Highly efficient eco-friendly corrosion inhibitor for mild steel in 5 M HCl at elevated temperatures: experimental & molecular dynamics study

Exploring the synthesis, characterization, and corrosion inhibition of new tris-thiosemicarbazone derivatives for acidic steel settings using computational and experimental studies

A novel two tri-thiosemicarbazones derivatives, namely 2,2',2''-((2-Hydroxybenzene-1,3,5-triyl)tris(methanylylidene))tris(N-benzylhydrazine-1-carbothioamide) (HBC) and 2,2',2''-((2-hydroxybenzene-1,3,5-triyl) tris (methanylylidene)) tris (N-allylhydrazine-1-carbothioamide) (HAC), have been synthesized and their chemical structures were determined using different spectroscopic and analytical approaches. Then, utilizing methods including open circuit potential, potentiodynamic polarization, and electrochemical impedance spectroscopy, the inhibitory effect of the synthesized thiosemicarbazones on mild steel (MS) in an acidic environment (0.5 M H2SO4) was thoroughly investigated. Remarkably, raising the concentration of our recently synthesized tri-thiosemicarbazones HBC and HAC increased the inhibitory efficiency values. The η values of the two investigated tri-thiosemicarbazones derivatives (HAC and HBC), at each concentration are extremely high, and the maximum values of the efficiencies are 98.5% with HAC and 98.8% with HBC at the 800 ppm. The inhibitors adsorbed on the mild steel surface and generated a charge and mass movement barrier that protected the metal from hostile ions. According to polarization curves, HBC and HAC act as mixed-type inhibitors. Electrochemical impedance testing revealed a notable rise in charge transfer resistance (Rct) readings to 4930-Ω cm2, alongside a reduction in the Constant Phase Element (CPE) value to 5.81 μF, suggesting increased effectiveness in preventing corrosion. Also, density functional theory (DFT) was applied to investigate the assembled tri-thiosemicarbazones HBC and HAC. Moreover, the adsorption mechanism of HBC and HAC on the mild steel surface was explored using Monte Carlo simulation. Finally, the theoretical outputs were discovered to support the practical outcomes.

Electrochemical and computational insights into the utilization of 2, 2- dithio bisbenzothiazole as a sustainable corrosion inhibitor for mild steel in low pH medium

Industries today place a high premium on environmentally friendly supplies that may effectively inhibit metal dissolution at a reasonable cost. Hence, in this paper, we assessed the corrosion inhibition effectiveness of the Thiazole derivative namely, 2, 2-Dithio Bisbenzothiazole (DBBT) against mild steel (MS) corrosion in 1 M HCl. Several experimental approaches, including gravimetric analysis, potentiodynamic polarization (PDP), electrochemical impedance spectroscopy (EIS), and surface exploration using scanning electron/atomic force microscopy (SEM/AFM) and contact angle (CA), were utilized to conduct the measurements. In 1 M HCl corrosive medium at 298 K in the subsistence of 800 ppm of DBBT, this experiment indicated DBBT as an environment-friendly and sustainable corrosion inhibitor (CI) for MS, demonstrating an inhibition efficiency (IE %) of 97.71%. To deliver a deeper knowledge of the mechanism behind inhibitive behavior, the calculated thermodynamic and activation characteristics were applied. The calculated Gibbs free energy values indicated that the CI interacted physically and chemically with the MS surface, validating physio-chemical adsorption. The findings of the EIS research revealed that an upsurge in the doses of the CI is escorted by an upsurge in polarization resistance (Rp) from (88.05 → 504.04) Ωcm2, and a diminution in double layer capacitance (Cdl) from (97.46 → 46.33) μFcm-2 at (50 → 800) ppm respectively, affirming the inhibitive potential of DBBT. Additionally, the greatest displacement in Ecorr value being 76.13 mV < 85 mV, indicating that DBBT act as a mixed-form CI. To study the further impacts of DBBT on the inhibition capabilities of the compound under investigation, density functional theory (DFT) and molecular dynamics (MD) simulation were employed. Chemical and electrochemical approaches are in agreement with the computational analysis indicating DBBT is the most efficient CI.

