Asking ChatGPT to Provide Consulting on Solving a User’s
Problem Regarding Reciprocating Gas Compressors in
Corrosive CO2 Gas Service; By Abdulrahman Alkhowaiter
The results were not very accurate at first; Initially ChatGPT answers correctly regarding
general statements about CO2 corrosion impact. However once ChatGPT tries to be a
consulting engineer down to selecting metallurgy for the affected parts, it gets half of the
component material selections wrong.
However, when I started correcting ChatGPT in its report, it produced excellent answers, with
the guidance of this human consultant. Its almost like I am reviewing a junior engineers
report.
Question posed to ChatGPT: You are an expert in reciprocating gas compressors. I ask that
you produce a technical analysis report of at least 30 sentences on the following subject;
The subject is; can a compressor user take a used reciprocating gas compressor that is
designed for compressing H2S gas mixtures at 20 mole%, and use that for a different gas that
has 25% CO2 gas? Please discuss technical suitability and what changes in compressor are
needed if any, for the metallurgy and which parts specifically need certain alloys? please
specify the alloys needed.
ChatGPT replied with following report: Technical Analysis Report: Suitability of a Used
Reciprocating Gas Compressor for Compressing CO₂ Gas Mixtures
Page 1 of 10
Asking ChatGPT to Provide Consulting on Solving a User’s
Problem Regarding Reciprocating Gas Compressors in
Corrosive CO2 Gas Service; By Abdulrahman Alkhowaiter
Introduction:
Reciprocating gas compressors are commonly employed in industries where compression of
gases under varying conditions is required, including hazardous environments. A compressor
that has been previously used for compressing a gas mixture containing hydrogen sulfide (H₂S)
at 20 mole% and is being considered for use with a new gas mixture containing 25% carbon
dioxide (CO₂) requires careful technical evaluation. This report explores the technical
suitability of such a compressor for this new application, focusing on the potential changes
needed to ensure safe, efficient operation, particularly with respect to metallurgy, material
selection, and component compatibility.
Suitability of the Compressor for CO₂:
Reciprocating compressors designed for H₂S mixtures must be constructed to handle the
specific corrosive and abrasive properties of hydrogen sulfide. The introduction of CO₂, while
not as corrosive as H₂S, still presents challenges due to its own corrosive properties and the
potential for the formation of carbonic acid (H₂CO₃) in the presence of water. Additionally,
CO₂ can lead to material degradation, particularly in high-pressure environments, and can
cause issues such as stress corrosion cracking or pitting.
Key Differences Between H₂S and CO₂ Mixtures:
Corrosivity: H₂S is more corrosive than CO₂, but CO₂ poses a different set of corrosion risks,
especially under high-pressure conditions and when moisture is present.
Component Stress: CO₂ can create high-pressure environments leading to possible stress on
compressor components, and under certain conditions, can exacerbate metal fatigue.
Moisture Handling: CO₂ mixtures with higher moisture content may lead to the formation of
carbonic acid, which is mildly corrosive to certain metals, requiring careful control of water
levels and proper material selection.
Metallurgical Considerations:
The critical concern when switching from an H₂S mixture to a CO₂ mixture is ensuring that the
compressor’s materials are compatible with CO₂’s potential to cause corrosion, stress
corrosion cracking, and material fatigue over time.
Components Affected by CO₂ Exposure:
Cylinder and Piston Components: These components are most directly exposed to the gas
mixture and are susceptible to corrosion, fatigue, and wear. Therefore, the material selection
for these parts needs to be carefully considered.
Page 2 of 10
Asking ChatGPT to Provide Consulting on Solving a User’s
Problem Regarding Reciprocating Gas Compressors in
Corrosive CO2 Gas Service; By Abdulrahman Alkhowaiter
Valve Components: Valves within the compressor are particularly vulnerable to the corrosive
effects of CO₂, especially under high pressure.
Seals and Gaskets: These components need to be resistant to both the pressures involved and
the corrosive effects of CO₂, which can degrade some standard elastomers.
Material Selection and Alloys:
To ensure safe and reliable operation when converting a compressor from handling H₂S to
CO₂, certain materials must be chosen for their resistance to CO₂-induced degradation,
particularly when moisture or acidic conditions are present. The key components requiring
material upgrades are the cylinder, piston, valve components, and seals.
