CCS: Corrosion Dosing System 

The Core Separations CO₂ Corrosion Dosing System creates controlled CO₂ streams containing defined concentrations of water and gaseous impurities. Available for gas phase and dense phase operation, it enables laboratories to reproduce representative transport and storage conditions for corrosion testing.

The system provides precise control of pressure, composition and flow, with configurations available up to 35 bar for gas phase studies and 200 bar for dense phase CO₂ studies.

Why consider a CO₂ Corrosion Dosing system

Reproducing captured CO₂ transport conditions

Captured CO₂ must be transported from the capture facility to its storage or utilisation location, whether by pipeline, ship, road tanker or another transport network. Existing oil and gas infrastructure may be considered for this purpose, but it was not necessarily designed for exposure to captured CO₂ streams.
Depending on the capture process, the CO₂ may contain impurities such as water, oxygen, hydrogen sulphide, sulphur oxides and nitrogen oxides. Water and CO₂ can form carbonic acid, while interactions with other impurities may create more aggressive corrosive environments.
Controlled laboratory testing helps researchers investigate how these compositions affect pipelines, valves, seals, coatings and other materials used throughout CO₂ transport and storage infrastructure.

Controlled Impurity Composition

Introduce water and gaseous impurities at controlled concentrations to reproduce different captured CO₂ compositions. Mixtures can include H₂S, O₂, SOₓ and NOₓ, depending on the application and required operating envelope.

Gas and Dense Phase Operation

Configure the system for gas phase studies up to 35 bar or dense phase CO₂ studies up to 200 bar. This allows researchers to investigate conditions relevant to different stages of CO₂ handling, transport and storage.

Continuous Flow Corrosion Studies

Deliver a controlled CO₂ stream through a customer supplied autoclave or test cell. Flowing experiments can be used to investigate material exposure under conditions that are more representative of pipeline transport than static batch testing alone.

Precise Mass Flow Control

Mass flow controllers regulate the individual gas streams used to create the final composition. For dense phase CO₂, Core Separations combines a Coriolis mass flow meter with a purpose designed proportional control valve to provide controlled mass flow.

Stable Pressure Control

Adaptive Pressure Control maintains the required back pressure while the CO₂ mixture flows through the test system. This supports stable exposure conditions and improves experimental repeatability.

Customisable System Configuration

Systems can be configured with multiple dosing channels according to the number of impurities required. Each channel can be selected for the fluid, flow range, pressure and target concentration.

Integration with Corrosion Test Equipment

The system can supply a customer provided autoclave, flow loop, corrosion cell or analyser. This allows it to be incorporated into a wider experimental platform rather than limiting users to one vessel arrangement.

Long Duration Testing

Pressure mode maintains the supply cylinder at its set pressure, automatically topping it up as required. This supports extended corrosion studies without requiring continuous manual pressure adjustment.

Corrosion Dosing System

The Corrosion Dosing System is designed to prepare and continuously deliver controlled CO₂ compositions for corrosion, materials compatibility and CCUS research. Up to six independently controlled dosing channels can combine a main CO₂ stream with prepared CO₂ based mixtures, including water saturated CO₂ and CO₂ containing defined concentrations of impurities such as H₂S, SO₂, NOx or O₂. Each stream is independently metered before being combined and delivered to the customer’s test arrangement under controlled pressure and flow. This allows researchers to reproduce complex CO₂ environments with defined water content and impurity concentrations while retaining control over their own test cell, flow loop, sample arrangement and analytical method.

Corrosion Delivery System - Gas

Designed for operation up to 35 bar, the gas phase system enables corrosion and materials testing using controlled lower pressure CO₂ compositions.

The required composition can be produced by combining CO₂ with independently controlled impurity streams using mass flow control. Where suitable compositions are commercially available, premixed gas cylinders can also be incorporated as part of the supply arrangement. Up to six independently controlled dosing channels can be configured to create the required stream composition.

Each stream is accurately metered before being combined and continuously delivered at the selected pressure and flow through a customer supplied test cell, autoclave, flow loop or analytical system.

System’s technical specifications:

Specification Gas phase system
Maximum operating pressure 35 bar
Typical operating phase Gas
Number of dosing channels Up to 6
Possible impurities H₂S, O₂, SOₓ, NOₓ
Flow control Gas mass flow controllers
CO₂ flow TBC
Pressure control accuracy +/- 2 bar
Test equipment Customer supplied

Corrosion Delivery System - Dense Phase

Designed for operation from approximately 55 to 200 bar, the dense phase system enables corrosion and materials testing under conditions representative of high pressure CO₂ transport, injection and storage.

