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In the oil and gas industry, thermally sprayed aluminum (TSA) coatings are commonly used, primarily, to reduce anode demand in cathodic protection systems and impart some degree of sacrificial protection in the topsides and splash zone areas. The use of TSA coatings has advantages in systems where long service life is required. TSA coatings are also used to reduce the formation of calcareous deposits, normally a combination of CaCO3 and Mg(OH)2, on heat exchanger piping.
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Several components in geothermal power plants need to be protected from the environment due to the corrosive nature of geothermal fluids used to generate the energy. Depending on the fluid properties for any location, the type of protection varies. In geothermal power plants, wear, erosion, corrosion, and scaling are all known problems1. These issues can lead to a variety of outcomes, ranging from decreased plant efficiency to upstream component failure. Failure of a component is thus a significant challenge in the geothermal industry, where materials need to operate in high temperature and high pressure environments. A major cost factor is also linked to the drilling of geothermal wells, where cost rises due to increased depth/distance of drilling, increased trip times, higher high temperature and high-pressure conditions which can lead to increased wear and corrosion of the materials. To address the issue, coatings can be considered to be a potential solution to extend the service life of downhole equipment.