Shiladitya Paul

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 (SO_x, NO_x, H₂S, H₂O, O_2, 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.

The need for the rapid advancement of lithium-based energy storage technologies continues to outpace progress in materials development and manufacturing, creating a widening gap between laboratory-scale innovation and industrial deployment. There is a need to examine the key materials and processing challenges that limit the performance, cost-effectiveness, and sustainability of next-generation lithium batteries. For material considerations, many commonly used electrodes face issues of volumetric expansion and performance degradation over charging cycles. To address these issues, binders are a crucial component to consider as they adhere active materials to the electrodes, and their structure can be altered to mitigate undesirable effects from these components. Hence, the selection and exploration of alternative binders are becoming increasingly important in the pursuit of longer-lasting and safer Li-batteries. From a manufacturing perspective, current production lines rely on multistep, energy-intensive processes, e.g., from slurry-mixing to cell assembly, that elevate costs and complicate scale-up. Emerging chemistries incorporating nanomaterials or solid-state components face additional barriers related to yield, process control, and defect management, all of which can exacerbate safety risks related to processing during production and thermal runaway in produced batteries. End-of-life considerations, including disassembly, recycling, and the safe handling of toxic materials, further contribute to the technological and logistical complexity of large-scale deployment. The field is moving toward sustainable material alternatives, more efficient and adaptive manufacturing routes, and advanced technologies such as solid-state electrolytes and nanostructured electrodes. Together, these developments provide a roadmap for overcoming current bottlenecks and enabling the next generation of high-performance, safe, and sustainable lithium battery technologies. This review examines the progress made in finding alternative materials and synthesis methods for the optimization of lithium battery cells, with a focus on the development of novel binders, slurry synthesis and manufacturing framework. In addition, the advantages and limitations of the alternative binder materials and processes are also explored, with a focus on scalability for manufacturing, safety concerns, sustainability and end-of-life challenges.

This study investigates the corrosion and scaling behaviour of Extreme High-speed Laser Application (EHLA)-fabricated corrosion-resistant alloy (CRA) claddings under simulated geothermal brine conditions. EHLA 316L stainless steel and alloy 625 coatings were produced and tested in simulated brine (chloride–carbonate–silica geothermal brine) at 70 °C for 720 h to evaluate the influence of additive manufacturing (AM) microstructures on corrosion performance. The EHLA coatings exhibited dense, metallurgically bonded microstructures with minimal porosity. Microstructural analysis revealed Nb- and Mo-rich segregation in EHLA 625 and fine columnar dendritic morphology in all coatings. EHLA 625 developed a stable passive film with only a thin deposit of Mg-O-containing compounds, whereas EHLA 316L exhibited localised pitting and significant Si- and Mg-containing scale accumulation, especially in as-built conditions. Surface finishing reduced corrosion activity by minimising roughness and defect-driven localised attack. Critical pitting temperature (CPT) tests confirmed the superior localised corrosion resistance of EHLA 625 relative to EHLA 316L under laboratory conditions. While these results indicate promising corrosion and scaling resistance of EHLA coatings, further process optimisation and post-deposition thermal treatments might be required to achieve coating performance comparable to wrought alloys. The results indicate the potential of EHLA-fabricated coatings for producing corrosion and scaling resistance surfaces.

This study investigates the corrosion and scaling behaviour of Extreme High-speed Laser Application (EHLA)-fabricated corrosion-resistant alloy (CRA) claddings under simulated geothermal brine conditions. EHLA 316L stainless steel and alloy 625 coat-ings were produced and tested in simulated brine (Chloride–carbonate–silica geo-thermal brine) at 70°C for 720h to evaluate the influence of additive manufacturing microstructures on corrosion performance. The EHLA coatings exhibited dense, met-allurgically bonded microstructures with minimal porosity. Microstructural analysis revealed Nb- and Mo- rich segregation in EHLA 625 and fine columnar dendritic morphology in all coatings. EHLA 625 also displayed stable passive film formation but had a thin deposit of Mg-O-containing compounds from the brine. EHLA 316L on the other hand exhibited localised pitting and heavy Si- and Mg-containing scale accumu-lation, especially in as-built conditions. Surface finishing reduced corrosion activity by minimizing roughness and defect-driven localised attack. Critical pitting temperature tests confirmed the superior localised corrosion resistance of EHLA 625 compared to EHLA 316L. However, further process improvements and perhaps post-deposition thermal treatments might be required to bring the performance of the coatings in line with the wrought alloys. The results demonstrate that EHLA-fabricated coatings offer corrosion and scaling resistance. This coating technique has the potential to provide cost-effective solutions to produce corrosion resistant coatings on geothermal components.