Cylinder and Piston:
Recommended Alloy: Stainless steel alloys, particularly 304L or 316L, offer excellent corrosion
resistance in CO₂ environments. These grades are known for their high resistance to stress
corrosion cracking, which is essential for compressor components exposed to high-pressure
CO₂. {Author comment: this selection is a partially technically correct selection although it
is not necessary [and very expensive] to use 300 series stainless steel Cylinders for lubricated
cylinders, only may be required in dry cylinder non-lubricated applications, with wet CO2
gas services. Majority of CO2 services will do well with NI Resist Ductile cast iron liners.
However, for the pistons its correct that 316 or 304 SS are recommended materials for Wet
CO2 services.]
Other Considerations: In some high-pressure applications, duplex stainless steels such as 2205
or 2507 may be more suitable, as they offer superior resistance to both general corrosion and
pitting. These materials are also highly resistant to chloride stress corrosion cracking, which
is critical in environments where moisture is present.
Author comment; ChatGPT missed providing any correct metallurgy for the piston rods.
Valve Components:
Recommended Alloy: Inconel 625 [ very expensive, its overkill; but can work] or Monel 400
are nickel-based alloys commonly used in corrosive gas environments like CO₂. These
materials offer exceptional resistance to a wide range of aggressive gases, including CO₂, and
have a high degree of strength at elevated temperatures.
Other Considerations: 316L stainless steel can also be used for valves, but special care should
be taken regarding the specific operating conditions (such as temperature and pressure)
when choosing this alloy. [No: 316 SS is too soft as a valve seat, will fail early. No mention
of the valve soft parts materials selection such as plates or rings/poppets.]
Page 3 of 10
Asking ChatGPT to Provide Consulting on Solving a User’s
Problem Regarding Reciprocating Gas Compressors in
Corrosive CO2 Gas Service; By Abdulrahman Alkhowaiter
Seals and Gaskets:
Recommended Material: Seals and gaskets need to be resistant to CO₂ and other
environmental factors. Elastomers such as Viton® or Kalrez® are ideal for high-pressure CO₂
applications due to their chemical resistance and durability in sealing applications.
Other Considerations: For more severe conditions, PTFE (Polytetrafluoroethylene) seals or
gaskets can be used as they have excellent resistance to CO₂ and offer a wide temperature
range. However, PTFE may require additional support or encapsulation to avoid damage due
to the high-pressure environment.
Additional Components:
Bearings: Bearings should be made from materials like chrome steel or ceramic composites
to handle the wear conditions imposed by the compressing environment. Ceramic bearings
are especially useful in handling corrosive gases without suffering degradation. [No: incorrect
material selection, it thinks it’s a Screw compressor with rolling element bearings].
Lubricants: The lubricant used in the compressor should also be compatible with CO₂ to
prevent degradation. Synthetic lubricants that provide a higher level of protection against
oxidation and wear are recommended for such applications.
Modifications to the Compressor:
While most of the changes needed for the compressor involve upgrading the materials in
direct contact with the gas, several operational changes may also be necessary:
Moisture Control: A compressor handling CO₂ should have a highly efficient moisture removal
system in place to prevent the formation of carbonic acid. This includes moisture separators,
dehydration systems, and regular maintenance of the water vapor removal equipment.
Pressure Management: The compressor’s pressure ratings and operating conditions must be
reviewed to ensure that they are suitable for the CO₂ gas mixture, as CO₂ can be more
aggressive in higher-pressure environments.
Cleaning and Passivation: The compressor should undergo a thorough cleaning and
passivation process before it is repurposed for CO₂. This ensures that any residual H₂S or
corrosive compounds from the previous application are completely removed, preventing
potential contamination of the new gas mixture.
