Driving Cost Reduction in CCUS Projects: Innovating Qualification Technologies to Replace Expensive CRA with Cost-Efficient Glass Fiber Polymer Composites

Abstract The imperative role of Carbon Capture, Utilization, and Storage (CCUS) in achieving the global carbon emissions reduction target of 15-20% by 2050 is widely recognized. However, the sluggish progress in CCUS deployment stems primarily from substantial initial capital outlays, notably attributed to the use of costly Corrosion-Resistant Alloys (CRA). These alloys are essential due to the corrosion challenges posed by supercritical CO2 from the capture facility to the injection wells. Glass Fiber Reinforced Polymer Composite (GFPC), with its high corrosion resistance and excellent mechanical strength, emerges as a cost-efficient alternative to CRAs. Despite this potential, GFPC faces challenges related to limited data, poor understanding of degradation mechanisms, especially in supercritical CO2, and difficulties in evaluating its operational lifespan. To expedite the adoption of GFPC, this study systematically investigates the degradation mechanisms of GFPC in CCUS injection wells and introduces an industry-crucial model for qualifying GFPC grades for long-term usage as downhole liners. Conventional GFPC tubular qualification methods involve excessively long aging tests (e.g., 417 days as per ISO 14692) with overly conservative safety margins, making qualification cost- and time-prohibitive. To overcome this challenge, a mature GFPC grade with over 50 years of field deployment data was chosen, and a novel accelerated lab testing method (completed in 56 days) was established by plotting mechanical property decay as a function of time at temperatures below its glass transition temperature. Systematic investigations, employing various characterization tools, were conducted to analyze microstructure changes, polymer/fiber bond alterations, and thermomechanical property variations. A numeric degradation model was developed by correlating lab test results with long-term field data to provide a reasonable evaluation of the long-term application of GFPC as liner materials in specific CCUS well conditions. The GFPC was found to suffer from severe degradation issues, primarily debonding caused by chemical attacks on the fiber/polymer interface from impurities in supercritical CO2, such as water. The newly developed accelerated qualification methods and evaluation model, focusing on these unique debonding issues, efficiently screen fit-for-purpose GFPC grades for given conditions and offer a reasonable prediction of their performance over typical operation durations (15-20 years). This study presents the first qualification method and model for GFPC materials in CCUS applications. The significantly shortened testing period not only expedites the application and market acceptance of GFPC as a replacement for expensive CRAs but also provides material formulators with a crucial tool and clear guidance for developing GFPC materials tailored to diverse CCUS corrosion conditions. Through collaborative efforts, this advancement contributes to a substantial reduction in CCUS project costs, facilitating easier promotion in developing economies to address carbon emissions reduction.