ASSESSMENT OF PROTECTIVE COATINGS FOR CORROSION PREVENTION OF CARBON STEEL IN HIGH-CONCENTRATION SULFURIC ACID ENVIRONMENTS

Abstract

This study evaluates the performance of three advanced protective coatings—Belzona 4341, Carboline Plasite 4550, and DuraPol UHT—on carbon steel subjected to the aggressive conditions of 98% sulfuric acid. The primary objective is to determine the effectiveness of these coatings in preventing corrosion and extending the lifespan of carbon steel in highly corrosive environments.To achieve this, a series of tests were conducted to assess key performance indicators, including adhesion strength, chemical resistance, hardness retention, and weight loss over time. Adhesion strength was measured to evaluate how well each coating bonded to the carbon steel substrate, which is critical for maintaining protective properties under corrosive conditions. Chemical resistance tests were performed to determine the coatings' ability to withstand the harsh effects of concentrated sulfuric acid, while hardness retention assessments provided insights into the coatings' durability and resistance to mechanical wear. Weight loss measurements were taken to quantify the extent of corrosion that occurred over the testing period.The results of the study revealed that Belzona 4341 outperformed the other coatings in all evaluated parameters, demonstrating superior adhesion strength and exceptional chemical resistance. Additionally, it exhibited minimal weight loss, indicating its effectiveness in preventing corrosion. Carboline Plasite 4550 and DuraPol UHT showed varying degrees of performance, but neither matched the overall effectiveness of Belzona 4341.These findings underscore the importance of selecting appropriate protective coatings for carbon steel in industrial applications, particularly in environments characterized by high acidity. By identifying Belzona 4341 as the most effective solution, this research provides valuable insights for industries seeking to enhance the longevity and reliability of their materials in corrosive settings. The study aims to inform future strategies for corrosion prevention and material selection, ultimately contributing to improved operational efficiency and reduced maintenance costs in industrial applications.