Corrosion Technology Forum 2018 – Focus control & prevention

Corrosion Technology Forum – Focus on prevention strategies

6:48 AM, 16th May 2018
Corrosion Technology Forum 2018 – Focus on control & prevention

The Corrosion Technology Forum 2018 - Domain of Corrosion which will be held on 07th & 08th June, will have some of the most experienced and brightest minds in the field of anticorrosion technology.

Before the real action begins, here is a sneak peek into the galore of knowledge that the speakers will coat through the two-day conference next month… So, book your dates to get enlightened on anticorrosion technologies by the best in the industry …

Compiled by Debarati Das

Maintenance is a part of corrosion management which cannot be eliminated but can be minimized by using better corrosion control technologies. Almost all three technologies viz., protection by coatings, use of cathodic protection and use of chemical inhibitors are being used in chemical industry. Latest technology and use of corrosion technology in combination can minimize maintenance expenditures. Advanced functional coatings, self-healing coatings, coatings based on nano-technology are the best bet for strong corrosion protection.

Industry 4.0 also has a major role to play in this segment with continuous increase in robotics and online monitoring of corrosion in many industrial applications. Specialized coatings such as thermal spray, laser-based coatings are usually done using robots which eliminates the chances of irregularities in coatings and keeps the basic parameters of coating same. With Industry 4.0, any flaw, leakage or coating failure can be checked immediately.

Professor A S Khanna, Fellow NACE, Fellow ASM, Department of Metallurgical Engineering and Materials Science IIT Bombay and Chairman SSPC India.

 The corrosion control in Oil & Gas and Chemical Industry is often a very challenging activity. According to general published information, the total annual cost of corrosion in the oil and gas production industry is estimated to be $1.372 billion, broken down into $589 million in surface pipeline and facility costs, $463 million annually in downhole tubing expenses, and another $320 million in capital expenditures related to corrosion. It is widely recognized in industry that effective management of corrosion will contribute towards achieving the following benefits:

  • Statutory or Corporate compliance with Safety, Health and Environmental policies
  • Reduction in leaks and Increased plant availability
  • Reduction in unplanned maintenance and deferment costs

The presentation will cover the following corrosion control aspects and approach:

  • Appropriate material selection during the design stage.
  • External and internal corrosion by protective coatings, linings, corrosion inhibitors and cathodic protection for buried and immersed pipelines, piping and equipment during construction and asset maintenance.

Mr. Venkateswaraswamy Gomatham, Senior Materials & Corrosion Engineer – TA2, Shell Technology India Pvt Ltd.

Corrosion is ubiquitous in oil and gas industry affecting assets and their integrity during operations.

The current processes function in feedback system where industry typically responds to corrosion once it has happened.

Advanced understanding in corrosion science can enable to have pre-emptive action to not only avoid but better manage the processing conditions.

For instance, the corrosion refining process is dominated by naphthenic acid and sulfides present in the oil that concentrates into various process streams.

While Total Acid Number (TAN) represents corrosion potential of crudes, understanding the corrosion causing molecules can better prepare the plant while purchasing crudes, blending and processing at various stages.

Dr. Kamalakanta Routray, Sr. Research Scientist (Refining R&D), Reliance R&D Centre, Reliance Industries

  My discussion will focus on “Innovation agenda @ Dow and innovation in coatings portfolio”. Dow, a 120 years old chemical company, has diversified business areas including packaging, Industrial intermediates & infrastructure, and performance materials & coating.

The initial part of the talk will emphasize on how Dow is working on the innovation agenda through corporate venturing and how can we create value for the customers through the innovations.

The presentation will subsequently discuss innovation on coating applications such as:

  • waterborne acrylics for wood protection
  • a new technology for metal coatings
  • synthetic binder for waterborne latex paint
  • evolution of hiding technology, and
  • traffic coatings.

Dr. C. S. Karthikeyan, Dy General Manager - Corporate Venturing, Dow Chemical International Pvt. Ltd.

The talk will delve into the future of anticorrosive coatings.

Conventional anticorrosive CED coatings being used by OEMs have been upgraded to low bake CED, lead-free CED, nano PT compatible tin free CED, high throw power CED coatings, but in future, these CED coatings will be replaced with next Gen Weather Durable CED coatings to have high weatherability without sacrificing anti corrosive performance.

Indian OEMs have implemented coatings to reduce VOC’s, CO2, regulated substances and planning to deploy energy efficient coatings with short & compact production processes eliminating number paint coats & reducing thickness of the coatings to improve the overall productivity and achieve next-gen challenges like light weight EVs, highest fuel efficiency, higher durability, scratch & mar resistance, etc.

Integrated Body & Bumper painting systems are being developed for OEMs to have common baking oven to save fuel energy & cost.

Mr. Pravin Bagale, Manager-Technical in R&D, Kansai Nerolac Paints Ltd

Coatings have played a role in everyday life for thousands of years. Today, virtually every structure and nearly every manufactured product use paints and coatings to maintain their appearance, functionality, and longevity. The functional aspects of paints and coatings have increased over decades - right from protection, aesthetics, special properties, durability to sustainability.

The increasing need to meet high compliance standard, demand for sustainable and eco-friendly coating will continue to stimulate growth in the global market. Paint manufacturers are increasingly seeking ways to reduce the VOC content of products in the solvent-based coatings. These trends have led to increases in raw material prices which include resins, additives and pigments. The focus of R&D is to consistently look at alternatives which are not only eco-friendly but also meet the price expectations of the market.

The presentation will delve into the developing trends which will bring a set of drivers and challenges for the industry and discuss its impact on market, products and processes of paints and coating industry.

Mr. B RamakrishnanEx-Managing Director, Akzo Nobel (High-Performance Coatings)

One of the solutions to combat corrosion is hydrogen induced resistant steel for Oil and Gas pipelines. Line pipe steels used for transporting crude oil, are required to posses “sour-resistance” against hydrogen induced cracking (HIC) and stress corrosion crack (SCC) resistance.

Both HIC and SCC depends on manganese sulphide (MnS) inclusion and hard second phase particles of steel. Research has been focused to control morphology and distribution of MnS and also to reduce sulphur to <0.002 wt%.

However, reducing S to <0.002 wt% is a very difficult task in industrial level. To explore other possibility of improving HIC and SSC performance, new API steel was developed at SAIL with addition of Cu.

The Cu has been immensely beneficial by increasing the corrosion resistance of the steel by altering the surface film and restricts the hydrogen diffusion thereby improving HIC and SSC resistance.

Dr. P. Saravanan, Senior Manager, Materials Technology & Corrosion Engg. Group, R&D Center for Iron and Steel, Steel Authority of India Limited (SAIL).

 Corrosion in power plants is the major cause of premature metal failure as well as deposit of corrosion products reduces both heat transfer & flow rate. It mainly happens because of water characteristics and metallurgy of the system.

The foremost reasons for corrosion are moisture and other corroding agents present in the surrounding atmosphere. Corrosion issues in power plants stretches maintenance, material losses, increases operating costs, reduces efficiency, critical downtimes and poses safety risks to workers. To optimize power-generating equipment, corrosion prevention is vital.

Industry experts recommend corrosion prevention in the form of preventive and control strategies, such as regular inspections, the use of protective coatings and suitable corrosion inhibitors.

Some of the topics that will be addressed for corrosion protection technologies in Power Plants are – Mechanism of corrosion; Classification of corrosion; Factors influencing the corrosion; Importance of corrosion protection; and Corrosion prevention methodologies in power plant.

Mr. S.A. Doss, General Manager, Protech Chemicals India Pvt. Ltd.

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