Downhole CO2 Corrosion Test System with Metal Coupon Arrays
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Solution Overview
Problem
Existing methods for storing captured CO2 in depleted oil wells face challenges due to the different behavior of CO2 compared to oil, leading to potential corrosion and pressure losses across downhole equipment, which affects the lifespan of storage structures and efficiency of CO2 storage.
Innovation Solution
A test system comprising CO2 vessels and a test section with controlled CO2 flow and sensors to monitor the effects of CO2 on downhole equipment, allowing for controlled pressure and flowrate testing to understand and mitigate potential issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If CO2 is pumped into existing oil wells for storage, then CO2 storage capacity is achieved, but corrosion of downhole equipment occurs due to CO2's different behavior compared to oil
Solution Approach 1:
The patent applies preliminary action by conducting corrosion tests on downhole equipment samples before actual CO2 storage operations. Test sections containing metal coupon arrays are installed in the well ahead of time to expose them to CO2 conditions, allowing corrosion rates to be measured and assessed before they affect the actual storage infrastructure. This advance testing enables prevention or mitigation strategies to be implemented before full-scale storage begins.
2Reliability
If new completion equipment is installed in wells for CO2 storage, then CO2 storage functionality is improved, but pressure losses increase across the equipment due to smaller inner diameters
Solution Approach 1:
The patent applies parameter changes by systematically varying flow rates, pressures, and CO2 properties in test sections to understand how these parameters affect pressure losses across downhole equipment. By conducting controlled experiments at different operating conditions, the study identifies optimal parameter ranges that minimize pressure losses while maintaining effective CO2 storage functionality. This enables selection of equipment and operating conditions that balance reliability with energy efficiency.
3Loss of information
If downhole equipment is tested with CO2 streams, then understanding of CO2 behavior is improved, but system complexity increases due to need for controlled testing infrastructure
Solution Approach 1:
The patent uses test sections containing metal coupon arrays as intermediary devices between the CO2 stream and the measurement system. These test sections serve as simplified intermediaries that capture corrosion effects without requiring complex real-time monitoring of the entire CO2 flow path. The coupons act as passive sensors that accumulate corrosion damage over time, providing information about CO2 behavior and its interaction with equipment materials without adding significant system complexity.
Data Source
AI summary
A test system comprising a first CO2 vessel having a first predefined volume configured to hold and/or receive a first predefined amount of CO2, having a first CO2 output, a second CO2 vessel having a second predefined holding volume configured to hold and/or receive a second predefined amount of CO2 having a second CO2 input, a test section having a third CO2 input in fluid communication with the first CO2 output and a third CO2 output in fluid communication with the second CO2 input, where the test section is configured to hold a first sample, a first valve arranged between the first CO2 output and the third CO2 input, and a second valve arranged between the third output and the second CO2 input.