AI against corrosion page 22
Donelli Eos’ strategic role in the corrosion protection of offshore structures page 44
The mystery of cathodic corrosion protection clarified page 56
EDITOR FROM THECOATING, FIREPROOFING AND INSULATION FOR INDUSTRIAL PLANTS, ENERGY, OFFSHORE AND INFRASTRUCTURES.
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16
Box cooler service: cleaning and maintenance to fight corrosion and fouling
Solving the false dilemma of seawater hydrotesting corrosion
18 ADVANCEMENTS
A new technology to automatically estimate the depth of corrosion on steel materials
22 AROUND THE WORLD
AI against corrosion
26 ADVANCEMENTS
HighMate Prepper - MontiPower's innovative robotic system for surface preparation 30 RESEARCH BREAKTHROUGH
LLNL researchers uncover culprits behind pitting corrosion in 3D-printed stainless steel
Biomineralization against microbial corrosion in marine concrete
36 THE BREAKDOWN
Practical coverage calculation and the necessary overconsumption factor
Italian shipowner Ignazio Messina & C. chooses Jotun as partner for sustainable vessel solutions
Donelli Eos’ strategic role in the corrosion protection of offshore structures 52
Maintenance and corrosion management in the global oil and
The
Cover photo:
© Lucrezia Roda, “La Nave Blu”, giclée print on Hahnemühle Baryta FB 350 paper, Imago Fine Art, 2019. Port (from the 1st century BC), Ravenna. From the exhibition “Everything is illuminated, Geographies of Views Between History and Contemporaneity” Curated by Gigliola Foschi and Nadia Stefanel - Fondazione Dino Zoli, Forlì
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Alessia Venturi Editor-in-chief
Acommon mistake that we editors of technical magazines often unintentionally make is to focus our content on technology, research, development, and innovation, sometimes straying into market analysis. However, we usually neglect the human factor, related to the skills, abilities, and talents required of employees by certain industries to be efficient, to guarantee quality, to prosper. We tend to describe in detail any technology, discovery, chemical product, or scientific achievement that comes our way, but rarely do we reflect on the fact that these technologies must be grasped, mastered, and promoted by people, by the operators who will use them on a daily basis in their respective lines of work to contribute to the advancement of the sector.
Technology facilitates tasks, shortens operating times, and improves performance, but it must be understood in depth to actually work. Within a company – whatever product or service it sells – training and consulting are just as essential investments as those made in technology, as they enable each worker to continue to be efficient and effective and work safely.
The skills required by the corrosion protection industry are not only technical and application-related but also soft skills such as mental flexibility and the ability to work under stress and in demanding situations (wet environments, challenging weather conditions, isolated or remote locations), which often entail spending a lot of time away from home. Focus, psychological strength, and passion for one’s job are as crucial as knowing and mastering the latest technologies. Technology facilitates tasks, shortens operating times, and improves performance, but it must be understood in depth to actually work. Within a company – whatever product or service it sells – training and consulting are just as essential investments as those made in technology, as they enable each worker to continue to be efficient and effective and work safely.
More than one article in this Corrosion Protection issue offers interesting insights into this topic. There are so many tools that can support corrosion protection operators and make their work easier nowadays: artificial intelligence, unmanned robotic units, corrosion analysis, evaluation and prediction models, and flexible equipment and application systems can be of great help not only in reducing the impact of corrosion on GDP (which is notoriously exorbitant) but also in enabling teams to work better, faster, more accurately, and more effectively, with benefits also for the personal balance and well-being of operators. The transfer of AI from research to industry thus becomes a key step to ease the workload of operators and improve their performance. Similarly, reducing the asymmetry of information and knowledge between contracting parties, as well as anticipating and avoiding the loss of expertise in the industry – in brief, the obsolescence of information and skills –play an important role in the advancement of the anti-corrosion industry and the welfare of its operators.
In recent years, we have witnessed a decrease in funding for technical training in favour of financial investments. However, this trend must be reversed because only adequate knowledge allows companies to progress and grow.
Magazines such as Corrosion Protection, full of studies, technological insights, but also real success stories of virtuous companies in the corrosion protection sector, contribute to fostering industrial culture and help new technologies and innovation paths take root. That is why they must be supported.
AkzoNobel’s International® marine coatings brand has unveiled updates to its groundbreaking digital forecasting tool, Intertrac® Vision. These new features include the ability to predict CII ratings, assess the financial impact of the EU’s Emissions Trading System (ETS), and provide detailed cost-saving insights over multiple dry-dockings. These improvements are designed to help vessel operators make smarter, data-driven decisions about their fouling control coatings. Intertrac® Vision draws from a vast database, analysing over 200,000 drydocks and 10,000 vessel operations. It combines this historical data with cutting-edge machine learning to forecast the impact of coatings on a vessel’s performance. The tool offers insights into how specific coatings will perform over the vessel's operational lifespan, allowing operators to evaluate their return on investment based on the vessel type and operational scenarios. The tool is invaluable for making informed decisions that reduce fuel consumption and CO2 emissions. A new update now provides a total cost of ownership summary, breaking down the cost contributions of each stage in the drydocking cycle. Additionally, users can now forecast over a 120-month cycle - either as two consecutive 60-month dockings or one continuous period - giving vessel owners a long-term view of the benefits of proper coating selection. With stricter regulations like the EU Emissions Trading System (starting in January 2024) and FuelEU regulation (effective from January 2025), vessel operators need reliable data to guide operational decisions. More than ever, there’s a demand for insights that help vessels stay compliant and efficient. According to a recent Lloyds List survey, over 59% of shipowners believe coatings are one of the most effective ways to meet the International Maritime Organization’s carbon reduction targets, such as the Carbon Intensity Indicator (CII) and Energy Efficiency Existing Ship Index (EEXI). Barry Kidd, Vessel Performance Manager at AkzoNobel, emphasized, “Intertrac® was designed to give shipowners and operators customised insights to improve vessel performance. With our team’s technical expertise and the advanced capabilities of Intertrac® Vision, vessel operators can identify areas for operational improvement, leading to smarter investment decisions. This latest version of Intertrac® Vision gives even deeper insights, helping customers navigate the ever-changing regulatory landscape.”
