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Calcareous Deposition On Thermally Sprayed Aluminium Surfaces

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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.

Product Number: 51322-17798-SG
Author: Edgar Hornus, Francisco Vouilloz, Yu Long, Mobin Salasi, Mariano Iannuzzi, Kjetil Andersen, Ola Krosness, Mike King, Roy Johnsen
Publication Date: 2022
Industries: Cathodic Protection , Corrosion Monitoring and Control , Coatings
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The formation of calcareous deposits on thermally sprayed aluminum(TSA)-coated surfaces immersed in natural seawater and connected to a cathodic protection system is a recurring issue. Calcareous deposition has occurred even though TSA coatings have a lower cathodic over potential compared with carbon and stainless steels, which should reduce the thermodynamic precipitation driving force. There is at present limited knowledge on the calcareous deposits’ formation kinetics on TSA in natural seawater following prolonged exposure at different temperatures. In this study, bare 25Cr super duplex stainless steel (SDSS) and TSA-coated SDSS samples (with and without an silicone-based sealer) were exposed to natural seawater under potentiostatic cathodic protection (CP) and open circuit potential (OCP) conditions at different temperatures (i.e., 20, 35, 60 and 80°C) for 1.5 years. Samples were extracted at various intervals to construct growth kinetics curves under the various test conditions. The deposits were subsequently examined using scanning electron microscopy, energy dispersive spectroscopy and X-ray diffraction. Lastly, recommended CP protection potentials and current density values were obtained based on the findings of this study.

The formation of calcareous deposits on thermally sprayed aluminum(TSA)-coated surfaces immersed in natural seawater and connected to a cathodic protection system is a recurring issue. Calcareous deposition has occurred even though TSA coatings have a lower cathodic over potential compared with carbon and stainless steels, which should reduce the thermodynamic precipitation driving force. There is at present limited knowledge on the calcareous deposits’ formation kinetics on TSA in natural seawater following prolonged exposure at different temperatures. In this study, bare 25Cr super duplex stainless steel (SDSS) and TSA-coated SDSS samples (with and without an silicone-based sealer) were exposed to natural seawater under potentiostatic cathodic protection (CP) and open circuit potential (OCP) conditions at different temperatures (i.e., 20, 35, 60 and 80°C) for 1.5 years. Samples were extracted at various intervals to construct growth kinetics curves under the various test conditions. The deposits were subsequently examined using scanning electron microscopy, energy dispersive spectroscopy and X-ray diffraction. Lastly, recommended CP protection potentials and current density values were obtained based on the findings of this study.

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