Exploring the Effectiveness of Natural Food Flavors in Protecting Carbon Steel against CO2-Induced Corrosion

Two food flavors, furfuryl mercaptan (2-FFT) and difurfuryl disulfide (DFDS), were investigated as green corrosion inhibitors for the N80 steel in a CO2-saturated solution containing 3.5% NaCl. Experimental methods, quantum chemical calculations, and molecular dynamics simulation were employed to evaluate the effectiveness of 2-FFT and DFDS. The results of the study indicate that both 2-FFT and DFDS act as mixed corrosion inhibitors, with a dominant inhibition effect on the cathodic reaction. 2-FFT is physiochemically adsorbed on the steel surface in a tiled form through the furan ring and the - SH groups as adsorption sites. On the other hand, DFDS is chemisorbed on the steel surface through the - S-S- groups in a parallel manner. DFDS exhibits a higher tendency for electron transfer and stronger adsorption to steel compared to 2-FFT. Overall, this study highlights the potential of natural food flavors as effective and environmentally friendly corrosion inhibitors for carbon steel in CO2-saturated environments. The findings of this research can contribute to the development of sustainable and nontoxic corrosion inhibitors for the oil and gas industry.

Investigation of synthesized ethyl-(2-(5-arylidine-2,4-dioxothiazolidin-3-yl) acetyl) butanoate as an effective corrosion inhibitor for mild steel in 1 M HCl: A gravimetric, electrochemical, and spectroscopic study

The corrosion inhibition effects of five concentrations (5E-5 M to 9E-5 M) of ethyl-(2-(5-arylidine-2,4-dioxothiazolidin-3-yl) acetyl) butanoate, a novel thiazolidinedione derivative code named B1, were investigated on mild steel in 1 M HCl using gravimetric analysis, electrochemical analysis and Fourier transform infrared spectroscopy. After synthesis and purification, B1 was characterized using nuclear magnetic resonance spectroscopy. All gravimetric analysis experiments were carried out at four different temperatures: 303.15 K, 313.15 K, 323.15 K and 333.15 K, achieving a maximum percentage inhibition efficiency of 92% at 303.15 K. The maximum percentage inhibition efficiency obtained from electrochemical analysis, conducted at 303.15 K, was 83%. Thermodynamic parameters such as ΔG°_ads showed that B1 adsorbs onto the MS surface via a mixed type of action at lower temperatures, transitioning to exclusively chemisorption at higher temperatures.

Inhibition Mechanism of Some Vinylalkylimidazolium-Based Polymeric Ionic Liquids against Acid Corrosion of API 5L X60 Steel: Electrochemical and Surface Studies

A corrosion inhibition mechanism of API 5L X60 steel exposed to 1.0 M H₂SO₄ was proposed from the evaluation of three vinylalkylimidazolium poly(ionic liquids) (PILs), employing electrochemical and surface analysis techniques. The synthesized PILs were classified as mixed-type inhibitors whose surface adsorption was promoted mainly by bromide and imidazolate ions, which along with vinylimidazolium cations exerted a resistive effect driven by a charge transfer process by means of a protective PIL film with maximal efficiency of 85% at 175 ppm; the steel surface displayed less surface damage due to the formation of metal-PIL complex compounds.

Formamidine-Based Thiuram Disulfides as Efficient Inhibitors of Acid Corrosion of Mild Steel: Electrochemical, Surface, and Density Functional Theory/Monte Carlo Simulation Studies

