Abstract
Mild steel sample was selected from acid storage tanks used in industry as a substrate, and two advanced technological polymeric resin-based coatings were developed, designated as LAM-P resin based which is LAM-P/FR coating and LAM-V resin based which is LAM-V/FR coating. These coatings were applied over steel samples by using the hand lay-up process. FTIR test was conducted to confirm complete curing, and SEM analyses were used to investigate surface morphology. A series of electrochemical tests were performed in acidic environment (mixed acid solution 56% H2SO4 + 26% HNO3 + 18% H2O by weight). The results indicated successful development of LAM-P/FR and LAM-V/FR to obtain coatings with desirable characteristics such as anticorrosion, thickness, adhesion, stability, charge store and more resistance to acidic environments. EIS data for mixed acid storage media demonstrated that LAM-V/FR coating has higher strength in mixed acid solution, higher values of impedance and phase shift, higher value of Rpore, and low value of Cc; corrosion rate percentage reduction is 96% of LAM-P/FR and 99.96% of LAM-V/FR compared to bare mild steel sample. The outcomes of this study can lead to assist in design guidelines for anticorrosive coating for industrial applications.
Highlights
Corrosion is electrochemical decay of materials and is caused by the reaction between materials and aggressive or corrosive environments
The surface of mild steel was coated by protective polymer coatings
Broad-spectrum transmittance line at 1119 cm−1 shows the presence of C–O–C ester linkage, while peak at 1719 cm−1 is characteristic peak of –C=O that con rmed the presence of ester group in polyester resin
Summary
Corrosion is electrochemical decay of materials and is caused by the reaction between materials and aggressive or corrosive environments. E annual cost of corrosion worldwide is estimated to be 2.2 trillion US dollars. National Association of Corrosion Engineers (NACE) estimated that the direct cause of corrosion in the United States was 276 billion dollars in 2014, approximately 3.1% of gross domestic product (GDP). By including the indirect losses of corrosion, it was estimated to exceed 1 trillion US dollars. Corrosion with in acid storage tank is dependent on several factors such as temperature, concentration of corrosive constituents, operational condition, and the purity of acids being used [2]. Mild steel corrosion rate in 95% H2SO4 is 5–20 mm/year when the temperature is less than 25°C. is depends on the material from which the tank is made and the purity of the received acid [3]
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