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Integrated Coating System for Corrosion Protection of Carbon Steel in Artificial Geothermal Brine
(2022)
Corrosive geothermal brines are a major challenge to geothermal power-plants. For cost reasons, plant designers prefer to use carbon and low alloyed steels, which are susceptible to uniform and localized corrosion when exposed to geothermal brines having acidic and saline properties. To solve such problem, coatings or inhibitors would be a protective solution as an alternative to the use of high alloyed materials.
This study investigated a coating system consisting of polyaniline/silicon dioxide based on resources locally available in Indonesia. Protection against corrosion of carbon steel was shown by long-term (28 day) exposure and electrochemical tests of coated carbon steels, performed in an artificial acidic and saline geothermal brine, comparable to the conditions encountered at a site in Indonesia.
Therefore, an integrated coating system is proposed for corrosion protection, combining the electrochemical functionality of polyaniline and the physical advantages of silica.
The suitability of an Al2O3 coating for corrosion protection on X20Cr13 was evaluated in various artificial geothermal brines, focusing on the influence of different pH (4, 6 and 8) and their chemical compositions on the coating properties. All experiments were performed in the laboratory using autoclaves at 150 ◦C and 1 MPa in deaerated condition for 1 and 7 days. Results showed that the pH of geothermal waters is the most detrimental factor in the transformation of ɣ-Al2O3 and its protective abilities. Delaminations were found in the Coating exposed to geothermal brines with pH 4. FTIR spectra indicated a transformation of ɣ-Al2O3 to boehmite AlOOH after exposure to pH 4 and 6, and bayerite Al(OH)3 was formed after exposure to pH 8. Different Crystal structures of the hydrated Al2O3 also contribute to the stability of the coatings, observed by the SEM- EDX of the surface and cross-section of coatings. This study indicated that ɣ-Al2O3 sol-gel coating presents a promising aspect of corrosion protection in geothermal environment with a neutral pH.
This paperback issue of the 2007 hardcover version within the “Corrosion Engineering Handbook” series presents various materials and methods for controlling and protecting against corrosion instead of using expensive alloys to construct a tank or processing vessel.
This book is a very comprehensive collection of the current knowledge about applied linings and coatings. So, it fulfills its intension, “that regardless of what is being built, … information for … whoever is responsible for the selection of material of construction will be found in this book to enable them to avoid unnecessary loss of material through corrosion”, to a very large extent.
This book introduces to aspects to be considered when dealing with coatings and linings. Philip A. Schweitzer covers and compares a variety of specific coatings and their applications. In 18 chapters he divided the content into two main parts: linings and coatings.
All professionals involved in design and maintenance processes get by this book a compact survey of necessary considerations which needs to be done when applying surface protection measures. The literature references at the end of some chapters support the readers finding additional information about the special topic, mainly written by the author himself. Since this newly issued paperback edition is a 1:1 re‐print of the 2001 hardcover version, neither current publications are referenced, nor revisions were made.
This book by Scrivener Publishing contains 14 chapters written by 82 leading scientists, experienced in the field of coatings. They demonstrate mechanisms, usage and manipulation of cutting‐edge coating methods. Each chapter is well structured and ends with a conclusion, highlighting the content. The book is divided into 3 parts: “Materials and Methods”, “Coating Materials Nanotechnology” and “Advanced Coating Technology and Applications”.
Finally, this book provides a comprehensive insight into innovative research in advanced coating materials and state‐of‐the‐art technologies, without being a real textbook. It fulfills its intension of being beneficial both for technicians and scientists.
This book grew out of a course on polymer coatings held by the author at the university. It shall serve as an introduction to the wide field of polymer coatings. It is not intended to cover completely all facts on polymer coatings.
All chapters are well structured. Selected figures and formulas illustrate the content and contribute to a good understandability. At the end of each chapter some hints for further reading are provided.
Finally, the book fulfills its intention to introduce into the topic by providing basics on science and technology of polymer coatings, suitable for chemists in industry, materials scientists, polymer chemists and physical chemists.
