Development of High-Temperature Fiber Reinforced Polymer Composites for Cost-Effective Carbon Capture, Utilization, and Storage (CCUS) Operations

Carbon Capture, Utilization, and Storage (CCUS) plays a critical role in achieving global carbon emission reduction targets of 15–20% by 2050. Despite its importance, the deployment of CCUS technologies remains slow, primarily due to high initial capital expenditures, driven largely by the reliance on expensive Corrosion-Resistant Alloys (CRAs). CRAs are essential to mitigate corrosion challenges associated with supercritical CO2 from capture facilities to injection wells. Fiber Reinforced Polymer Composites (FPCs) present a cost-efficient alternative, offering exceptional corrosion resistance and mechanical strength. However, the current commercial FPCs are limited to a maximum operational temperature of 95°C, restricting their use in high-temperature applications such as injection wells, where reservoir temperatures often exceed 120°C. This study introduces two newly developed high-temperature FPC, capable of withstanding temperatures up to 130°C and 150°C, respectively, using commodity raw materials, thereby unlocking its potential for downhole CCUS applications. The degradation mechanisms of FPCs in CCUS environments were systematically analyzed, focusing on the impact of water in supercritical CO2. A comprehensive screening of commercial raw materials was conducted, evaluating parameters including epoxy molecular structure, curing agents, fiber surface treatments, curing processes, and fabrication techniques. This extensive analysis led to the optimization of resin formulations and composite fabrication methods, resulting in a novel FPC system tailored for high-temperature CCUS operations. Conventional glass fiber FPCs exhibited significant degradation, primarily due to fiber/polymer interface debonding caused by chemical attacks from supercritical CO2 impurities. The study identified multifunctional epoxy and amine curing agents with specific molecular structures, along with carefully selected reinforcements and additives, as optimal solutions to counter these degradation mechanisms. ISO standard aging tests, complemented by predictive modeling, confirmed reliable performance of the developed FPC for operational durations of 15–20 years under CCUS conditions. This work represents the first report of an FPC system designed for high-temperature applications (up to 150°C) in CCUS operations. The novel composite system offers a viable alternative to CRAs, significantly reducing the cost of CCUS infrastructure, particularly in injection wells. By addressing the economic challenges associated with CCUS deployment, this advancement has the potential to accelerate adoption, especially in developing economies, contributing meaningfully to global carbon emissions reduction efforts.