Acid Drop-Out in Carbon Capture and Transport Systems: Causes, Consequences, and Countermeasures

Carbon capture and storage (CCS) technology can play an important role in meeting net-zero ambitions; however, its successful deployment depends on the transport and storage infrastructure for CO2, as they are the backbone of the carbon management industry. Among the key integrity threats for dense-phase and supercritical CO2 pipelines, acid precipitation or dropout in CO2-rich streams containing reactive impurities (SOx, NOx, H2S, H2O, O2, etc.) is one of the most serious. These impurities can alter phase behavior, promote formation of highly acidic liquid-phase condensates, and trigger severe localized corrosion and rapid wall-thickness loss. This review focuses on understanding the effects of specific combinations of impurities on CO2 phase envelopes, acid formation, and corrosion mechanisms in pipelines under realistic flow and operating conditions. It further assesses mitigation and design strategies, including impurity specification and control, deep dehydration, operational envelope management, corrosion-resistant alloys, internal linings and advanced coatings, and emerging modeling tools for predicting corrosive dropout. The knowledge gap in long-term performance under multi-impurity conditions, thermo-hydraulic transients, and coupled corrosion damage is highlighted. Additionally, the importance of future experimental, modeling, and standards development work to enable safe, cost-effective material solutions for CCS technology deployment is proposed.