According to the results of the experiments carried out, the following points can be concluded:
1. Exposure tests showed that specimens with the addition of SiO2 particles and polyaniline particles exhibit better corrosion resistance than specimens with the addition of only polyaniline particles or binder only.
2. Open circuit potential measurements showed that in the beginning of the experiments, both coatings had an open circuit potential 100 mV higher than carbon steel. Within one day of immersion, the potential of carbon steel increased significantly, indicating the formation of oxide layer. After extended exposure the carbon steel potential sat between PS1 (which had higher potential) and PS2 (which had a lower potential) and all three were in the range –600 mV to –500 mV vs Ag/AgCl.
3. Both coatings PS-1 and PS-2 were degraded with increasing exposure time, shown by the decrease of absolute impedance value at low frequency range after 2, 4, and 6 days exposure.
4. Potentiodynamic test was performed after 3 hours and 6 days exposure, and it was shown that the coating in the initial stage exhibited more passive behavior than the specimens exposed for 6 days.
This book provides a state‐of‐the‐art overview on the processing, characterization, and modelling of metallic and ceramic materials used for energy and environmental applications. 17 scientists show a collection of current knowledge in 8 chapters.
This book fulfills its intention to provide a reference book containing a collection of publications on thin films and coatings made of ceramic and metals used for energy and environmental applications. It covers a broad range of this topic and provides a comprehensive insight. Graduate and undergraduate students of materials science and mechanical engineering can find an overview on this topic to step in this interesting field of engineering.
In this work, the focus was set on the corrosion process of condensate as drops on the surface of carbon steels (X52, X70), martensitic steel UNS S41500, and superaustenite UNS N08031 in CO2 atmosphere with impurities at 278 K (to simulate the transportation condition in a buried pipeline). Exposure tests were performed at both normal pressure and high pressure where CO2 is supercritical or in dense phase. The drop, 1 ‑ 10 μL in volume, was prepared by dropping CO2 saturated ultra-pure water onto the surface of steel coupons in a one-liter-autoclave. The CO2 gas stream, simulating the oxyfuel flue gas with varying concentration of impurities (SO2 and O2 ), was then pumped into the autoclave to observe the condensation and corrosion impacts of impurities. Comparable exposure tests were carried out with the same gas mixture and the same volume of water as vapor to observe the drop formation and the corrosion process that follows. The wettability and stability of drops on the surface of steel coupons in CO2 supercritical/dense phase environment was evaluated additionally by contact angle measurement.
Geothermal brine is a complex system containing a wide variety of dissolved salts resulting from the condition s in a geothermal well. These fluids lead to corrosion in pipes and other parts of geothermal system construction and necessitate intense research efforts in finding new suitable materials. Carbon steel is susceptible to corrosion in geothermal brine especially when it is exposed to a high temperature and high-pressure medium, which is considered to be an aggressive environment. An artificial geothermal water, bas ed on a brine composition found in Indonesia, was used to investigate the performance of high alloyed materials. The electrolyte has pH 4 and contains 1,500 mg/l Cl-, 20 mg/l SO4 2-, 15 mg/l HCO3 -, 200 mg/l Ca 2+, 250 mg/l K+, and 600 mg/l Na+. In order to protect the bare material in geothermal application, it is necessary to either use high alloyed material s or coatings. In this research, a coating system consisting of polyaniline and silicon dioxide was investigated regarding its behavior to protect carbon steel. In detail, the effect of SiO2 and polyaniline (PANi) addition was evaluated by exposure and electrochemical tests for 7 days, i.e. electrochemical impedance spectroscopy (EIS) and open circuit potential (OCP ) at room temperature and 150 °C with 1 MPa pressure .
Finally it can be summarized that this book fulfills its intention of providing theoretical background and examples for practical applications of coatings used for corrosion protection.
It can be recommended to those being interested in coatings, serving as an overview on aspects which needs to be considered when working with such systems.