energy to evacuate the reference solvent from within the inner-shell

of the reference solute in a cluster is used as a constraint

• Distribution of solvent around a solute gives an estimate of equilibrium concentration of various species and also the average hydration number

• Excellent agreement is obtained for the solvent distribution around a solute using the corrected theory

Multi-body effects & SAFT-EoSDistribution of solvent around a solute for an associating mixture

ρσ3=0.8 ρσ3=0.9

• Association contribution to chemical potential of the solute gives the free energy of charging the solute, from a zero association potential to the fully coupled state, in an associating solvent

• Good agreement is obtained for chemical potential with the corrected theory• High density fluid still a challenge

Multi-body effects & SAFT-EoSChemical potential of solute for associating mixture

Ion-pairing & Speciation

• Hydration structure and thermodynamics of scale forming species• Importance of ion-pairing in modeling solubility at xHTHP; case of Ca2+ and SO42-

➡ These insights inform the unified model and can inform other continuum-scale models


Framework


Solution Species

Free Energy Models





Speciation

Ca2+ SO42- HSO4

- H+ OH- CaSO4o

Quasichemical theory of hydration Tying quantum chemistry to thermodynamic predictions

• Theory allows us to incorporate the chemically significant ion-water interactions in the

context of simplified (continuum solvent) models of the bulk

Quasichemical theory of hydration Tying quantum chemistry to thermodynamic predictions

• Predicted free energies of alkaline-earth metals in excellent agreement with available data (at infinite) dilution

• We validated existing MD parameters for Ca2+ and Mg2+ against the quasichemical theory results

• We developed a new parameter model for Ba2+

Prediction of Ca2+ and SO42- association

− 20

− 15

− 10

− 5

0

5

W(r

)/k B

T

2 4 6 8 10r (S− Ca) (A)

298.15 K

573.15 K

2SIP1SIPCIP

• With increasing temperature association is predicted to increase


− 20

− 15

− 10

− 5

0

5

W(r

)/k B

T

2 4 6 8 10r (S− Ca) (A)

298.15 K

573.15 K

2SIP1SIPCIP

• MD simulations capture free energy of transition from SIP to CIP


Ca2+ and SO42- association

Unified Model Predictions

1

2

3

4

5

273 323 373 423 473 523 573

-log

ms

T (K)

psat

CaSO4+H2O experiment.... This study— This study (corrected for IP)

• Association constants from MD inform solubility prediction

Mixed solvents

• Atomistic simulations support the predictions based on unified model• In the report and previous presentations we have already covered the competition

between hydration by water and solvation by MEG or Methanol


Framework


Solution Species

Free Energy Models Atomic/molecula

r scale information




Mixed Solvents

Prediction of Solubility in Mixed Solvent at xHTHP

− 50

− 40

− 30

− 20

− 10

0

k BT

∂ ∂r

lnx

0(r

)p

0(r

)(k

cal/

mol

/A)

2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0r (A)

Na+ (aq)K+ (aq)F− (aq)Cl− (aq)Born Model

− 140

− 120

− 100

− 80

− 60

− 40

− 20

k BT

∂ ∂r

lnx

0(r

)p

0(r

)(k

cal/

mol

/A)

2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0r (A)

Na2+ (aq)K2+ (aq)Born Model

T = 573 K

0

2

4

6

8

10

0.0 0.2 0.4 0.6 0.8 1.0

Solu

bilit

y (m

ol/k

g of

solv

ent)

xMEG

NaCl+MEG/Water○, 298.15 K, Kraus (1964)□, 467.15 K, Djamali et al. (2015)—This study

0.0

2.0

4.0

6.0

8.0

10.0

0.0 0.2 0.4 0.6 0.8 1.0

Solu

bilit

y (m

ol/k

g of

solv

ent)

xMeOH

466.15 KNaCl + Methanol + Water● Pitzer et al. (1984)○ Djamali et al. (2012)— Unified theory

Corrosion and Scale Overarching summary & future directions

• SAFT EoS model with MSA– can model electrolyte systems with few

parameters – Predicted densities at xHTHP with

transferrable parameters

• Novel solvation approach – Applicable to mixtures of salts and

solvents– New theory for dielectric constant of

brine solutions– Predicted distribution of ion hydration

states across concentration at xHTHP

• Predicts standard state thermodynamics to xHTHPconditions

• Preferential solvation of ions in water-Methanol/MEG Mixed solvent systems described

• Hydration structure and free energies of scale forming species Ba2+

, Sr2+ and Ca2+ from first principle simulations

• Solubility at xHTHP : ion-pairing between Ca2+ and SO4

2-

Phase Equilibria

Multiple components at xHTHP


Solution Chemistry & Speciation


Project Outcomes

Corrosion and Scale Overarching summary & future directions

Groundwork has been laid Predictive tools at multiple scales to

complement experiment and engineering correlations

• Quantum mechanics for intermolecular potentials and reactive force fields

• Molecular simulation for speciation, interfacial behavior, and scale and corrosion kinetics (pitting and uniform corrosion)

• Molecular theory for computationally efficient predictions of bulk and interfacial properties at xHTHP and mixed salt / solvent conditions

AcknowledgementRPSEA

Opportunities

1 tomson.com 8285 El Rio Street, Suite 100 | Houston, Texas 77054 P 713.487.5813

Peer Review Workshop


RPSEA 10121-4202-01

Workshop Topic A – Group activity

Describe a specific scale and/or corrosion HPHT challenge you have encountered

in the field and what actions were needed to solve the problem. If applicable,

include areas of research that could reduce the uncertainty and risks associated

to this challenge in HPHT applications.

Names (optional):

http://tomson.com/

Peer Review Workshop


RPSEA 10121-4202-01

1 tomson.com 8285 El Rio Street, Suite 100 | Houston, Texas 77054 P 713.487.5813

Workshop Topic B – Individual activity

Rank the areas or research and development in HPHT (250°C; 24,000 psig) that

are important for research in Phase III of this project. Ranking 0 to 10.

Importance

State of knowledge

Research area

Solubility of scale species at HPHT

Experimental work on iron species solubility at HPHT

Corrosion inhibitor thermal stability at HPHT

Interplay between scale and corrosion at HPHT

Thermal stability of commercially available corrosion inhibitors at HPHT

Scale inhibitor squeeze efficiency and mechanisms at HPHT

Investigate simultaneous precipitation of multiple scale species in complex brine systems at HPHT

Material selection database expansion for HPHT

Nucleation kinetics and inhibition of various scale species at HPHT

Enhance current scale prediction software to include kinetics for additional scale species, co-precipitation of multiple scale species or other features

Modeling of iron solubility at HPHT

Other topic(s)

Name (optional):

http://tomson.com/

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