Because customised dense phase CO₂ mixtures are not commonly available, the system uses a principal CO₂ supply together with prepared CO₂ based dosing streams. These can include water saturated CO₂ and CO₂ containing defined concentrations of impurities. Up to six independently controlled dosing channels can be used to create the required stream composition.

Each stream is accurately metered before being combined and continuously delivered at the selected pressure and flow through a customer supplied test cell, autoclave, flow loop or analytical system.

System’s technical specifications:

Specification Dense phase system
Maximum operating pressure 200 bar
Typical operating phase Liquid or dense phase CO₂
Number of dosing channels Up to 6
Possible impurities H₂S, O₂, SOₓ, NOₓ and water
Flow control Coriolis meter and proportional control valve
CO₂ flow 0.1 to 1,000 g/h
Pressure control accuracy Approximately ±2 bar
Test equipment Customer supplied

Core Separations adaptive pressure control logo.

Pressure Mode CO₂ Supply

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Pressure Mode CO₂ Supply

Custom dense phase CO₂ mixtures are not commonly available from standard gas suppliers. Core Separations uses its CO₂ pumping technology to pressurise liquid CO₂ and create a controlled supply between approximately 55 and 200 bar.
Pressure mode maintains the contents of the high pressure supply cylinder at the selected pressure, automatically adjusting pump operation as demand changes. This provides a stable supply for extended corrosion experiments.

Adaptive Pressure and Flow Control

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Adaptive Pressure and Flow Control

During continuous testing, the CO₂ mixture must flow through the corrosion cell while the required test pressure is maintained. Core Separations Adaptive Pressure Control regulates the downstream restriction to maintain stable back pressure as flow and fluid properties change.

The stream can then pass to an analyser or suitable downstream collection system for composition monitoring or further analysis.

Precise Gas and Dense Phase Dosing

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Precise Gas and Dense Phase Dosing

Gas phase streams are controlled using appropriately selected mass flow controllers. For dense phase CO₂, Core Separations uses a Coriolis mass flow meter with a purpose designed proportional control valve to provide controlled flows from 0.1 to 1,000 g/h.
Gas and liquid metering technologies can be combined within one system, allowing each channel to be configured for its particular fluid, pressure and required concentration.

How it works

CCS: Corrosion Dosing System

The system provides precise control of pressure, composition and flow, with configurations available up to 35 bar for gas phase studies and 200 bar for dense phase CO₂ studies.

A

Flow through system

B

Upto 6 mixing channels

C

Maximum pressure upto 180 bar

D

Dense phase and gas phase mixing

E

Adaptive pressure control

Component Description
A Flow-through system
B Up to 6 mixing channels
C Maximum working pressure 180 bar
D Dense phase and gas phase mixing
E Adaptive pressure control

CDS Software Control

The Corrosion Dosing System is built on the SFX software suite used throughout Core Separations technology, bringing established pressure control, process monitoring and real time data collection into the CDS platform.

Pressure within the customer test cell is managed using the adaptive control functions developed for the Core Separations automatic back pressure regulator, allowing the system to respond continuously to changing flow and process conditions. The main CO₂ supply pump can also operate in pressure mode to fill and maintain the high pressure mixing cylinders at the required pressure, providing a stable dense phase CO₂ supply for dosing.

For the CDS, the software has been extended to provide independent control of each mass flow channel using the Core Separations MFC valve. This proportional valve has been specifically adapted for controlled delivery of dense phase CO₂ and CO₂ based impurity mixtures.

Pressure, flow and other key operating parameters are monitored and recorded in real time, providing a complete view of system performance throughout the experiment.

Precise Flow Control

Independent mass flow control through the SFX corrosion software suite, using custom Core Separations proportional MFC valves developed for dense phase CO₂ and CO₂ based dosing streams, with controlled flow rates down to 0.1 g/h.

Automated Recipe Control

Create complex, fully automated test procedures using time based setpoints. Individual flow rates can be varied throughout the experiment, allowing the SFX software to automatically control changes in CO₂ and impurity composition over time.

Complete Event Recording

System events, setpoint changes and operating data are recorded automatically within an SQL database, creating a time stamped record of the experiment for review, traceability and process analysis.

Programmed Flow Profiles

Time based recipe set points allow individual flow rates to be increased, reduced or held automatically, creating controlled stepwise changes in flow and CO₂ stream composition throughout the experiment.

Specification Downloads

Certification

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