Software modelling system to predict the corrosion risk to CCS pipelines

Industry Context

Corrosion risks in carbon steel pipelines and wells arise due to aqueous phases induced by polar impurities in CO₂ streams. However, current corrosion prediction models struggle to fully account for the effects of impurities and their chemical interactions. This creates a critical knowledge gap in carbon capture and storage (CCS) risk assessment. Recognising the risks posed by liquid dropout and polar impurities, the project aimed to develop a robust solution that ensures the reliability and safety of CCS infrastructure.

Project Overview

The 15-month long project focused on developing a comprehensive understanding and predictive capability for corrosive behaviour in aqueous/liquid phases within carbon steel CCS pipelines. To achieve this, it leveraged advanced thermodynamic modelling, laboratory validation and software development to address these challenges. Specifically, key activities included developing thermodynamic model, conducting laboratory testing and creating a genetic algorithm to assess worst-case corrosion scenarios. Furthermore, insights form these efforts were integrated into the Corrosion Solution App developed by PACE CCS to evaluate the impact of pipeline integrity.

Key Results and Achievements

The project successfully addressed critical corrosion challenges in CCS systems through comprehensive research, modelling, and software development.

PACE CCS Corrosion Solution App – Click to expand

Industry Value

The project significantly advanced net zero targets by addressing critical CCS pipeline and well design challenges. As a result, it enabled cost-effective design solutions and filled a key knowledge gap. Additionally, it reduced early-stage corrosion risks and minimised the likelihood of project failures. The corrosion prediction software is expected to support the disposal of up to 2 billion tonnes of CO₂ over the lifecycle of CCS projects. Even a modest 1% improvement in injectivity and operability could result in 60 MTPA of CO₂ disposal. This would contribute to 3% of the overall CCS impact. By increasing CO₂ injectivity and reducing failure risks, the software improves resource utilisation. It also boosts operational profitability and ensures long-term reliability while minimising costs. These advancements directly contribute to effective disposal of CO2 by the initial wave of CCS project.

“The Net Zero Technology Centre’s unwavering support has been instrumental in bringing our innovative corrosion management solution for CCS applications to fruition. Their funding enabled us to pioneer technology that addresses critical infrastructure challenges in the carbon capture sector. Through this collaborative partnership, we’ve developed a solution that not only advances sustainability goals but also enhances operational safety and efficiency—demonstrating how strategic investment in emerging technologies can accelerate the transition to a net zero future.“

Matthew Healy, Managing Director of PACE CCS