Earlier this year, AkzoNobel showcased Intertrac® Vision’s predictive accuracy in a white paper . The tool was able to forecast the performance of a globally trading VLCC (Very Large Crude Carrier) over five years, with results coming within 1% of actual performance figures, measured according to ISO19030 standards.
www.international-marine.com
DÖRKEN offers a positive summary of WindEnergy Hamburg
From 24 to 27 September, Hamburg was once again the host for WindEnergy - the world's leading trade fair for wind energy. DÖRKEN was also represented with its corrosion protection solutions and topics relating to the planned PFAS ban. For four days in Hamburg, everything revolved around renewable energy generation in the onshore and offshore sector. WindEnergy impressively demonstrated that it continues to be the international platform for the latest developments and innovations in the wind industry. It attracted more than 43,000 visitors and 1,600 exhibitors in a total of ten halls - three halls more than two years ago. In addition to the exhibiting companies, there was a varied conference programme with more than 300 speakers offering insights into the future of wind energy. “WindEnergy has once again shown how valuable it is for our industry,” summarised Iñigo Hoz Imaz, Key Account Manager Industrial. “We were able to hold many interesting talks and discussions with visitors along the entire value chain.” Visitors to the booth were particularly interested in the topics of sustainability, low CO2 emissions and PFAS restrictions. In line with this, DÖRKEN brought its expertise in PFAS-free solutions with it and was able to present the DELTA-PROTEKT® TC 502 GZ hybrid topcoat. Thanks to the very narrow friction coefficient window, the silver topcoat is ideal for metric components such as screws or nuts. In general, DÖRKEN was able to demonstrate its expertise in the field of coating solutions at WindEnergy. “We can particularly emphasise the lively exchange with visitors to our stand on products with a low cross-linking temperature, efficient technologies and a low impact on the environment,” summarises René Rother, Key Account Manager Industrial. This also includes DELTA-PROTEKT® Repair - a high-performance zinc flake spray from the spray can that cures at low temperatures. This means it can be used both for repairing defects and for small-area coating. “As always, it was a pleasure to meet with the who's who of the wind industry. We are already looking forward to the next WindEnergy in two years‘ time,” says Klaus Gradtke, Key Account Manager Industrial.
www.doerken.com
PPG launched PPG STEELGUARD® 951 epoxy intumescent fire protection coating in the Americas. This innovative product is designed for advanced manufacturing facilities, including semiconductor plants, electric vehicle battery facilities, data centers and other commercial infrastructure. After a successful launch in Europe and the Middle East, PPG Steelguard 951 coating is now available in North and Latin America.
PPG Steelguard 951 coating provides up to four hours of fire protection by expanding from a thin, lightweight film into a thick, insulating foam. This maintains structural integrity, allows more time for evacuation and minimizes damage to buildings and assets. The coating delivers up to 3,500 microns of dry-film thickness in a single coat and cures rapidly, ready for handling the next day. PPG Steelguard 951 coating is ideal for modular construction projects optimized for off-site and field applications. PPG’s patented flexible epoxy technology ensures excellent durability and edge retention, reducing the risk of cracks during handling and transportation, and provides corrosion resistance up to ISO 12944 C5 without a topcoat.
Our shot blasting systems are made to measure. We take into account the available space, needs and objectives of our customers to structure a product that is functional and that responds to all processing requirements.
“We're excited to expand our offering of PPG Steelguard 951 coating to the commercial infrastructure sector, specifically advanced manufacturing in countries such as the U.S., Brazil, Mexico, Canada, Perú and Colombia,” said Stuart Bradbury, PPG business development manager, fire protection, Protective & Marine Coatings. “This solution offers up to four hours of fire protection, meets stringent testing standards, and supports modern construction methods with its robust, flexible and efficient application properties. We are committed to partnering with our customers to ensure the highest safety and performance in their projects.” PPG’s global technical team ensures that customers receive expert guidance for optimal application. The product's environmental credentials, including Environmental Product Declarations, underscore PPG's dedication to sustainability. PPG Steelguard 951 coating is tested in accordance with all recognized national and international fire and corrosion standards, including ISO 12944 C5, EN 13381-8, BS 476 standards, GB 51249, GB 14907, ASTM E119, UL 263 and ULC 5101.
www.ppgpmc.com
Eurotherm S.p.A. based in Turin, Italy
PLANT 1: 4.700 m2 of offices, metal work production and painting.
