Anti-Corrosive and Scale Inhibiting Polymer-Based Functional Coating with Internal and External Regulation of TiO2 Whiskers

Current Downhole Corrosion Control Solutions and Trends in the Oil and Gas Industry: A Review

In the oil and gas industry, the presence of aggressive fluids and gases can cause serious corrosion problems. Multiple solutions have been introduced to the industry to minimize corrosion occurrence probability in recent years. They include cathodic protection, utilization of advanced metallic grades, injection of corrosion inhibitors, replacement of the metal parts with composite solutions, and deposition of protective coatings. This paper will review the advances and developments in the design of corrosion protection solutions. The publication highlights crucial challenges in the oil and gas industry to be solved upon the development of corrosion protection methods. According to the stated challenges, existing protective systems are summarized with emphasis on the features that are essential for oil and gas production. Qualification of corrosion protection performance based on international industrial standards will be depicted in detail for each type of corrosion protection system. Forthcoming challenges for the engineering of next-generation materials for corrosion mitigation are discussed to highlight the trends and forecasts of emerging technology development. We will also discuss the advances in nanomaterial and smart material development, enhanced ecological regulations, and applications of complex multifunctional solutions for corrosion mitigation which have become of great importance in recent decades.

Novel Environmentally Friendly Waterborne Epoxy Coating with Long-Term Antiscaling and Anticorrosion Properties

Metal pipes in industrial production are exposed to various corrosive ions. The combined action of these ions with oxygen in water causes corrosion and contamination of the metal pipes and equipment. In addition, metallic ions in water react with anions to form scale on the surface of the metal, which significantly reduces the service life of the metal and equipment, resulting in safety hazards. Waterborne coatings have attracted tremendous attention due to the less negative impact on the environment, but their practical applications are severely restricted by poor barrier properties and poor mechanical durability. Herein, the barrier properties of water-based coatings are successfully improved by adding functional slow-release nanofillers, and the fillers also endow the coating with excellent antiscaling properties. A functional slow-release nanofiller (lecithin/SiO₂/HEDP) was prepared using HEDP (etidronic acid) as the scale inhibitor active material and SiO₂ as the carrier, combined with a phospholipid membrane with slow-release permeability. With the addition of slow-release fillers, compared with the EP coating, the impedance modulus of composite coatings increases about 1 order of magnitude, the scale inhibition rate is as high as 80.7%, and the antiscaling life is double that of the coating without the phospholipid-coated filler. Thus, this study is expected to provide a new perspective for the preparation of new slow-release fillers and high-efficiency scale inhibitor coatings.

Dispersion of Poly(urea-formaldehyde)-Based Microcapsules for Self-Healing and Anticorrosion Applications

An effective dispersant, oleyl phosphate (OP), for the dispersion of poly(urea-formaldehyde)-based microcapsules in a typical epoxy coating material is proposed. Based on electron microscopy observations and rheological and mechanical characterizations, it is observed that the addition of merely 0.5 wt % of OP is sufficient to obtain good dispersion of the microcapsules in the epoxy. In the self-healing and anticorrosion experiments, a microcapsule content of at least 15 wt % is required to efficiently restore the epoxy matrix and provide corrosion protection to underlying low-carbon steel when the particles are not dispersed; however, the amount of microcapsules required to obtain good self-healing and anticorrosion efficiencies can be greatly reduced to only 5 wt % when the microcapsules are dispersed by OP.

Micro-/Nanoscale Approach for Studying Scale Formation and Developing Scale-Resistant Surfaces

Blockage of pipelines due to accretion of salt particles is detrimental in desalination and water-harvesting industries as they compromise productivity, while increasing maintenance costs. We present a micro-/nanoscale approach to study fundamentals of scale formation, deposition, and adhesion to engineered surfaces with a wide range of surface energies fabricated using the initiated chemical vapor deposition method. Silicon wafers and steel substrates are coated with poly(1 H,1 H,2 H,2 H-perfluorodecylacrylate) or pPFDA, poly(tetravinyl-tetramethylcyclotetrasilohexane) or pV4D4, poly(divinylbenzene) or pDVB, poly(1,3,5,7-tetravinyl-1,3,5,7-tetramethylcyclotetrasilohexane) or pV3D3, and cross-linked copolymers of poly(2-hydroxyethylmethacrylate) and poly(ethylene glycol) diacrylate or p(PHEMA- co-EGDA). Particles of salt (CaSO₄·2H₂O) are formed and shaped with a focused ion beam and adhered to a tipless cantilever beam using a micromanipulator setup to study their adhesion strength with a molecular force probe (MFP). Adhesion forces were measured on the substrates in wet and dry conditions to evaluate the effects of interfacial fluid layers and capillary bridges on net adhesion strength. The adhesion between salt particles and the pPFDA coatings decreased by 5.1 ± 1.15 nN in wet states, indicating the influence of capillary bridging between the particle and the liquid layer. In addition, scale nucleation and growth on various surfaces is examined using a quartz crystal microbalance (QCM), where supersaturated solution of CaSO₄·2H₂O is passed over bare and polymer-coated quartz substrates while mass gain is measured in real time. The salt accretion decreased by 2 folds on pPFDA-coated substrates when compared to that on p(HEMA- co-EGDA) coatings. Both MFP and QCM studies are essential in studying the impact of surface energy and roughness on the extent of scale formation and adhesion strength. This study can pave way for the design of scale-resistant surfaces with potential applications in water treatment, energy harvesting, and purification industries.

Scalable synthesis of high-purity TiO2 whiskers via ion exchange method enables versatile applications

In this work, high-purity titanium dioxide (TiO₂) whiskers with different crystal forms were synthesized via ion exchange and controlled calcination methods. TiO₂ whiskers are of 5–10 μm in length with a length-to-diameter ratio of 10–20. A systematic investigation was established to explore the hydration process of K⁺/H⁺ exchange, anatase-rutile transformation in the calcination process and the applications of TiO₂ whiskers. Compared with the other strategies previously used for the synthesis of TiO₂ whiskers, it was found that large-scale production was obtained under mild reaction conditions, which represented a facile and mild route for industrial production and expanded the versatile applications of TiO₂ whiskers. Moreover, with the addition of nano TiO₂ colloid as a special accelerant, the calcination process yielding uniform morphology and controllable crystal form was explored. Confirmatory experiments indicated that anatase and rutile TiO₂ whiskers respectively show excellent photocatalytic activities and unique carrier performance for fabricating functional whiskers.

In this work, high-purity titanium dioxide (TiO₂) whiskers with different crystal forms were synthesized via ion exchange and controlled calcination methods.