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Left unprotected, metals corrode quickly which over time contributes to the loss of structural integrity and the failure of buildings, bridges, oil & gas platforms, airplanes, cars and many other metal assets, all of which pose a risk to human safety and the surrounding environment. In 2016, the National Association for Corrosion Engineers (NACE) – now known as AMPP – published a landmark study, well-known to those attending this conference, that estimated the direct cost of corrosion to the world economy as $2.5T per year, equivalent to 3.4% of the Gross World Product (1). In the United States, the annual cost of corrosion is estimated at 3.1% of gross domestic product (2), equivalent to $635B (2018). When including indirect costs, such as asset downtime, ship dry-docking and the impact of bridge collapses, the cost of corrosion is estimated at twice that amount.
The authors have developed a new class of patent-pending multifunctional smart additives that deliver performance features like corrosion resistance, water repellency and surface selfcleaning for water-based, solvent-based or powder coatings. Upon exposure to changes in pH caused by metal corrosion, the additives release encapsulated corrosion inhibitors preventing further metal deterioration. Simultaneously, they impart hydrophobicity to coatings, preventing water intrusion and resulting in surface self-cleaning effects. This multifunctionality delivers longlasting corrosion protection without the use of heavy metals or other hazardous materials. The patent-pending platform technology allows for use of numerous types of corrosion inhibitors, thereby complying with current environmental regulation and allowing for compliance with future regulation, as well the opportunity to specifically target different metal alloys. Presented ASTM B117 salt spray testing demonstrates that these smart additives improve the corrosion protection performance of powder based, waterborne and solventborne coatings on carbon steel panels, presenting a step forward in corrosion protection for the coatings industry.
Seawater injection is commonly utilized for offshore wells to maintain or increase oil production; however, treatment for seawater before injection is always necessary to reduce or remove bacteria, dissolved oxygen, sulfate, and other impurities. Seawater typically has >2000 mg/L sulfate. Without proper sulfate removal, such high levels of sulfate can cause not only barium sulfate, strontium sulfate, and calcium sulfate scales, but also reservoir souring and H2S corrosion in the presence of sulfate reducing bacteria (SRB). Therefore, sulfate removal from seawater is critical before seawater injection into reservoir.
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Many asset owners struggle to identify the root cause of fluctuating corrosion rates due to unreliable inspection data. Facilities worldwide are tasked with monitoring thousands of Condition Monitoring Locations (CMLs) with established NDE techniques such as manual ultrasonic testing and radiography. While these techniques can provide valuable “snapshots” of the condition of particular locations, limitations and inherent errors can compound leading to ill-advised decision making. Manually taken thickness data can vary greatly and result in unwarranted complacency or excessive and costly inspections.
The polycondensation of silicate to form colloidal silica is a well-known process. Silica formation takes place through an SN2-like mechanism that involves an attack of a mono-deprotonated silicic acid molecule on a fully protonated one. Thus, monomeric silicate species produce silicate dimers, and oligomers, and eventually form colloidal silica particles. Nevertheless, this straightforward silica chemistry can be profoundly affected by the presence of certain metal cations, such as calcium, magnesium, aluminum, and iron. When such cations are present in a process water they enhance the rate of polymerization of silicate ions and induce the formation of metal silicate precipitates.