Conclusion:
The use of a reciprocating gas compressor designed for H₂S gas mixtures at 20 mole% in a CO₂
application with 25% concentration is technically feasible but requires careful consideration
of material compatibility, corrosion resistance, and mechanical integrity. Specific components
Page 4 of 10
Asking ChatGPT to Provide Consulting on Solving a User’s
Problem Regarding Reciprocating Gas Compressors in
Corrosive CO2 Gas Service; By Abdulrahman Alkhowaiter
like cylinders, pistons, valves, and seals require replacement with more corrosion-resistant
alloys like 316L stainless steel, Inconel 625, and Viton® for seals. Proper moisture control,
pressure management, and routine maintenance will also be necessary to ensure safe and
efficient operation.
Comment by Author: Here we see several errors by ChatGPT, some suggested material
selections by ChatGPT were wrong, as it only looked at CO2 corrosion resistance, but did
not look at the other critical mechanical properties needed on those same parts. Next we
return to ChatGPT and explain that it made errors, and then we explain to it which errors
occurred, and each time ChatGPT responds with a very correct answer.
My new comment to ChatGPT: Overall, the report is 75% accurate, you made errors in some
material selections.
ChatGPT said:
Thank you for the feedback! I appreciate the opportunity to refine the report. Please let me
know which material selections were incorrect or need further clarification, and I'll revise the
analysis accordingly.
You said:
1- The cylinders can be of ductile cast iron, with Ni Resist ductile cast iron liners, if the
cylinder is oil lubricated. It is not necessary to use 304 or 316 SS materials unless it is a wet
CO2 gas, plus cylinder is non-lubricated.
ChatGPT said:
Thank you for the clarification! You’re absolutely right, and I appreciate you pointing that out.
For cylinders in a reciprocating gas compressor operating in CO₂ environments, the material
selection indeed depends on factors like lubrication and moisture content.
Corrected Cylinder Material Recommendations:
1. Ductile Cast Iron: In oil-lubricated compressors, ductile cast iron is a common material
choice due to its excellent mechanical properties, wear resistance, and ability to
handle high-pressure gas environments. The addition of Ni Resist ductile cast iron
liners provides additional protection against corrosion, particularly in the presence of
CO₂ and mild acids.
2. Stainless Steel Use: Stainless steels like 304L or 316L are typically recommended for
situations where the gas mixture contains high moisture content or when the
compressor is non-lubricated. In such cases, these stainless steels provide enhanced
corrosion resistance. However, as you pointed out, if the system is oil-lubricated and
Page 5 of 10
Asking ChatGPT to Provide Consulting on Solving a User’s
Problem Regarding Reciprocating Gas Compressors in
Corrosive CO2 Gas Service; By Abdulrahman Alkhowaiter
the CO₂ is dry, there may not be a need for stainless steel unless the gas environment
is wet (where moisture or acidic conditions are present).
Revised Cylinder Material Selection Summary:
• For oil-lubricated applications and dry CO₂ gases, ductile cast iron with Ni Resist ductile
cast iron liners would be a more suitable choice. This material offers good wear
resistance and can withstand the pressures involved in compression without the need
for the more expensive stainless steels.
• 304L or 316L stainless steel would only be necessary in a non-lubricated system or if
the gas mixture is particularly wet or acidic, where corrosion concerns are heightened.
I hope this adjustment better aligns with your expectations. Would you like me to revise any
other sections of the report based on additional insights?
You said:
Your answer above is 100% correct. Next the Piston Rods: This component was missed in
your report; such Rods in CO2 services should be made of AISI-400 series SS or 17-4 PH SS.
ChatGPT said:
Thank you for pointing out the omission regarding piston rods. You're absolutely right—this
component is crucial, and I appreciate the opportunity to correct and expand on the report.
Piston Rod Material Selection for CO₂ Service:
In a reciprocating compressor, the piston rods are subjected to significant stress, wear, and
potential corrosion from the gas being compressed. In the case of CO₂ service, piston rods
must be made from materials with high tensile strength, good resistance to wear, and
corrosion resistance to avoid degradation over time.
For CO₂ environments, particularly when dealing with dry or mildly moist CO₂, the following
materials are suitable:
1. AISI 400 Series Stainless Steel (Martensitic Stainless Steel):
o AISI-410 or AISI-420 are examples of martensitic stainless steels within the 400
series. These materials offer high strength, moderate corrosion resistance, and
excellent wear resistance, which are critical for the harsh operating conditions
of CO₂ service.
o These alloys are preferred when the compressor operates in a moderately
corrosive environment with minimal moisture or acidic conditions. The
Page 6 of 10
Asking ChatGPT to Provide Consulting on Solving a User’s
Problem Regarding Reciprocating Gas Compressors in
Corrosive CO2 Gas Service; By Abdulrahman Alkhowaiter
increased strength from martensitic stainless steels also ensures the piston
rods can withstand the mechanical stresses during compression.
