Session: 09-05 Part IV Integrity management of hydrogen pipelines

Submission Number: 185385

Internal Al/Al2o3 Ultra-Thin Multi-Layer Coating for Natural Gas Transmission Pipelines: Increasing Throughput, Eliminating Corrosion and Unlocking Hydrogen Blending 

Bulk transportation of CO₂ and hydrogen is a crucial development to reach net zero by 2050.

While using natural gas transmission pipelines is a straightforward and cost-effective solution, these pipes suffer (i) strong corrosion from carbonic acid when transporting CO₂, and (ii) accelerated fatigue crack growth rate when hydrogen is blended with natural gas, even in small percentages.

A thin, multilayer coating made of aluminum and aluminum oxide, developed at MIT, can increase flow efficiency, protect pipes from internal corrosion and fully block hydrogen from reaching the steel. The flow efficiency increase derives from the lower absolute roughness provided by the innermost aluminum oxide layer, which is combined with a smoother pipe internal surface obtained after cleaning and coating application, which remains unchanged over time thanks to the coating corrosion resistance. The corrosion protection comes from the stability of aluminum oxide within a pH range of 4.0 to 8.9, covering most oil and gas products transported via pipes. The hydrogen permeation barrier effect is obtained thanks to the formation of extended space-charge zones at the metal/oxide interface, which repel incoming positively charged hydrogen ions diffusing in the oxide layer. Furthermore, the aluminum interlayer provides compatibility between pipeline steel and the oxide layer, improving adhesion and preventing delamination, while the multilayer composite structure offers strong micro-cracking resistance and self-healing potential in presence of trace amounts of oxygen. Additionally, the non-polymeric nature and ultra-low thickness of the coating make it long-lasting and compatible with current in-line inspection technologies.

The study introduces the SputterPig, a smart tool designed to apply the multilayer coating on the internal surface of natural gas transmission pipelines via magnetron sputtering. In collaboration with Starfire Industries and N2 Solutions, the SputterPig enables coating application through a vacuum-based technology without disassembling the pipeline. The study also presents results from DNV studies on the coating's effectiveness in reducing internal friction and lowering operating expenses, along with preliminary results from testing conducted at Southwest Research Institute and Louisiana State University.

Presenting Author: Gianluca Roscioli, Arculus Solutions, Inc.

Presenting Author Biography: Gianluca is the founder and CEO of Arculus. With nearly a decade of research experience in materials engineering and metallurgy, he is an expert in the design and fabrication of setups for in-situ scanning electron microscopy experiments as well as failure analysis. He holds a Science Doctorate in Materials Science and Engineering from MIT, an M.Sc. in Materials Engineering and Nanotechnology from Politecnico di Milano, and an M.Sc. in Materials Engineering from Politecnico di Torino.

Authors:

Gianluca Roscioli Arculus Solutions, Inc.
Kelvin Maliyakal Arculus Solutions, Inc.
Bowen Li Arculus Solutions, Inc.
Biman Herlekar Arculus Solutions, Inc.
Daniel Menet Starfire Industries, LLC.
Nicholas Connolly Starfire Industries, LLC.