PLANT 2: 5.300 m2 for production, preassembling, warehouse and logistics.
Cathodic protection and remote monitoring expert Omniflex completed the addition of remote monitoring to the existing cathodic protection systems at five berths in Port Kembla, NSW, Australia. The existing impressed current CP systems vary in age – some installed as far back as the 1980s – and the port owners, NSW Ports, enlisted Omniflex to install remote monitoring to these CP systems to enhance their surveillance and provide accurate energy monitoring.
The available space to mount remote monitoring equipment inside each CP system enclosure was different, so Omniflex designed custom configurations for each monitoring system. CP systems on both concrete and steel structures are monitored, with different numbers of transformer/rectifiers, anodes and reference electrodes, which further complicated the monitoring requirements.
The measurement data is sent via the 4G mobile phone network to the NSW Ports Data2Desktop web portal, which integrates these CP systems at Port Kembla into the NSW Ports existing remote berth monitoring. This single portal monitoring all the NSW Ports CP assets provides a convenient single point for monitoring of cathodic protection performance and energy consumption.
“Monitoring of CP systems involves measuring T/R output voltages as high as 60 volts, individual anode currents using existing current shunts which are only millivolts, and reference electrodes which require very high input impedances” explained David Celine, managing director of Omniflex. “Our PowerView iRef8 monitoring unit, with its individual channel isolation, high input impedance and multiple measurement ranges is purpose designed for these CP monitoring applications”.
“Traditionally, checking cathodic protection functionality is done by inspection once every six or twelve months,” continued Celine. “Corrosion is silent and any failures such as disconnected anodes or failed power supplies could go unnoticed for up to a year, leaving structural steel unprotected against corrosion.”
Tracking the electricity usage of CP systems has other benefits too. Firstly, energy consumption can be quantified for cost allocation purposes, especially if third parties are operating the berths. Furthermore, a business’s sustainability depends today on accurately measuring its carbon footprint, and monitoring energy usage of CP systems is key to meeting this goal.
www.omniflex.com
GMA Garnet expands product line across Asia Pacific with the launch of ToughBlast™ and ExtremeBlast™
GMA Garnet Group, a global leader in abrasives, has introduced ToughBlast™ and ExtremeBlast™ to customers in the Asia Pacific region. These premium abrasives are designed for efficient removal of heavy coatings and can create surface profiles over 90-100 microns, making them the coarsest in GMA's product range. Building on the success of introducing the blends to the American market, this strategic release highlights GMA’s commitment to delivering high-performance blasting solutions to its Asia Pacific customers for various industrial projects across the region. With this launch, GMA now offers our Asia-Pacific customers a comprehensive range of five high-performing blast abrasives. "The launch of these 2 new products into the Asia-Pacific market marks another significant milestone for GMA,” said Flynn Cowan, GMA’s General Manager of International Sales and Marketing. “This expansion not only reinforces our commitment to providing innovative abrasive solutions but also reflects our strategic focus on meeting the growing demands of this dynamic region.”
Dr. Chris Manger, GMA’s Sales Manager for Asia Pacific, highlighted that the release "reflects GMA’s commitment to innovation and empowering our customers with versatile solutions that elevate
their project outcomes, particularly in the area of tough coating removal. In today’s fast-paced industrial landscape, choosing the right abrasive is crucial. The balance of key factors like hardness, toughness, and particle sizing directly impacts effectiveness across applications. Our extensive research and global testing have provided critical insights into what drives blasting efficiency”.
GMA’s wide range of abrasives enables customers to optimize productivity, streamline operations, and meet project deadlines with confidence. Whether dealing with thick coatings, heavy rust, or delicate restoration work, GMA's engineered blends provide customised solutions for every challenge, ensuring projects are completed on time and within budget. “We are also pleased to offer our Asia-Pacific customers this extended product range through our new distribution hub, located in Malaysia. The ability to deliver quickly within the region has been well-received, especially as demand for high-performance abrasive products continues to grow,” added Dr. Manger. Opened in June this year, the new facility supports customers throughout Asia, from Indonesia to Japan, enhancing GMA’s regional distribution footprint.
www.gmagarnet.com
The international paints and coatings manufacturer Hempel has launched the new Hempaguard Ultima silicone hull coating system, the latest addition to the Hempaguard portfolio. The new solution offers optimised performances while increasing fuel savings up to 21% and reducing emissions, allowing then vessel owners and operators to reach their decarbonisation goals.
“Hempaguard Ultima is our most significant innovation in a decade and an important step forward in our ability to protect and improve the most important assets of our customers. It has been designed to safeguard vessels from fouling with a unique two-layer system, enabling our clients to reach their sustainability objectives while also achieving operational excellence,” has stated Alexander Enström, the executive vice-president of Hempel A/S.