Electrochemical, surface, and density functional theory (DFT)/Monte Carlo (MC) simulation studies were used in investigating the characteristics of N,N'-(disulfanne-1,2-dicarbonothioyl)bis(N,N'-bis(2,6-dimethylphenyl)formimidamide) (DS1), N,N'-(disulfanne-1,2-dicarbonothioyl)bis(N,N'-bis(2,6-diisopropylphenyl)formimidamide) (DS2), N,N'-(disulfanne-1,2-dicarbonothioyl)bis(N,N'-dimesitylformimidamide) (DS3), and N,N'-(disulfanne-1,2-dicarbonothioyl)bis(N,N'-bis(2,6-dichlorophenyl)formimidamide) (DS4) as inhibitors of acid corrosion of mild steel. The inhibitors were found to effectively reduce the rates of steel dissolution at the anode as well as cathodic hydrogen evolution. The order of inhibition efficiencies of studied compounds is DS1 (PDP/LPR/EIS: 98.60/97.98/96.94%) > DS2 (PDP/LPR/EIS: 98.36/96.86/96.90%) > DS3 (PDP/LPR/EIS: 94.66/87.44/94.30%) > DS4 (PDP/LPR/EIS: 83.57/77.02/75.17%) at 1.00 mM, and the overall efficiencies appeared to depend on the molecular and electronic structures of the compounds. The compounds offered high resistance to charge transfer across the electrode/electrolyte system by forming adsorbed film whose resistance increased with an increase in concentration. Findings suggested that the adsorption process involved combined chemisorption and physisorption. DFT calculations and MC simulations provided theoretical justifications for the experimental results.

A Brief Review on Fruit and Vegetable Extracts as Corrosion Inhibitors in Acidic Environments

The corrosion of metals, i.e., the initiation and acceleration of the surface deterioration of metals through an electrochemical reaction with the surrounding intrusive environment, is a global concern because of the economic and environmental impacts. Corrosion inhibitors are considered the most practical choice among the available corrosion protection techniques due to their effectiveness in terms of functionality and cost. The use of traditional and toxic corrosion inhibitors has led to environmental issues, arousing the need for green counterparts that are environmentally friendly, easily accessible, biodegradable, and cost-effective. In this review, the utilization of green corrosion inhibitors purely acquired from renewable sources is explored, with an in-depth focus on the recent advancements in the use of fruit and vegetable extracts as green corrosion inhibitors. In particular, fruits and vegetables are natural sources of various phytochemicals that exhibit key potential in corrosion inhibition. To shed light on the true potential of such extracts in the protection of steel in acidic environments, the experimental techniques involved in corrosion inhibition and the mechanism of corrosion inhibition are discussed in detail. The study highlights the potential of fruit and vegetable extracts as non-toxic, economical, and effective corrosion inhibitors in the pursuit of green chemistry. In addition to discussing and outlining the current status and opportunities for employing fruit and vegetable extracts as corrosion inhibitors, the current review outlines the challenges involved in the utilization of such extracts in corrosion inhibition.

Green inhibitor of carbon steel corrosion in 1 M hydrochloric acid: Eruca sativa seed extract (experimental and theoretical studies)

The adsorption activity and inhibition effect of Eruca sativa seed extract as a green inhibitor for the dissolution of carbon steel in 1 M hydrochloric acid solution were investigated. In this study, we used a chemical technique (gravimetric method), electrochemical techniques, electrical frequency modulation (EFM), electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization techniques, and theoretical studies. In addition to these techniques, we examined the surface morphology of the carbon steel utilizing different methods. The measurements of the polarization technique indicate that this extract acts as a mixed-type inhibitor. Thermodynamic parameters were calculated and discussed. The adsorption of Eruca sativa seed extracts on the alloy obeys the Langmuir and Henry adsorption isotherms. The extract gives an excellent inhibition efficiency 94.8% by a gravimetric method at 0.3 g L-1 from the extract. The relationship between the calculated % IE from experiments and the theoretical studies was established.

Effective Inhibition of Carbon Steel Corrosion by Waterborne Polyurethane Based on N-tert-Butyl Diethanolamine in 2M HCl: Experimental and Computational Findings

The efficiency of corrosion inhibition for waterborne polyurethane based on N-tert-butyl diethanolamine (tB-WPU) is investigated using different techniques. Corrosion weight loss, open circuit potential experiments, electrochemical impedance spectroscopy, and potentiodynamic polarization measurements show that both a commercial reagent and a polyurethane-based inhibitor prevent corrosion at increasing temperature to 50 °C. At 75 °C, the activity of both reagents is reduced. In stirring conditions, the effectiveness of acid corrosion inhibition (25 °C, 500 ppm) drops abruptly from 89.5% to 60.7%, which is related presumably to the complexity of binding the polymer molecules to the metal surface. As follows from thermodynamic calculations, the adsorption of tB-WPU on the metal surface in 2M HCl can be treated as a physisorption. Model quantum–chemical calculations support the experimental studies and elucidate the nature of steel surface–inhibitor molecule chemical bond, which is realized mainly by carboxyl and amino groups. It is concluded that WPUs can be considered as a perspective alternative to commercial oilfield reagents due to their versatility.

