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The life of corrosion protection coating systems very often will not meet the design life of the steel structures they are supposed to protect. Decisions about corrosion protection coating selection are usually focusing on the costs for the initial application, ignoring the certain future maintenance costs. However, repeated maintenance operations, and resulting downtime, can add significantly to the total cost of ownership.
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According to the Petroleum Safety Authority (PSA) in Norway, corrosion under insulation (CUI) caused about 50% of all hydrocarbon leaks at onshore plants. In the case of Alberta’s oil sands, CUI has also been observed in thermal operations in above ground assets carrying emulsions, steam, hot water and/or warm water that are externally insulated to ensure safe and energy efficient operations. CUI has also been observed in oil sands mining operations in various piping systems and in tanks and vessels on structural supports and insulated support rings that are frequently in contact with soil or standing groundwater.
Surface layers often form on carbon steel surfaces in carbon dioxide (CO2) saturated environments and under certain conditions can offer corrosion protection to the underlying steel. One such layer, magnetite (Fe3O4) is a semiconductor, having a reported electrical resistivity of the order of 10-2 to 10-1 Ω∙cm and band gap of 0.1 eV. The conductive properties of Fe3O4 are of significant importance when understanding the corrosion behaviour of carbon steel, as Fe3O4 can readily establish a galvanic couple with the steel surface upon which it has formed.
Corrosion risk due to AC interference has been known to be a possibility for decades but really came to the awareness of pipeline industry professionals starting around 2000 to 2004. Prior to that time there were some lab simulations as well as some suspected incidents in actual field situations, but many in the industry resisted accepting this as a real risk even as late as 2012 or later. Part of the reluctance to view AC interference as a genuine corrosion risk was that corrosion directly attributed to AC interference had not really been seen in the century of buried pipeline management, as well as a lack of understanding as to how this interference produced or accelerated corrosion on the pipeline.
With growing concerns of climate change and carbon footprint, many companies and industries arelooking into ways to reduce their impact on the environment. For the coatings industry, this can beachieved by tackling a multitude of different sources that contribute to climate change such as energyconsumption, solvent emissions, and more. Recently, there have been more discussions on bio-basedraw materials and their contribution to meeting sustainability goals set by both resin and paintmanufacturers.
Corrosion’s destructive effects on critical steel infrastructure have costly economic and securityimplications for the United States. According to a NACE International report from 2001, the annualcorrosion costs in the United States industrial sector were $47.9 billion per year, with the largest portionstemming from the maintenance of critical utilities such as gas, water, electric, and telecommunications. Catastrophic failure due to corrosion jeopardizes the resilience of critical utilities, risking the interruption of service to millions and creates weak-points the nation’s homeland security.
Rare earth elements (REE) and lithium are metals that are considered critical materials due to their use in electronics, magnets, batteries, and a wide variety of industrial processes important for the economy and military preparedness. Today, these metals are commonly harvested as metal oxide, halide or hydroxide minerals. Fiber reinforced p with even greater design temperatures lastic (FRP) has been used with great success for more than 50 years to build corrosion resistant mineral processing equipment.
Mining is the essential process of extracting materials from the earth. It dates back to prehistoric times when the earliest humans mined flint, copper and gold. These basic materials were then used for tools, weapons, currency. Today, there is a wide array of mined products from the extraction of valuable materials. Mining is a growing industry with many varied processes and system designs depending on the extraction requirements, processing techniques, and restoration of the land after a mind is closed.
Syncrude is one of the largest operators in Canada’s oil sands industry, with an over 55-year history of innovation. Based in Fort McMurray, AB, Canada and with a large research and development (R&D) facility in Edmonton, AB, Canada, this joint venture company operated by Suncor Energy Inc. has pioneered many of the processes used in the industry. The production process starts with oil sands surface mining using shovels and trucks, followed by a crushing and screening process.
Produced water recycling for hydraulic fracturing (fracking) operations has been an increasingly common practice to support oil and gas development in the Permian Basin. Aside from the economic benefits associated with reusing the water produced which is a byproduct of oil and gas operations, recycling reduces both the need for sourcing water (brackish or fresh) from the environment as well as the volume of produced water requiring disposal. Produced water ponds support successful recycling by providing temporary storage of recycled water and volume buffer for fracking. Raw produced water is usually treated in recycling facilities before being stored in the ponds.
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.