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Anticorrosive coatings, processes and uses thereof

a technology of anticorrosion coatings and coatings, applied in the direction of coatings, solid-state diffusion coatings, synthetic resin layered products, etc., can solve the problems of compromising the protective layer, too little concrete cover or loss of coverage, and easy rusting, etc., to achieve the effect of reducing the carbon footprin

Inactive Publication Date: 2016-06-16
SOLIDIA TECH
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The invention is about methods for protecting iron or steel surfaces from corrosion using low-cost coating methods. These methods can be used in a variety of applications, such as protecting reinforcement components embedded in composite materials or steel surfaces of oil and gas pipelines and vessels. The coating formed using these methods is strong and bonded to both the metal and the composite material. The process is carried out in an aqueous environment with saturated carbon dioxide and can be done on a large-scale with lower energy consumption. Various additives can be used to improve the consistency and properties of the resulting composite material, including chemical admixtures, rheology modifying admixtures, and pigments. The invention offers an affordable and efficient solution for protecting iron or steel surfaces from corrosion.

Problems solved by technology

The common rebar is made of unfinished tempered steel, making it susceptible to rusting.
However, too little concrete cover or loss of coverage over time can compromise this guard through carbonation from the surface and salt penetration.
While the high pH of the concrete may protect reinforcing steel from corroding, the concrete is affected by chloride penetration from salts during winter season or carbonation reaction with atmospheric carbon dioxide (CO2), which reduces the pH of concrete.
This breaks the passivation layer on the rebar leading to corrosion of steel.
As rust takes up greater volume than the steel from which it was formed, it causes severe internal pressure on the surrounding concrete, leading to cracking, spalling, and ultimately, structural failure.
One way to improve anticorrosion performance is to use components made of stainless steel, which significantly increases the product cost.
Another approach would be to pre-treat the steel components before embedment to form a protective coatings, which could add to the manufacturing complexity including additional steps for protective treatment and coating formation as well as increased cost for related materials and energy consumption.
In the oil and gas industry, corrosion remains a major impediment to long service life of the pipelines used to transport oil, gas and hazardous liquids.
Corrosion is one of the leading causes of failures in onshore transmission pipelines in the United States.
It is a threat to gas distribution mains and services as well as oil and gas gathering systems.
Corrosion is also responsible for a significant portion of incidents involving pipelines.
However, many challenges remain in developing an effective and inexpensive technology for long-term anticorrosive protection of the pipelines.

Method used

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  • Anticorrosive coatings, processes and uses thereof
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  • Anticorrosive coatings, processes and uses thereof

Examples

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example 1

Anticorrosive Coating for Steel Rebar

[0161]Anticorrosive coatings were formed and corrosion performance was tested. The raw materials were mixed. The mixture proportions (Solidia Cement) used to cast concrete cylinders are shown in Table 2.

TABLE 2Mixing Proportions (for 10 Kg batch size)AmountIngredientsWt. %(kg)Ground calcium silicate18%1.701Sieved Construction sand31%2.929¼″ aggregate25%2.344⅜″ aggregate26%2.457Total of Solid Components94.40%  9.431Tap water5.50% 0.556Glenium75000.013Total of Liquid Components5.60% 0.563Total of Solid and Liquid100% 10.000

[0162]Cylinder-shaped objects (4″ diameter×8″ long as shown in FIG. 13) were casted in a mold with plain carbon steel embedded inside as reinforcing components. The cylindrical objects were demolded after 2 hours of casting.

[0163]The two-casted cylinders were placed in a curing chamber and cured at about 60° C. for about 60 hours under an atmosphere of water and CO2 having a pressure at about ambient atmospheric pressure and havi...

example 2

Anticorrosive Coating for Steel Panel

[0166]Two plain carbon steel coupons of size 1″(width)×3″ (Length)×⅛″(thickness) were submerged completely in a beaker filled with tap water. This beaker was then exposed environmental conditions (60° C. and atmospheric pressure) typically used to carbon cure concretes containing ground calcium silicate for 65 hours. This coupon was made of composition which is normally used for making racking materials for curing chambers. The products formed during carbonation curing were analyzed using x-ray diffraction. The x-ray diffraction pattern is shown in FIG. 18, which indicates formation of siderite coating on plain carbon steel during exposure to CO2 environment.

example 3

Anticorrosive Coating on Ductile Cast Iron

[0167]In another experiment, ductile cast iron specimen (0.71 diameter×2.2055 inch long) were put in 1 M NaHCO3 solution in 1500 mL jars. The jars were put in oven at 60° C. and 90° C. for 24 hours. The specimens were then removed and rinsed with tap water before XRD and SEM analysis to characterize the corrosion products formed. FIG. 19 depicts XRD pattern which shows siderite coatings formed on the surface. FIG. 20 shows SEM image for this specimen which confirms the formation of siderite coatings during this reaction.

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Abstract

The invention provides novel methods for anticorrosive protection of iron or steel surfaces, such as on embedded iron or steel reinforcement components in composite materials and on steel surfaces of piles and vessels. The unique siderite coating formed during a carbonation curing possesses excellent anticorrosive properties and is suitable for improving the overall service life of coated objects.

Description

PRIORITY CLAIMS AND RELATED PATENT APPLICATIONS[0001]This application claims the benefit of priority from U.S. Provisional Application Ser. No. 61 / 922,059 filed on Dec. 30, 2013, the entire content of which is incorporated herein by reference in its entirety.FIELD OF THE INVENTION[0002]This invention generally relates to anticorrosive coatings for metal surfaces and processes and uses thereof. More particularly, the invention relates to formation of anticorrosive coatings on iron or steel surfaces, such as on embedded iron or steel reinforcement components in composite materials and on surfaces of iron or steel piles and vessels. The unique siderite coating possesses excellent anticorrosive properties, can be formed alongside curing of the bulk composite material, and can significantly improve the service life of coated objects.BACKGROUND OF THE INVENTION[0003]Precast concrete objects, such as pre-stressed concrete girders, beams and railway ties, are elongated beams typically with ...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): C23C22/05
CPCC23C22/05C04B28/04C23C8/18C22C47/04C04B20/107C04B32/02
Inventor JAIN, JITENDRAATAKAN, VAHIT
Owner SOLIDIA TECH
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