A Review on Plants and Biomass Wastes as Organic Green Corrosion Inhibitors for Mild Steel in Acidic Environment

Acid corrosion is a problem pertaining to corrosion that involves an acid solution. It is important to treat metal to preserve its integrity. Thus, acids are utilized to clean and treat metal surfaces. In return, this may lead to over-etching and metal degradation. Corrosion inhibitors were introduced as a solution for the issue. However, there are some problems associated with the usage of conventional corrosion inhibitors. Traces of nitrites and chromates that are present in the inhibitors may lead to serious health and environmental issues. As a solution, organic green corrosion inhibitors have been studied to replace the conventional corrosion inhibitors. These inhibitor molecules form a protective layer on top of the metal surface to suppress metal dissolution when added to the acid solution. This process prevents direct contact between the metal surfaces and the acid environment. This study explores the usage of natural resources and biomass wastes as the basis for organic green corrosion inhibitors. This study also provides some suggestions for new biomass wastes that can be studied as new organic corrosion inhibitors, and it is aimed at opening the perspective of researchers on exploring new organic inhibitors by using natural resources and biomass wastes.

Ethanedihydrazide as a Corrosion Inhibitor for Iron in 3.5% NaCl Solutions

Corrosion of iron in sodium chloride (3.5% wt) solutions and its inhibition by ethanedihydrazide (EH) have been reported. Electrochemical impedance spectroscopy (EIS), cyclic potentiodynamic polarization (CPP), and change of current with time at -475 mV (Ag/AgCl) measurements were employed in this study. Scanning electron microscopy (SEM) and energy-dispersive X-ray (EDX) techniques were utilized to report surface morphology and elemental analysis, respectively. The presence of 5 × 10-5 M EH was found to inhibit the corrosion of iron, and the effect of inhibition profoundly increased with an increase in EH concentration up to 1 × 10-4 M and further to 5 × 10-4 M. The low values of corrosion current and high corrosion resistance, which were obtained from the EIS, CPP, and change of current with time experiments, affirmed the adequacy of EH as a corrosion inhibitor for iron. Surface investigations demonstrated that the chloride solution without EH molecules causes severe corrosion, while the coexistence of EH within the chloride solution greatly minimizes the acuteness of chloride, particularly pitting corrosion.

Synthesis and Assessment of Two Malonyl Dihydrazide Derivatives as Corrosion Inhibitors for Carbon Steel in Acidic Media: Experimental and Theoretical Studies

Despite the extensive use of carbon steel in all industrial sectors, particularly in the petroleum industry, its low corrosion resistance is an ongoing problem for these industries. In the current work, two malonyl dihydrazide derivatives, namely 2,2'-malonylbis (N-phenylhydrazine-1-carbothiamide (MBC) and N'1, N'3-bis(-2-hydroxybenzylidene) malonohydrazide (HBM), were examined as inhibitors for the carbon steel corrosion in 1.0 M HCl. Both MBC and HBM were characterised using thin-layer chromatography, elemental analysis, infrared spectroscopy, and nuclear magnetic resonance techniques. The corrosion tests were performed using mass loss measurements, polarisation curves, and electrochemical impedance spectroscopy. It is obtained from the mass loss studies that the optimal concentration for both inhibitors is 2.0 × 10^-5 mol/L, and the inhibition efficiencies reached up to 90.7% and 84.5% for MBC and HBM, respectively. Electrochemical impedance spectroscopy (EIS) and potentiodynamic polarisation (PDP) indicate an increased impedance in the presence of both MBC and HBM and mixed-type inhibitors, respectively. Both inhibitors can mitigate corrosion in the range of 298-328 K. Values of free energy changes obtained from the Langmuir model suggest that the inhibitors suppress the corrosion process principally by chemisorption. The computational investigations were conducted to identify the factors connected with the anti-corrosive properties of the examined inhibitors.