“I am excited to introduce this ground-breaking innovation to our customers and look forward to following its success and impact in the market.” As the maritime industry faces increasing pressure to decarbonise, Hempel has invested in further developing its cuttingedge innovation Hempaguard X7 – verified and validated for its performance and decarbonisation efforts by DNV – which has been applied to more than 4,000 vessels. With the new two-layer coating system Hempaguard Ultima, customers will now be able to better
navigate the increasingly strict regulatory environment. The new product combines the tried-and-tested performance of Hempaguard X7 with the biocide-free silicone topcoat Hempaguard XL, preventing growth of marine organisms while ensuring long-lasting hull protection.
Advantages of Hempel Hempaguard Ultima hull coating system:
Up to 21% fuel savings;
160 fouling-free idle days;
Only 0.9% speed loss on average;
6% immediate out-of-dock performance increase.
“With Hempaguard Ultima, the hull of a vessel is able to achieve a more stable surface smoothness, even into the fourth or fifth year of the docking cycle. This reduces the risk of fouling after long service periods, even when the coating’s hydrogel and biocide can start losing some effectiveness. At the same time, the Hempaguard XL topcoat acts as a modulator for the release of biocide from Hempaguard X7, allowing a lower biocide amount per square metre to last longer,” has explained Diego Meseguer Yebra, the director of the Marine Research and Development division of Hempel A/S.
www.hempel.com
Edited by Säkaphen GmbH, Gladbeck, Germany
Säkaphen is a company specialising in corrosion protection coatings and application services. Its global network of authorised applicators enables it to serve the maritime industry worldwide, where it has noticed increasing interest in the re-coating of box coolers as a sustainable way to lengthen these systems’ service life.
Box coolers are a specific type of heat exchanger developed as a water cooling system for vessels of any kind, from yachts and ferries to ice breakers and cargo freighters. Boasting excellent resistance to marine environments, using seawater as a coolant, and requiring limited energy to operate, they can be considered an environmentally friendly engineering choice, helping reduce a ship’s carbon footprint. Since box coolers are made of various grades of alloys, ranging from aluminium-brass (CuZn20Al) to copper-nickel (Cu-Ni) and are installed in carbon steel sea chests, however, there is considerable potential for galvanic (due to the dissimilar metallurgy) and sea water corrosion. That is why it is vital to apply a protective coating not only in the sea chest but also on the surface of the box cooler.
Such a protective coating should be resistant to the harsh operational conditions of the marine environment, which go well beyond contact with seawater or brackish water, but also able to withstand the mechanical stress caused by the flow of water through the cooler tubes as well as vibrations and air bubbles, potentially causing cavitation. Finally, the ideal paint product has to withstand the permanent electrical stress caused by the Impressed Current Anti Fouling (ICAF) system, which impresses an electrical current into a copper anode to reduce fouling and marine growth on the box cooler. Fouling itself, of course, is another factor potentially jeopardising a box cooler’s performance.
Säkaphen (Glabeck, Germany) is a family-owned business with 70 years of experience in corrosion protection products and processes. Its solutions for the maritime industry include some coatings with excellent resistance to aggressive marine environments, including one, SÄKATONIT Extra AR-F, that is suitable for flooding applications. In particular, this company can maintain, clean, and repair box coolers in all designs, including round, rectangular, or stepped, thanks to its unique portfolio that includes both coating products and application services, also through a global network of authorised applicators. Together with its partners Multi Solutions (Uskedalen, Norway), a leading service provider specialising in the eco-cleaning and re-coating of box coolers in shipyards worldwide, and NGP (Straume, Norway), a specialist in box cooler re-coating and maintenance services, Säkaphen recently participated in SMM, the leading international maritime trade fair held in Hamburg (Germany) every September. While exhibiting here, they noted increasing interest in the cleaning and re-coating of box coolers as a sustainable way to lengthen these systems’ service life (the expected life cycle of a box cooler is usually 15 years).
Säkaphen has specifically designed a coating product that is ideal for protecting box coolers: a floodable, 2-pack, cold-cured, epoxy hybrid lining called Säkatonit Extra AR-F. Its unique blend of resin and a hardener, also combined with specialised application methods, ensures a smooth hydrophobic finish offering outstanding protection against abrasion and reducing caking, fouling, and incrustation, as well as superior electrochemical insulation.
Säkaphen has specifically designed a coating product that is ideal for protecting box coolers: a floodable, 2-pack, cold-cured, epoxy hybrid lining called SÄKATONIT
AR-F.
The heat transfer rate of carbon steel coated with 150 microns of Säkatonit Extra AR-F is 25 W/mK, as third-party tested by 3M. In particular, when coating box coolers, it limits the adhesion of marine growth, including barnacles, and provides safe and reliable operation and, above all, protection against galvanic corrosion.
Säkaphen’s coating is not negatively affected by the use of Marine Growth Prevention Systems (MGPS), such as Impressed Current Anti Fouling (ICAF) systems.
Säkatonit Extra AR-F contains no biocidal filler for greener, more environmentally friendly shipping operations. The coating withstands the harsh marine environment in both warm and cold waters. Therefore, the use of box coolers combined with cleaning and re-coating with Säkatonit Extra AR-F allows companies to extend the service life of their assets, thus further improving sustainability and operating in line with UN sustainability development goals and ESG standards.
“Over the years, we have consistently experienced the exceptional quality of Säkaphen’s coatings, particularly in preventing galvanic corrosion,” confirms Egil Fallmayr, Business Development Manager at Multi Solutions. “Their cold-cured epoxy paint enables us, as service partners for various box cooler manufacturers, to offer vessel owners a reliable solution during
A box cooler before treatment.
