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Title: Influence of nano additives on electroless nickel phosphorous coatings for corrosion prevention of steel pipes
Author: Mirza, Muhammad Mumtaz
ISNI:       0000 0004 7655 5475
Awarding Body: Glasgow Caledonian University
Current Institution: Glasgow Caledonian University
Date of Award: 2018
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Coatings for corrosion prevention of steel pipelines that transport oil/gas in the Middle East region are typically polymer based: Fusion Bonded Epoxy (FBE). These coatings tend to suffer from embrittlement and subsequent cracking due to high ambient temperatures, leading to corrosion problems. Electroless Nickel Phosphorous (EN-P) coatings, widely used in aerospace and automotive industries, have the potential to offer a solution to this problem for the oil and gas pipelines. The robustness and porosity of EN-P coatings can be further enhanced with Nano additives. To this end, this research aimed to develop EN-P coatings with Nano additives for steel pipes operating in Middle East environmental conditions. More specifically, the research investigated the effects of adding Nano particles such as Al2O3, CuO, ZnO and SiO2 with varying concentrations on the corrosion prevention abilities of EN-P coatings. The physical, chemical and corrosion resistance properties were analyzed experimentally for the range of EN-P coatings developed. Based on the experimental work, optimum type and concentration of the Nano additive were identified. The investigation was extended to examine the thermal properties using a simulation tool in order to corroborate the experimental results for the optimized coating. The coatings were prepared in three stages for each Nano additive concentration ranging from 0.1 to 2 %. EN-P coating with 1% concentration of Nano Al2O3 was identified as the best, where corrosion rate was initially reduced to 58.12% and the coating efficiency was confirmed to be 24.72%. In order to improve the coating properties further, two types of surfactants - Cetyl Trimethyl Ammonium Bromide (CTAB) and Sodium Dodecyl Sulfate (SDS) - were incorporated. This resulted in significant improvements for the optimum case, EN-P coating with 1% concentration of Nano Al2O3 and SDS surfactant, yielded a coating efficiency of 94% and almost 100% corrosion rate reduction. The experimental results were verified through thermal simulation using ANSYS APDL 18.1 software under transient conditions. The simulated results were based on heat transfer rate and thermal stress in comparison with FBE coatings. The coating performance parameters of EN-P with Nano Al2O3 at 1 % concentration with SDS surfactant at high ambient temperature presented better results compare to FBE coating. The thermal performance efficiency of the EN-P coating was 96% in comparison with FBE coating, and thermal stress efficiency was 86% as compared to the uncoated pipe. The simulated results of the heat transfer rate and thermal stress indicated EN-P coating have superior robustness as compared to FBE coating. The significant and original contribution from this research is novel Electroless Nickel Phosphorus coatings incorporating Nano additives and surfactants to yield superior corrosion protection for oil and gas pipelines operating at high ambient temperatures. The evaluated results were confirmed and recommended to be further investigated on a commercial basis, based on standard industrial techniques and procedures.
Supervisor: Not available Sponsor: Not available
Qualification Name: Thesis (Ph.D.) Qualification Level: Doctoral
EThOS ID:  DOI: Not available