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Controlling corrosion of steel is expensive. The direct costs of corrosion maintenance are estimated to be over 3% of GDP every year.1 Metallic zinc coatings provide very effective corrosion protection for steel by acting first as a barrier coating, keeping corrosive elements away from the steel, and secondly as a sacrificial anode.2 Should the zinc coating be compromised, accidentally by a scratch or on purpose with a drilled hole, the zinc will provide anodic protection to the exposed steel. Metallic zinc coatings can be pure zinc or zinc-based alloys and will be referred to generically as zinc coatings in the paper. Zinc coatings can be efficiently applied by thermal spraying, which involves projecting particles of semi-molten zinc onto the surface of the steel using compressed air. With thermal sprayed zinc (TSZ) coatings, there is no size limitation to the part to be coated, and the technology is fully portable, allowing easy field applications.
Above ground storage tanks display a large surface area that can often be covered in unsightly rust. A long-term coating is needed to reduce maintenance costs as scaffolding and tarping a tank for coating typically costs more than the actual blasting and re-painting costs. Thermal spray zinc (TSZ) duplex coatings have been shown to be highly durable. In a life cycle comparison with paint, the durability of metallic zinc coatings eliminates the repeat burdens of maintenance painting, significantly reducing the total cost of ownership of a structure. Furthermore, zinc coatings have significantly lower life cycle impact in terms of global warming potential, acidification potential, and photo-chemical ozone creation potential, providing a more sustainable corrosion maintenance strategy. A thermal spray zinc duplex coating applied with three aerial work platforms can eliminate the need for scaffolding and tarping and provide an economical and sustainable coating system with a service life typically exceeding 50 years.
This paper will provide recent corrosion data for stored chemicals. Duplex stainless steel corrosion curves obtained in nitric, sulfuric, phosphoric acids as well as several kinds of waters will be provided. In addition, atmospheric corrosion data obtained after 15+ years of sample exposures in several geographic areas will be shown. These results will be compared to those obtained with other materials commonly used for the construction of storage tanks.
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With the increased pollution and energy demand, industries are shifting towards cleaner and greener power generation source. Geothermal energy, where energy is derived from the sub-surface of earth, is an excellent and continuous source of energy. Despite having the potential of providing cleaner energy, there is a huge gap between the theoretical potential of geothermal power plants and their practical applications. Some of the major reasons are high power generation cost and poor efficiency of the plant.
The gap between fully immersed and ultra-thin film electrochemical measurements is wide, which suggests that the two conditions are independent of one another. There is a lot of work describing experiments, results, and trends regarding completely immersed electrochemical tests. However, in corrosion tests under thin electrolyte films, the information is not so abundant. A classical three-electrode cell used in conventional electrochemical tests cannot easily be scaled for immersion in electrolytes of micron thickness.