Corrosion mitigation performance of disodium EDTA functionalized chitosan biomacromolecule - Experimental and theoretical approach

Disodium ethylenediaminetetraacetate salt is known for its excellent coordinating properties with the metal ions. The present study deals with the investigation of the prepared Disodium EDTA functionalized chitosan in corrosion inhibition for mild steel in 1 M HCl. The modified chitosan was characterized by spectral studies, thermal analysis, and Zeta potential studies. The corrosion inhibition efficiency (%) was evaluated using the gravimetric method and electrochemical studies. The electrochemical studies included potentiodynamic polarization, linear polarization resistance, and electrochemical impedance methods. The modified chitosan polymer showed an inhibition efficiency of 96.63% for 500 ppm at 303 K. Adsorption process obeyed Langmuir isotherm. Experimental results and theoretical calculations endorsed initial physisorption followed by a chemisorption process. Surface characterization studies supported the formation of a protective film that enabled the inhibition process. Density functional theory, Monte Carlo studies, and molecular dynamics simulation studies show a good agreement with the experimental results. Two-way Analysis of Variance was performed to test the influence of immersion period and inhibitor concentration on the corrosion rate using the statistical software IBM SPSS 20.0. A quartic model was generated as the best fit with the highest R2 value of 0.973. Design Expert software was employed for statistical modeling fit.

Inhibition Evaluation of Chromotrope Dyes for the Corrosion of Mild Steel in an Acidic Environment: Thermodynamic and Kinetic Aspects

In this report, two chromotrope dyes, chromotropic acid (CA) and chromotrope 2R (CR), were explored as inhibitors against mild steel corrosion in 1.0 M sulfuric acid solutions at 303 K. Electrochemical, spectroscopic, chemical, and microscopic techniques, namely, potentiodynamic polarization (PDP), electrochemical impedance spectroscopy, mass loss, and scanning electron microscopy (SEM), have been employed to evaluate the inhibition efficiencies (%IEs) of the examined organic dyes. The %IEs were found to increase with the inhibitors' concentrations, while they decreased with rising temperature. The outcomes of the PDP technique displayed that the examined inhibitors operated as mixed-type inhibitors with anodic prevalence. The impedance spectra described by Nyquist and Bode graphs in the corrosive environment and in the presence of various concentrations of the examined inhibitors showed single depressed capacitive loops and one-time constants. This behavior signified that the mild steel corrosion was managed by the charge transfer process. The SEM micrographs of the surfaces of mild steel samples after adding the examined inhibitors revealed a wide coverage of these compounds on the steel surfaces. Thus, the acquired high %IEs of the examined inhibitors were interpreted by strong adsorption of the organic molecules on the mild steel surface. This constructed a shielding layer separating the alloy surface from the corrosive medium, and such adsorption was found to follow the Langmuir isotherm. Furthermore, the evaluated thermodynamic and kinetic parameters supported that the nature of such adsorption was mainly physical. Results obtained from all employed techniques were consistent with each other and revealed that the %IE of the CR inhibitor was slightly higher than that of CA under similar circumstances. Finally, the mechanisms of both corrosion of mild steel in sulfuric acid solutions and its inhibition by the tested organic dyes were also discussed.

Exploration of Sunflower Oil As a Renewable Biomass Source to Develop Scalable and Highly Effective Corrosion Inhibitors in a 15% HCl Medium at High Temperatures

