UHPC Pipe Design for CO2 Transport
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Solution Overview
Problem
The high cost and safety risks associated with transporting CO2 at high pressures, particularly due to the risk of pipe rupture and corrosion, in existing steel pipe systems used for carbon sequestration and Enhanced Oil Recovery (EOR) processes.
Innovation Solution
A pipe design featuring a tubular element composed of concentric layers, including a waterproofing layer, a prestressed concrete layer made of ultra-high performance fiber-reinforced concrete (UHPC) with steel metal fibers, and a circumferential mechanical reinforcement layer, capable of withstanding pressures up to 150 bar, while minimizing corrosion and pipe thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steel pipes are used for transporting CO2 at high pressure, then the risk of rupture is reduced due to ductile behavior, but the cost of production and installation increases significantly
Solution Approach 1:
The patent employs a composite structure consisting of a steel tube core surrounded by a concrete layer. The steel tube provides ductile behavior and pressure containment, while the concrete layer reduces material costs and provides corrosion protection. This composite approach allows the system to achieve the reliability of steel pipes at a lower overall cost.
Solution Approach 2:
The patent replaces expensive steel pipes with a more economical concrete-based composite structure. While concrete is traditionally considered less durable than steel, the composite design with proper reinforcement achieves sufficient service life for CO2 transport applications at significantly reduced cost.
2Strength
If steel pipes are used for transporting CO2, then structural strength is sufficient, but corrosion risk increases due to reactive CO2 and impurities
Solution Approach 1:
The patent introduces an intermediary layer (concrete coating or surrounding concrete structure) between the CO2 and the steel tube. This intermediary protects the steel from direct contact with corrosive CO2 and impurities, significantly reducing corrosion risk while maintaining structural integrity.
Solution Approach 2:
The concrete layer creates a chemically inert environment around the steel tube, isolating it from reactive CO2 and corrosive impurities. Concrete's low permeability and chemical stability provide effective corrosion protection without compromising structural strength.
3Ease of manufacture
If ordinary concrete is used for pipes, then production cost is low, but the pipe cannot withstand high pressure due to brittle behavior
Solution Approach 1:
The patent combines ordinary concrete with a steel tube reinforcement to create a composite pipe structure. The steel tube bears the high hoop stresses from internal pressure, while the concrete provides structural form and compression resistance. This allows the use of cost-effective ordinary concrete without sacrificing pressure resistance.
Solution Approach 2:
The patent applies different material qualities to different regions of the pipe structure. The steel tube is positioned where tensile stresses occur (circumferential direction), while concrete is used where compression stresses dominate. This localized material optimization achieves high pressure resistance at low overall cost.
4Stress or pressure
If prestressed concrete pipes are used, then low-pressure transport is feasible, but the risk of rupture remains high due to brittle material properties
Solution Approach 1:
The patent creates a composite system where prestressed concrete is combined with a steel tube. The prestressed concrete provides initial compression to counteract internal pressure, while the steel tube provides ductile backup that prevents catastrophic rupture. This combination maintains the low-cost advantage of concrete while eliminating its primary disadvantage of brittleness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The UHPC pipe design significantly reduces production and installation costs while ensuring safety by preventing bursting and corrosion, enabling efficient and safe transportation of CO2 over long distances with enhanced mechanical strength and durability.
Implementation Method 1
ultra high-performance fibre-reinforced concretes
Implementation Method 2
a material that has the ability to deform plastically (permanently) without breaking suddenly
Implementation Method 3
a prestressed concrete layer (also called a wall comprising a prestressed concrete layer)
Implementation Method 4
at least one circumferential mechanical reinforcement layer
Implementation Method 5
at least one sealing layer
Data Source
Figure 1
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AI summary
The present invention relates to a pipeline for the transport of gases, in particular carbon dioxide, comprising at least one tubular element, the tubular element (1) being formed by a juxtaposition of concentric layers comprising, from the inside out, at least one sealing layer (5), a wall comprising a prestressed concrete layer (6), and at least one circumferential mechanical reinforcement layer (8). Furthermore, the concrete composing the prestressed concrete layer (6) is selected from ultra-high-performance fiber-reinforced concretes (UHPFRC).