The same box cooler after cleaning, blasting, and coating.
drydock periods. This paint provides excellent protection for box cooler pipe bundles and is ideal for such applications. Säkaphen’s support from the beginning has been crucial to our success. Finally, the significant life extension their coating offers is not only a major cost-saver for vessel owners but also contributes to environmental protection.”
When it comes to application services, be they performed at the customers’ premises, in drydock, at its German workshop, or at the site of one of its worldwide authorised applicators, Säkaphen can handle the whole process, from inspection and surface cleaning to coating (or re-coating) and testing. Its network of partners and authorised applicators enables the company to serve the maritime industry from the North Sea (UK, Scandinavia) to the Persian Gulf (Dubai), from the Atlantic Ocean (Ghana to South Africa) to the Indian Ocean (Malaysia, Australia).
“We operate on a global scale, ensuring localised support and seamless service delivery across the globe, bringing expert applicators directly to the clients,” says Atle Falk, Chief Commercial Officer at NGP.
“Such regional focus allows for quick response times, reducing downtime and operational inefficiencies for customers. As part of Säkaphen’s network, we can bring extensive expertise in box cooler re-coating worldwide.”
“We are lucky to have so many highly qualified partners operate as authorised applicators of Säkaphen’s coatings,” states Christoph Fischer-Zernin, the Commercial Director of Säkaphen.
“While we support them with our coating products and know-how in application processes and inspection procedures, they enable us to reach a wide client base worldwide and in the most diverse industries with reliable services of the highest quality.”
A few years ago, for example, Säkaphen was contacted by a Scandinavian vessel operator to provide a box cooler re-coating
solution that was suitable for all the geographical regions in which its fleet of offshore supply vessels operated. Ideally, that had to be done without shipping the box coolers to Europe. Locations included Rio de Janeiro, Singapore, Eastern Europe, Scandinavia, and the Middle East. Due to the high investment costs per location, the large number of potential docking sites, and above all, the unavailability of curing ovens, it soon became clear that the best solution would be a cold-cured coating.
Therefore, this was required to have a pot life long enough to allow the paint to be applied on the whole box cooler surface but, at the same time, a curing speed fast enough to achieve feasible processing times. Moreover, the application process had to work under various environmental conditions, ranging from colder temperatures in Scandinavia (10 °C) to elevated temperatures in South America or the Middle East (38 °C), and potentially at
elevated humidity (up to 80%). Last but not least, the application procedure had to be simplified to allow cleaning and re-coating of the box coolers around the world in or near the respective drydock location chosen by the vessel operator for this 5-year class renewal project. Säkaphen’s Säkatonit Extra AR-F ticked all the boxes. Some months ago, Säkaphen had the opportunity to check its product’s performance on the occasion of some of these box coolers’ subsequent 5-year class maintenance milestone. Its coating product proved to guarantee excellent performance: marine growth was less than expected thanks to the hydrophobic surface formed by the lining, and any barnacles and fouling traces were easily removed. Mechanical damage was minimal and largely caused by routine handling of the box coolers during service. Neither the Marine Growth Prevention System (MGPS) nor erosion had had a negative effect on the coating. “Afterwards, more and more box coolers treated with Säkatonit Extra AR-F have reached their next 5-year class renewal milestone and have been subjected to inspection,” notes Fischer-Zernin.
“They have all shown equally good results, making our customers consistently satisfied with our linings and services.” ‹
A few years ago, a Scandinavian vessel operator approached Säkaphen for a box cooler re-coating solution that could work across all the regions where its offshore supply vessels operated, without needing to ship the coolers to Europe. Due to the high investment costs per location, the large number of potential docking sites, and above all, the unavailability of curing ovens, it soon became clear that the best solution would be a cold-cured coating.
Temperature resistance from -40°C to +70°C
Resistance to extreme weathering, UV and salt
spray protection
Immediate use of coated items
Easy to repair
Oil and gas companies, tank manufacturers, and shipyards in offshore or coastal environments face a common dilemma. Should they save money by using the abundant seawater around them for hydrotesting or ballasting and risk aggressive corrosion inside their vessels? Or should they pay more for fresh water and avoid exposing their metals to an extra corrosive environment? Cortec® offers a third option for this false dilemma by recommending the use of corrosion inhibitors developed specifically for use in seawater.
EcoLine® VpCI®-642 and VpCI®-645 are two biobased corrosion inhibitor products that can be added to seawater for hydrotesting tanks, pipelines, fire sprinklers, and a variety of other components. These corrosion inhibiting products dissolve readily in water for easy application and inhibit corrosion at a low dose (0.3-0.75% by volume for EcoLine® VpCI®-642 and 0.5-1% by volume for VpCI®645). After the hydrotest seawater is drained, the vessel should be rinsed with fresh water treated with 0.5% VpCI®-609 (by weight) for post-hydrotesting protection. EcoLine® VpCI®-642 and VpCI®645 can also be added to seawater in ballast tanks of ships and offshore platforms to protect against water-bottom corrosion.
