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Microorganisms vs Petrochemicals: Tackling Microbial Corrosion with Innovation

Microbial corrosion is a phenomenon, caused by specific microorganisms, that can weaken and damage metals and other materials used in petrochemical infrastructure, such as pipelines and storage tanks. In this technical article, we will explore microbial corrosion in detail and present the most advanced coating technologies employed to combat this growing problem.

Antonio Zavarce.

Published: June 23, 2023

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Introduction

Microbial corrosion. This phenomenon, caused by specific microorganisms, can weaken and damage metals and other materials used in petrochemical infrastructure, such as pipes and storage tanks. The petrochemical industry plays a crucial role in our modern society, supplying a wide range of essential products and materials. However, there is a silent enemy that threatens the integrity of your facilities:

In this technical article, we will explore microbial corrosion in detail and present the most advanced coating technologies employed to combat this growing problem.

Microbial Corrosion: A latent problem

Microbial corrosion is a specialized form of corrosion influenced by microorganisms that find a favorable environment in the petrochemical industry. These microorganisms can include bacteria, fungi, and algae, among others. Taking advantage of factors such as humidity, temperature and the presence of specific chemical substances, microorganisms can colonize metal surfaces and generate corrosive metabolic products that attack materials.

The percentage of involvement of microbial corrosion in relation to the rest of the types of corrosion can vary depending on the industry and the specific environment. In some cases, microbial corrosion can account for a significant fraction of corrosion problems, especially in industries such as petrochemicals, oil and gas, where conditions conducive to microbial growth are present.

It is estimated that microbial corrosion can contribute up to 20-30% of corrosion cases in industrial environments. However, it is important to note that this figure can vary widely depending on environmental factors, the types of materials used, and the corrosion management implemented in each industry.

Although microbial corrosion may represent a minor percentage compared to other types of corrosion, it is a significant challenge due to its insidious nature and often difficult to detect. The presence of corrosive microorganisms can accelerate the corrosion process and cause serious damage to infrastructure and equipment.

It is important to highlight that the prevention and control of microbial corrosion are crucial to guarantee the integrity and useful life of industrial structures and equipment. By implementing proper prevention and control strategies, such as the use of inhibitors and coatings, the impact of microbial corrosion compared to other types of corrosion can be significantly mitigated.

Microbial corrosion presents additional challenges compared to other types of corrosion . Not only is it more aggressive, but it can also occur in hard-to-reach areas, making it difficult to detect and treat. Additionally, as microorganisms adhere and grow on metal surfaces, they can form tough biofilms that act as a protective barrier against conventional protection methods.

Anti-corrosion Coatings: Innovative Protection

To combat microbial corrosion, highly effective anti-corrosion coating technologies have been developed. These coatings are applied to metal surfaces to provide a protective barrier against microorganisms and the corrosive substances they produce.

One of the most promising approaches in the fight against microbial corrosion is the use of special polymeric coatings. These coatings are formulated with built-in corrosion inhibitors and antimicrobial agents. Corrosion inhibitors help prevent electrochemical corrosion by interacting with metal surfaces and forming a protective layer, while antimicrobial agents inhibit the growth and adhesion of microorganisms.

A prominent example of these coatings is polyphenylmethylsiloxane-modified polyurethane (PPMS). This type of coating has demonstrated excellent resistance to corrosion and to the adhesion of microorganisms in challenging environmental conditions. Its application in the petrochemical industry has provided promising results by extending the useful life of structures and reducing maintenance costs.

Corrosion Inhibitors: Stopping the Microbial Threat

In addition to anti-corrosion coatings, another key approach to combating microbial corrosion in the petrochemical industry is the use of corrosion inhibitors. These chemical compounds are added to systems and fluids to prevent or reduce corrosion, either by interfering with electrochemical processes or by inhibiting the growth of corrosive microorganisms.

There are different types of corrosion inhibitors used in the petrochemical industry, such as volatile inhibitors and contact inhibitors. Volatile inhibitors are chemical compounds that vaporize and distribute throughout the system, forming a protective layer on metal surfaces. These inhibitors are especially effective in protecting hard-to-reach areas.

On the other hand, contact inhibitors are chemical compounds that dissolve in fluids and come into direct contact with metal surfaces. These inhibitors form a protective layer on the metal, reducing corrosion and preventing the growth of microorganisms.

It is important to note that the selection of the appropriate corrosion inhibitor must be based on a careful evaluation of the operating conditions, the materials used and the microorganisms present. The application of corrosion inhibitors in the petrochemical industry can help prevent microbial corrosion and extend the useful life of structures and equipment.

Advances in coating technologies

Innovation in coating technologies continues to drive the fight against microbial corrosion in the petrochemical industry. New materials and formulations are constantly being researched and developed to improve corrosion resistance and microbial growth inhibition.

One of the research areas in development is nanotechnology applied to anticorrosive coatings . Nanostructured coatings offer enhanced properties, such as higher mechanical strength, greater durability, and a greater ability to prevent corrosion and microbial growth. These coatings can also be more environmentally friendly by reducing the use of toxic components.

In addition, new coating application techniques such as electrostatic deposition and immersion methods are being explored to achieve more uniform and long-lasting coverage. These technological advances allow for more effective protection against microbial corrosion and greater resistance to extreme conditions.

Suppliers of technologies to combat microbial corrosion: inhibitors and coatings

In the industry there are several companies dedicated to the development and production of inhibitors and coatings to combat microbial corrosion in different sectors, including the petrochemical industry. Next, I will mention some recognized companies in this field:

Nalco Water: Nalco Water, an Ecolab company, offers comprehensive solutions for the prevention and control of microbial corrosion. They provide a wide range of specific biocides and corrosion inhibitors for the petrochemical industry.
Ashland: Ashland is a leader in specialty chemicals, including corrosion protection solutions. They offer advanced anti-corrosion coatings that help prevent damage caused by microbial corrosion in various industrial settings.
AkzoNobel: AkzoNobel is a global supplier of chemicals and coatings, including high-tech anti-corrosion solutions. Its product portfolio includes coatings specifically designed to combat microbial corrosion in the petrochemical industry.
Hempel: Hempel is a company specializing in industrial coatings and paints. They offer corrosion protection solutions, including high-strength coatings designed to meet the challenges of microbial corrosion in petrochemical environments.
BASF: BASF is a leading global chemical company and has a wide range of products for corrosion protection, including inhibitors and special coatings. His focus includes innovative solutions to combat microbial corrosion in the petrochemical industry.

These are just some of the leading companies in the development of inhibitors and coatings to combat microbial corrosion. It is important to note that the market for corrosion protection products and technologies is vast and constantly evolving, so there are many other companies that also offer effective solutions in this field.

When selecting suppliers, it is essential to evaluate the reputation, experience and quality of the products offered, as well as their suitability for the specific needs of each application in the petrochemical industry.

Conclusions

Microbial corrosion represents a latent threat in the petrochemical industry, but with the application of innovative coating technologies and corrosion inhibitors, it is possible to combat this problem effectively. The combination of anti-corrosion coatings, such as polyphenylmethylsiloxane-modified polyurethane (PPMS), and the proper use of corrosion inhibitors can extend the life of petrochemical structures and equipment, reduce maintenance costs, and improve operational safety.

It is essential that companies in the petrochemical industry are aware of these new technologies and incorporate them into their corrosion management strategies. By investing in the right protection against microbial corrosion, the integrity of the facilities is guaranteed and contributes to the sustainability and efficiency of the entire petrochemical industry.