2. 17-4 PH Stainless Steel (Precipitation-Hardening Stainless Steel):
o 17-4 PH SS is a precipitation-hardened stainless steel alloy that combines
excellent mechanical properties (high tensile strength and hardness) with good
corrosion resistance, making it ideal for CO₂ service in high-pressure
applications.
o It is highly resistant to stress corrosion cracking (SCC), which is crucial in CO₂
environments where slight moisture content can lead to corrosion risks.
o 17-4 PH is commonly used in critical applications where strength and
resistance to corrosive environments are required, such as in aerospace,
chemical processing, and high-pressure gas compressors.
Piston Rod Material Summary:
• For CO₂ service, AISI 400 series stainless steel (specifically AISI-410 or AISI-420) or 17-
4 PH stainless steel would be ideal for piston rods. These materials provide the
necessary strength, wear resistance, and moderate corrosion resistance to ensure the
component’s longevity and operational reliability under typical CO₂ compression
conditions.
Additional Considerations:
• Coatings: For even further protection against wear and corrosion, piston rods can be
coated with hard chrome plating or nitriding to improve surface hardness and provide
an additional layer of protection against corrosion.
• Seals and Bearings: As piston rods interact with seals and bearings, it’s essential to
ensure that these components are also made from materials compatible with CO₂
service, such as Viton® for seals or ceramic bearings for added durability.
Thanks again for highlighting the importance of piston rods, and I'm glad we could correct
and update that section. If there are any further details you'd like to address or refine, feel
free to let me know!
You said: Next you mentioned using Inconel for the Cylinder valves. Actually, Inconel is very
expensive although it can work well. However, for corrosion resistance and lower price, its
best to use instead Hardened AISI-420 Martensitic SS.
Page 7 of 10
Asking ChatGPT to Provide Consulting on Solving a User’s
Problem Regarding Reciprocating Gas Compressors in
Corrosive CO2 Gas Service; By Abdulrahman Alkhowaiter
ChatGPT said:
Thank you for your valuable input! You’re absolutely correct regarding the material selection
for cylinder valves in CO₂ service. While Inconel offers excellent corrosion resistance, its high
cost may not always justify its use when other materials, such as AISI-420 Martensitic Stainless
Steel, can provide comparable performance at a lower cost.
Corrected Material Selection for Cylinder Valves:
1. AISI-420 Martensitic Stainless Steel:
o AISI-420 is a martensitic stainless steel known for its high hardness, good
corrosion resistance, and excellent wear resistance. It is often used in
applications requiring high strength, good mechanical properties, and
moderate corrosion resistance in environments such as CO₂ compression.
o In CO₂ service, particularly where the gas is dry or has low moisture content,
AISI-420 provides a good balance between cost and performance. This material
offers excellent resistance to CO₂-induced corrosion and wear, making it a
suitable and more economical alternative to Inconel.
o AISI-420 is also hardenable, meaning it can achieve high surface hardness
through heat treatment, which helps improve its wear resistance and longevity
in valve applications.
2. Inconel (for high-performance, critical applications):
o While Inconel (e.g., Inconel 625 or Inconel 718) offers superior resistance to a
wide range of corrosive environments, including CO₂, it is often cost-
prohibitive for many standard compressor applications. Inconel is typically
reserved for severe environments or applications with extreme temperature
variations or highly corrosive mixtures.
o In applications where cost is a significant factor and the corrosive environment
is manageable, AISI-420 provides sufficient corrosion resistance at a much
lower cost.
Material Selection Summary for Cylinder Valves:
• For CO₂ service, Hardened AISI-420 Martensitic Stainless Steel is a more cost-effective
alternative to Inconel. It provides adequate corrosion resistance, good strength, and
excellent wear resistance for valve components in dry or mildly moist CO₂
environments.
