Development of Hybrid Coatings for Anti-Corrosion Applications in Oil and Gas sector

The physical, and mechanical properties as well as chemical and corrosion resistance of hybrid coatings comprising polyurethane/acrylic hybrids (PUA/AC) and acrylic polymers (AK) were investigated. Polyurethane (PUA) was synthesized through polyaddition polymerization of isocyanates [Isophorone diisocyanate (IPDI) and hexamethylene diisocyanate (HDI)] with polyols (GP 2000 and GP 4000) at an NCO/OH ratio of 0.85 and a temperature of 100°C. The acrylic copolymer (AC), based on methyl methacrylate (MMA) and butyl methacrylate (BuMA), was produced via bulk polymerization with benzoyl peroxide as a catalyst. The acrylic copolymer (AK) was prepared by grafting xanthan gum with styrene in various ratios (XG: St = 1:1.6, 1:5, and 1:8 w/w%). The results revealed that hybrid coatings demonstrated optimal chemical and corrosion resistance when PUA/AC hybrids were combined with AK. Enhancing both mechanical properties and corrosion resistance was achieved by integrating PUA/AC-10 with AK containing 8% styrene, resulting in superior anticorrosion performance including chemical and solvent resistances for the hybrid coating.