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BASF has developed a novel crosslinking isocyanate-free coating technology based on carbodiimide chemistry. A polycarbodiimide crosslinker with suitable functionality for coating applications and ultra-low free monomeric isocyanate has been introduced to the market. We formulated a 60% solids industrial primer using the new isocyanate-free coating technology and applied it on different metal substrates.
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The author previously introduced a method to evaluate protective coatings using a novel segmented cell approach. (1) Briefly, the technique intended to monitor natural current exchange between isolated segments, coated or uncoated, to supplement visual rankings of coating performance. The goal was to predict failure earlier than might otherwise be visible or to distinguish between coatings that had a similar visual appearance at the end of the proscribed test period. The experimental design also allowed for the instrumented segments, which act as sensors, to be prepared and coated as intended for a real-world industrial exposure, i.e., the metallic surfaces could be abrasive blasted and painted unlike thin-film, foil-like sensors also explored for similar purposes.
Managing the equipment used to prevent external corrosion of buried structures is a critical component of effective corrosion control. Many repairs or replacements are reactive in nature, occurring after a failure. This can result in lack of cathodic protection, or anode beds being replaced prematurely at significant costs to the operator.
Super insulation granules (SIG) based on a fumed silica core can be formulated into coatings to achieve high thermal insulative efficiency performance. The basis of the super insulation functionality in coatings is derived from the specially engineered microporous structure, optimized density combined with high hydrophobicity which allows high filler loading levels, far above conventional fumed silica. The high thermal insulative efficiency comes from an innovative design leading to significant passivation of the three major pathways of heat transfer. Ultra-high loading of this mineral based filler with a minimized viscosity build-up allows the coating to achieve an outstanding thermal insulation value with spray quality application utility.
Horizontal directional drills (HDD) have become an essential pipeline construction tool for crossing spans of the right of way with obstructions such as wetlands, rivers and streams, railroads, roads, businesses, and high consequence areas (HCA). This trenchless technology allows a pipeline to be installed without open cutting the ground. Prior to any construction, geological surveys with core samples are performed to determine the optimum route for the HDD (Figure 1).
Seawater biofouling is a major threat in heat exchanger operations. It decreases the heat transfer efficiency and service life of heat exchangers1,2. The formation of deposits caused by biofouling on the heat exchanger metal surfaces increases surface roughness and decreases cross-sectional flow area, which leads to higher friction loss in fluid flow3,4. Mitigation methods, including surface scrubbing, fluidizing bed heat exchangers, cleaning-in-place and dosing anti-fouling chemicals, are the main ways to tackle biofouling5. Conventional approaches to treat biofouled components by periodic electrochlorination or acid flushes are costly and environmentally hazardous. Huge costs are associated with heat exchanger biofouling losses, but there is still a lack of research to develop heat-conducting antifouling coatings to heat exchangers3.
Pipeline under, solids deposition deposit corrosion (UDC) is a localized corrosion phenomenon that develops beneath or around solid deposits, which settle at the bottom of low flow/intermittent flow pipelines. These deposits are complex mixtures of water, organic, inorganic, and biological materials, and their composition can vary significantly depending on the properties of the product being transported and the operating conditions in the pipeline.
Transportation of energy carriers (not only oil & gas, but also hydrogen, ammonia, methanol, heating fluids) and carbon dioxide requires the use of extensive pipeline networks that are usually built in metallic materials which are subject to material degradation. Carbon steel being the most prevalent due to its properties, availability, cost, and references. Carbon steel as well as other metallic materials suffer from corrosion processes.
During the 72-year history of using high performance coating systems for pipe internal corrosion control, there has been a slow introduction of different resin chemistries that serve as the backbone of these coating systems. While phenolic resins systems were the primary starting point, it transitioned to include epoxies, novolacs, nylons, urethanes and others. As needs outside corrosion control like deposit mitigation and wear resistance arose, coatings based on other specialty resin chemistries, like from the fluoropolymer family, were developed.
Environmental, market, and cost pressures have led to the development of alternatives to conventional 2K polyurethane topcoats, including isocyanate-free binders. For example, 1- and 2K coating systems based on alkoxysilane chemistry find increased use in protective coatings.
For many corrosion-resistant alloys (CRA´s), crevice corrosion under gaskets, paint or O-rings required to define the exposed area and avoid solution contact with electrical connections interferes with measurements of the critical pitting potential (EPIT). This undesired and uncontrolled crevice corrosion occurs at a lower potential than the one for the onset of pitting corrosion. Many approaches have been used to avoid this artifact.