Page 8 of 10
Asking ChatGPT to Provide Consulting on Solving a User’s
Problem Regarding Reciprocating Gas Compressors in
Corrosive CO2 Gas Service; By Abdulrahman Alkhowaiter
• Inconel remains a strong option for highly critical or extreme conditions, but AISI-420
is typically preferred in standard applications for its lower cost while still offering
excellent corrosion resistance and durability.
Additional Recommendations:
• Heat Treatment: For AISI-420, ensuring proper heat treatment (hardening and
tempering) is critical to achieve optimal hardness and wear resistance, especially for
valve components that undergo frequent contact and mechanical stress.
• Surface Coatings: In applications where wear resistance and additional corrosion
protection are needed, hardened coatings such as nitride coatings or chrome plating
may further enhance the longevity and performance of valve components.
This revision should better reflect the cost-effective and performance-oriented choices for
valve materials. I’m glad to make these updates based on your valuable feedback. If there's
anything else you'd like to address or clarify, please let me know!
You said:
Next, you mentioned using 316 SS for valves; this may be correct as a cage material but not
for the valve seat as it is not a hard material, so it will wear down from valve impact.
ChatGPT said:
Thank you again for your insightful feedback! You’re absolutely right—316 SS can be suitable
for certain components of the valve, like the valve cage, but it is not ideal for the valve seat
due to its relatively low hardness, which makes it susceptible to wear from the impact of the
valve during operation.
Corrected Material Selection for Valve Seats:
For valve seats in CO₂ compressors, materials need to have a high degree of hardness to resist
wear and impact fatigue from the valve's repetitive motion. Since 316 SS is a relatively softer
material, it is prone to wear and deformation under these conditions. Instead, more wear-
resistant alloys should be used for valve seats.
1. Hardened Stainless Steel (e.g., AISI-420 or AISI-440C):
o AISI-420 (Martensitic SS) or AISI-440C (high-carbon martensitic stainless steel)
are ideal choices for valve seats because they can be hardened through heat
treatment to achieve higher wear resistance. These materials maintain
Page 9 of 10
Asking ChatGPT to Provide Consulting on Solving a User’s
Problem Regarding Reciprocating Gas Compressors in
Corrosive CO2 Gas Service; By Abdulrahman Alkhowaiter
sufficient corrosion resistance while offering the necessary hardness and
strength to withstand the impact and repetitive motion of the valve.
o AISI-440C in particular offers excellent hardness (up to 60 HRC after heat
treatment), which is critical for valve seat applications where wear and
deformation need to be minimized.
2. Carbide-Infused Alloys (e.g., Stellite® or Tungsten Carbide):
o In some high-performance applications, Stellite® or Tungsten Carbide can be
used for valve seats. These materials are extremely hard and wear-resistant,
making them highly suitable for compressors under high stress and wear
conditions.
o Stellite® (an alloy based on cobalt-chromium) is commonly used for valve seats
because it offers outstanding resistance to wear, erosion, and corrosion. It is
especially beneficial in environments where high-impact contact between the
valve and seat is frequent.
Material Selection Summary for Valve Seats:
• Valve seats in CO₂ compressors should be made of hardened AISI-420 or AISI-440C
stainless steel, as these materials offer the necessary hardness and wear resistance.
• Carbide-infused alloys such as Stellite® or Tungsten Carbide can be used in high-
performance or severe-duty applications where superior wear resistance is required.
Material Use in Other Valve Components:
• As mentioned earlier, 316 SS is suitable for the valve cage due to its corrosion
resistance and adequate mechanical properties in non-wear-intensive parts.
• Valve stems can also be made from AISI-420 or 17-4 PH stainless steel to ensure high
strength, resistance to stress, and durability against wear.
Conclusion:
• For valve seats, hardened stainless steel such as AISI-420 or AISI-440C, or carbide-
infused alloys like Stellite® or Tungsten Carbide, would be ideal choices to ensure
minimal wear from valve impact.
• 316 SS can be used effectively for valve cages but should not be used for valve seats
due to its relative softness.
Thank you again for your valuable input! Please let me know if any other components or
aspects need further clarification or adjustment.
Page 10 of 10