Oil field microorganisms cause highly localized corrosion on chemically inhibited carbon steel

Carbon steel pipelines, a means for crude oil transportation, occasionally experience highly localized perforation caused by microorganisms. While microorganisms grown in laboratory culture tend to corrode steel specimens unevenly, they rarely inflict a corrosion morphology consistent with that of pipelines, where centimetre-sized corrosion features are randomly distributed within vast stretches of otherwise pristine metal surface. In this study, we observed that corrosion inhibitors (CIs), widely used for the control of acid gas (H₂S, CO₂) corrosion in oil fields, also affect microbial growth and activity. Inhibited carbon steel resisted biofilm formation and underwent negligible corrosion (< 0.002 mm Fe⁰ year⁻¹), despite 15 months of exposure to oil field waters harbouring a diverse microbiome. In contrast, physical scavenging of CI in these waters led to severe and highly localized corrosion (up to 0.93 mm Fe⁰ year⁻¹) underneath biofilms dominated by methanogenic archaea and sulfate-reducing bacteria. A sharp decline in CI concentration, as well as its active components, quaternary ammonium compounds (QACs), correlated with microbial sulfidogenesis. CIs are ubiquitously present in oil field waters and play an underappreciated role in microbial corrosion mitigation. Physical and biological scavenging of CIs may create local differences in steel inhibition effectiveness and thus result in highly localized corrosion.