The feasibility study of utilizing sunflower oil as renewable biomass source to develop highly effective inhibitors for mild steel corrosion (MS) in the 15% HCl medium was done by weight loss, potentiodynamic polarization (PDP), dynamic electrochemical impedance spectroscopy (DEIS), and electrochemical impedance spectroscopy (EIS), supported with energy-dispersive X-ray (EDX), atomic force microscopy (AFM), and field-emission scanning electron microscope (FESEM) techniques. Moreover, a complementary theoretical investigation was carried out to clarify the inhibition mechanism of inhibitors by density functional theory (DFT), density functional based tight-binding (DFTB), and molecular dynamics (MD) simulation approaches. The obtained results confirm that sunflower-oil-based corrosion inhibitor (SFOCI) has a significant anticorrosion property toward the dissolution of MS in 15% HCl solution in the temperature range 20-80 °C. In addition, the results show that SFOCI could provide an inhibition efficiency of 98 and 93% at 60 and 80 °C, respectively. The inhibition mechanism of SFOCIs was mixed-type and their adsorption on the surface of MS was mainly chemisorption. The FESEM and EDX studies proved the presence of SFOCI molecules on the surface of MS. In addition, the adsorption energy of SFOCI indicated an intense interaction between the inhibitor and surface of Fe. The results of this study could open a new window for the design and development of scalable and effective eco-friendly vegetable-oil-based corrosion inhibitors for highly corrosive solutions at high temperatures.

Development of a New Borax-Based Formulation for the Removal of Pyrite Scales

In the oil and gas industry, pyrite forms one of the most hardened scales in reservoirs, which hinders the flow of fluids. Consequently, this leads to blockage of the downhole tubular, formation damage, and complete shutdown of production and operational processes. Herein, a new green formulation based on borax (K2B4O7) is proposed for pyrite scale removal. The temperature effect, disk rotational speed, and borax concentration have been investigated using a rotating disk apparatus. Also, XPS and SEM-EDX analyses were conducted on the pyrite disk surface before and after the treatment with the green formulation. The new formulation showed the potential ability to dissolve pyrite without generating the toxic hydrogen sulfide (H2S). The dissolution rate of the scale in the new formulation is increased by 16% compared to that in a previous green formulation composed of 20 wt %DTPA+9 wt % K2CO3. Molecular modeling technique using DFT was used to study the solvation energies of Fe2+ and Fe3+. The latter had a higher solvation energy than the former, which confirmed that upon using the borax-based formulation to oxidize Fe2+ to Fe3+. It will aid the dissolution of pyrite scales. The new formulation achieved a corrosion rate that is 25 times lower than that of 15 wt % HCl, which is commercially used in treating scales. Finally, the proposed new formulation does not require the use of corrosion inhibitors; hence, it is expected to result in a more economical scale treatment method.

Epoxy pre-polymers as new and effective materials for corrosion inhibition of carbon steel in acidic medium: Computational and experimental studies

Present study is designed for the synthesis, characterization and corrosion inhibition behavior of two diamine aromatic epoxy pre-polymers (DAEPs) namely, N1,N1,N2,N2-tetrakis (oxiran-2-ylmethyl) benzene-1,2-diamine (DAEP1) and 4-methyl-N1,N1,N2,N2-tetrakis (oxiran-2-ylmethyl) benzene-1,2-diamine (DAEP2) for carbon steel corrosion in acidic medium. Synthesized DAEPs were characterized using spectral (Nuclear magnetic resonance (1H NMR) and Fourier transform infrared-attenuated total reflection (FTIR-ATR)) techniques. Viscosity studies carried out at four different temperatures (20-80 °C) increase in temperature causes significant reduction in their viscosities. The anticorrosive properties of DAEPs differing in the nature of substituents, for carbon steel corrosion in 1 M HCl solution was evaluated using several experimental and computational techniques. Both experimental and computational studies showed that inhibitor (DAEP2) that contains electron releasing methyl (-CH3) showed higher protectiveness as compared to the inhibitor (DAEP1) without substituent (-H). Electrochemical results demonstrate that DAEPs act as reasonably good inhibitors for carbon steel in 1 M HCl medium and their effectiveness followed the sequence: DAEP2 (92.9%) > DAEP1 (91.7%). The PDP results show that the diamine aromatic epoxy pre-polymers molecules (DAEPs) act as mixed type inhibitors. Electrochemical study was also supported using scanning electron microscopy (SEM) method were significant improvement in the surface morphology of inhibited (by DAEPs) metallic specimens was obtained. Results derived from computational density functional theory (DFT) and molecular dynamics (MD) simulationsand studies were consistent with the experimental results derived from SEM, EIS and PDP electrochemical studies. Adsorption of the DAEPs obeyed the Langmuir adsorption isotherm model.