For those concerned about the environment, EcoLine® VpCI®642 and VpCI®-645 have several advantages. First, they are both USDA Certified Biobased Products that contain 93% USDA certified biobased content, relying heavily on renewable raw materials. Secondly, they are effective replacements for corrosion inhibitor formulations based on nitrite, chromate, or hydrazine. While local requirements should always be checked before disposal, EcoLine® VpCI®-642 and VpCI®-645 are more likely to be compliant than corrosion inhibitors of the past.
Another corrosion inhibitor option for seawater hydrotesting is M-645. This product is an oil-based float coat suited for use in tanks. It rides on the surface of the water, coating all metal surfaces with a water-displacing film as the seawater is raised and lowered. This behaviour also makes it a nice option for ship ballast tanks, which need to be repeatedly filled with seawater and emptied over time after the vessel is hydrotested and put into service. Since M-645 floats on the surface of the water, it does not contaminate the ballast water, allowing for normal discharge procedures.
With oceans covering more than two-thirds of the globe, it is important to have seawater as a hydrotesting option for the many pipeline, tank construction, and shipbuilding projects in process. Cortec® corrosion inhibitors make that economical option viable by protecting against the corrosive effects of seawater. ‹
NTT Corporation (NTT) has established an image recognition technology that automatically detects corrosion of steel materials from images taken of infrastructure facilities using a digital camera and estimates the depth of corrosion (the amount of loss in a steel section due to corrosion). As a result of verification using steel pipeline facilities, it was confirmed that the defect amount of the steel section can be estimated with an accuracy of 0.44 mm. This technology can automatically grasp the corroded areas of the equipment and the thickness of the remaining steel material from the images, enabling highly accurate evaluation of equipment durability and load-bearing performance. This reduces maintenance costs by allowing repairs to be performed in a timely manner. This new technology was introduced at the Tsukuba Forum 20241, which took place from May 16-17, 2024.
Many steel structures such as bridges, steel towers and guardrails have been installed, and the aging of infrastructure facilities is a major social problem. The main cause of deterioration of these facilities is corrosion of steel. Corrosion in the equipment causes the steel to lose its cross section as it progresses, and the durability and load resistance of the equipment gradually deteriorate, which may eventually lead to damage or collapse.
1 https://www.tsukuba-forum.jp/e/index.html
Therefore, it is important for the facility manager to inspect the deterioration condition to properly diagnose the remaining durability and load-bearing capacity. However, it is difficult to accurately evaluate the remaining durability and load-bearing capacity using the current inspection method. Steel thickness is essential for structural calculations to accurately evaluate durability and load-bearing performance. However, at present, the depth of corrosion (the amount of defect in the steel section due to corrosion) cannot be ascertained because workers visually inspect the exterior of the equipment. There is a method to measure the thickness of steel using ultrasonic waves, but it is not practical because a probe needs to be placed at the measuring point, which requires a lot of work cost for the entire facility. In addition, inspections of large structures such as bridges may require the installation of scaffolding and other costs.
A simple and low-cost method for measuring the thickness of steel materials is necessary for the maintenance of safe and secure facilities by highly accurate diagnosis of steel structures.
We have established an image recognition technology that automatically detects corrosion from images of steel structures taken with a digital camera and estimates the amount of defects in steel sections due to corrosion. This technology was established using steel conduit facilities (steel pipes), which are telecommunication infrastructure facilities owned by NTT (Fig. 1).
Technical points:
Corrosion detection
The areas are classified into areas where minor corrosion has occurred without defects in the steel section, areas where corrosion has occurred with defects in the section, and healthy areas where no corrosion has occurred. This allows quantitative determination of the areas of highly monitored corrosion with defects in steel sections.
Estimation of steel section defect
NTT has established an image recognition technology that automatically detects corrosion from images of steel structures taken with a digital camera and estimates the amount of defects in steel sections due to corrosion.
Highly accurate estimation is achieved by building a machine learning model using NTT’s proprietary database. Among the various appearance features that change with the progress of corrosion, such as the extent of corrosion, colour, and the size of the rust hump, we clarified the features that are highly related to the amount of defect in the steel section. Based on this feature, corrosion images with various degrees of progress were grouped, and corrosion images and cross-sectional defect measurements in the images were prepared so that each group was sufficiently and equally corroded. The high-quality database constructed by selecting images based on appropriate features and accurately measuring the amount of defects enables highly accurate estimation of defects. The image in Figure 1 shows the inner surface of a steel pipe photographed using a pipe camera. In detecting corrosion, areas of corrosion with cross-sectional defects are detected. The amount of loss in the pipe cross-section is then estimated by analysing the degree of corrosion progression. Finally, since the thickness of the communication steel pipe is 4.20 mm in its sound state, the remaining steel thickness in the corroded area can be calculated to be 2.95 mm by subtracting the amount of sectional loss.
Verification contents
Using the steel pipe installed at the site, we photographed the inner surface of the steel pipe with a pipe camera.
Using this technique, we estimated the amount of loss in the steel section due to corrosion from the images. In addition, steel pipes were cut in the cross section direction at 30 corrosion points estimated by this technology, and the amount of defect in the cross section was measured using an electron microscope (Fig. 2).
