Abstract
In the oil and gas industry, the application of epoxy phenolic coatings has been the main route to obtain high heat resistance from coatings and to mitigate corrosion under insulation (CUI) of both insulated carbon and stainless steel pipes operating up to 200°C. These coatings, however, are sensitive to over-application, are prone to cracking and costly to repair when damaged. Additionally, if they are applied below 10°C epoxy phenolic coatings do not cure properly and can fail prematurely, and when applied close to this temperature, can impact shop heating costs, maintenance schedules, and productivity.
Highlights
In order to produce epoxy coatings, epoxy resins are used to cross-link a variety of curing agents
Bisphenol A resins have the lowest functionality (n = 1.9) of the three classes and are mainly used to produce solvent based and solvent free epoxy coatings for less severe environments. They can be co-reacted with high functionality curing agents to produce immersion grade coatings suitable for corrosion under insulation (CUI) services at temperatures up to ca 300°F (149°C)
Bisphenol F resins can be co-reacted with high functionality curing agents to produce greater, (a) crosslink density, (b) chemical resistance and (c) temperature resistance of the immersion grade epoxy
Summary
In order to produce epoxy coatings, epoxy resins are used to cross-link a variety of curing agents (e.g., amines, polyesters, mercaptans, fatty acids, and acrylics). The cross-link density, glass transition temperature (Tg), and thermal and chemical resistance of epoxy coatings may follow the rough order of epoxy novolacs > Bisphenol F-based (phenolic) epoxies > Bisphenol A-based epoxies. While cross-linked densities of epoxy coatings are related to the functionality and molecular length of their epoxy resins, it should be emphasized that the curing agent structure and reactivity plays a pivotal role in the thermal and chemical resistant properties of the film
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