Validation results
Figure 3 shows the measured values of defects in steel sections of steel pipes and the results of the estimated values using this technology. The correlation coefficient2 was 0.803, confirming a high correlation. The average error of the estimated value was 0.20 mm, and the variance was 0.12 mm3. Based on these results, it was confirmed that the defect amount of the steel section could be estimated with an accuracy of an error of ±0.44 mm4
This technology enables us to quantitatively grasp the thickness of steel materials in structures, so that we can accurately diagnose the remaining durability and load-bearing capacity. This allows repairs to be performed in an appropriate time and manner, ensuring safe and secure facility functions and reducing maintenance costs.
NTT Group companies plan to commercialize this technology in fiscal 2024. In addition, it will contribute to the realization of a sustainable society by solving problems such as an increase in the maintenance and management costs of the entire social infrastructure by applying the system to various infrastructure facilities such as bridges, steel towers and guardrails. ‹
2 Correlation coefficient is an index that measures the strength of a linear relationship between two sets of data. The closer the coefficient is to 1, the stronger the positive relationship.
3 Variance is standard deviation (σ) of the estimation error of the defect amount of the cross section by this technique.
4 Accuracy/estimation accuracy: 95% confidence interval (2σ).
MORE THAN 30 YEARS OF EXPERIENCE IN INDUSTRIAL AND ANTI-CORROSION
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Rabea Osol, Helmholtz-Zentrum Hereon GmbH - Geesthacht, Germany
The CHAI project, led by the Helmholtz-Zentrum Hereon and funded by the federal state of Schleswig-Holstein, utilizes AI to enhance monitoring and prediction of corrosion damage in maritime areas, reducing maintenance costs.
Corrosion leads to the impairment and loss of function of structural components in maritime areas. In SchleswigHolstein, the northernmost of the 16 states of Germany, these areas include the harbour in Kiel and the floodgate in Brunsbüttel. Although coating systems help to mitigate the effects of corrosion, they can be compromised by a wide variety of factors, leading to corrosion damage and material fatigue. Given the immense costs associated with this, the integrity of these coating systems and steel structures must be thoroughly monitored to detect damage early and assess its severity. However, scheduled maintenance and inspections of infrastructures are also costly. To address this, the CHAI project, led by the Helmholtz-Zentrum Hereon and funded by the federal state of Schleswig-Holstein with a total of 900,000 euros, is developing methods that will enable the implementation of a predictive maintenance strategy. The overarching goal is to detect (critical) damage as early as possible and prioritize it based on maintenance requirements, effort, and costs. It was observed that local variations in water quality can influence the stages of corrosion, making standardized monitoring very challenging. As part of the project, the partners aim to establish the necessary infrastructure for monitoring environmental conditions and for detecting and assessing corrosion damage at two locations. The collected data will also serve as a training dataset for developing data-driven prediction models to estimate maintenance intervals.
The CHAI project, which stands for “Clever Corrosion Management for Ports and Waterways in Schleswig-Holstein using Automated Infrastructure Monitoring,” involves partners such as the Port of Kiel, Christian Albrechts University of Kiel (CAU), and AC Korro-Service GmbH, and aims to leverage AI to enhance the detection and prediction of corrosion damage in maritime areas. Dr. Daniel Höche and Dr. Christian Feiler from the Hereon Institute for Surface Science are leading the project. They are using sensors to record environmental conditions in Kiel harbour and at the lock of the Kiel Canal in Brunsbüttel. For example, they collect data on the temperature and composition of the water, solar radiation, or the presence of organic substances such as algae or bird droppings. All of these factors contribute to the chemical degradation, i.e., corrosion, of steel structures and coatings in the port and at the lock. This results in issues such as holes, cracks, or rust on the material. Until now, complex and expensive inspections have been necessary to detect and prevent such damage, but this is set to change.
Höche and Feiler use the collected data to train an AI. Based on the data, this AI is to predict which material will corrode how
Schleswig-Holstein's Minister of Digitization Dirk Schrödter (in the middle) personally handed over the state's grant notifications to the project partners at the port of Kiel. Daniel Höche, Christian Feiler (left from the middle) and Dr Haijie Tong (left) from Hereon were also present.
Above: Corrosion damage at a quay.
It was observed that local variations in water quality can influence the stages of corrosion, making standardised monitoring very challenging. As part of the project, the partners aim to establish the necessary infrastructure for monitoring environmental conditions and for detecting and assessing corrosion damage at two locations. The collected data will also serve as a training dataset for developing data-driven prediction models to estimate maintenance intervals.
quickly and severely under certain conditions - and how this can be prevented. The more data the AI has at its disposal, the more reliable its predictions will be.
“Our major goal with the CHAI project is to transfer technology from basic research to industry,” says Christian Feiler. “And that the forecasting system will eventually work so well that it can be used by players such as the Port of Kiel or AC Korro-Service GmbH.”
The Minister of Digitalization of Schleswig-Holstein, Dirk Schrödter, also hopes so. “The use of AI technologies can help to make protection systems in our ports, locks and barrages even better and more environmentally friendly at the same time. This minimizes downtimes, reduces maintenance costs and thus strengthens our competitiveness,” he said at the presentation of the grant notifications in the port of Kiel. He personally handed them over to the partners of the CHAI project. The Helmholtz-Zentrum Hereon received 400,000 euros, the largest share of the 900,000 euros in funding. The project costs a total of 1,3 million euros. It is scheduled to run until mid-2027. The data collected will also be stored beyond this date so that it can be used for other projects.
Helmholtz-Zentrum Hereon conducts international cutting-edge research for a changing world: approximately 1,000 employees generate knowledge and innovation toward greater resilience and sustainability. Hereon’s scientific spectrum encompasses high-performance materials, processes, and environmentally friendly technologies for mobility and renewable energy systems. Furthermore, research is conducted on biomaterials for medicine and to enhance the quality of life. Through research and consulting, Hereon addresses the challenges of climate change in a solution-oriented manner and facilitates sustainable management as well as the protection of coasts and the marine environment through comprehensive scientific understanding. From basic understanding to practical applications, the interdisciplinary research centre covers a unique spectrum. As part of an international network and a member of the Helmholtz Association, Hereon supports political, economic, and societal institutions in shaping the future through the transfer of its expertise. Founded in 1956, the centre is the largest non-university research institution in Schleswig-Holstein. In addition to its main location in Geesthacht and its site in Teltow near Berlin, Hereon has branches in Hamburg, Kiel, Berlin, and Garching bei München. The research centre has an annual budget of approximately 100 million euros. ‹
Edited by MONTI - Werkzeuge GmbH, Hennef – Germany
Corrosion is typically an electrochemical process in which oxygen and water cause iron to rust or copper to develop a green patina. This phenomenon leads to significant economic losses, estimated at around 4% of global GDP. Areas affected by corrosion must either be treated or replaced, and in the case of transport pipelines, costs can quickly escalate into the hundreds of thousands of euros. Corrosion also poses substantial risks, especially when gas or other hazardous materials are transported, as corroded sections of pipes may weaken and break.
The solution to corrosion lies in eliminating one or more of its primary causes - water, oxygen, or the electrochemical reaction itself. Traditional metal coatings, such as bitumen, polyethylene (PE), polypropylene (PP), and epoxy powder coatings (FBE), are unable to completely block water and oxygen from reaching the metal surface. To address the electrochemical aspect, transport pipelines often employ cathodic protection, where an electric current halts the ionization of iron. However, this requires continuous monitoring to ensure the coating remains effective. Furthermore, failures in protective coatings can occur for various reasons, including defective materials, application errors, improper coating selection, and environmental factors. However, inadequate surface preparation stands out as the leading cause, responsible for 83% of failures. MontiPower, the German company that since 1987 engineers, manufactures and distributes hand-tool and automated machine systems for surface preparation, in collaboration with its sales partner in China, Robot++, launched a revolutionary automated surface preparation robot, which is designed to elevate the efficiency, precision, and quality of surface treatment processes at high altitudes, the HighMate
Prepper®. “It is a state-of-the-art robotic surface preparation tool that integrates advanced technology with the trusted performance of the MBX and the Bristle Blaster and following the method of bristle blasting”, says J. F. Doddema, Monti Group’ CEO. “Engineered for industrial applications, the Prepper is ideal for surface preparation tasks that require precision and consistency, such as in tanks and terminals, shipbuilding maintenance and repair, pipelines, OEM manufacturing, and the wind energy industry. Key applications include preparing surfaces for coating, welding, and other industrial processes for pipeline field joints and or flat roofs, tank wall, or ship decks, not only on-site but also in manufacturing facilities”.
“HighMate Prepper is not just a robotic tool; it is a revolution in surface preparation to avoid scaffolding”, Doddema continues. “Our partnership with Robot++, our esteemed sales partner in China, was strategic. With a dedicated team of 160 employees, Robot++ has proven to be an exceptional partner in both research and development and sales support for our operations in Germany. Currently, they provide support for over 300 robotic surface preparation tools, showcasing their capability and commitment to innovation. In terms of research and development, this company is exploring the exciting possibility of integrating a built-in resharpening device to enhance the bristle blasting performance of our tools. This collaboration not only strengthens our presence in the Chinese market but also underscores our commitment to delivering high-quality solutions in surface preparation.”
Dual Bristle Blaster system:
- enhanced efficiency: the Prepper is equipped with a Bristle Blaster Double, allowing it to treat up to approximately 3 square meters per hour, achieving rust grade B per the ISO 8501-1 on a flat surface.
- Consistent surface quality: delivers cleanliness similar to Sa2.5 (SSPC-SP10) and a surface profile greater than 50 microns (2 mil), ensuring optimal adhesion for coatings and treatments.
Automated surface treatment:
- Pre-set routines: the HighMate Prepper can be programmed with standard routines to automatically treat specific surface patterns, such as circles around pipes, square meters, or straight lines.
- Customizable settings: every aspect of the treatment process can be adjusted, including angle, speed, pressure, width, distance, and time. This flexibility ensures the Prepper can handle a wide range of surface preparation tasks with precision.
- Dust control.
Advanced robotics integration:
- High precision: with the latest robotics technology from Robot++, the HighMate Prepper offers unmatched accuracy in surface treatment.
- Easy programming: users can easily program and adjust settings via a user-friendly interface, making the HighMate Prepper accessible even to those with minimal technical expertise.
Durability and reliability:
- Industrial-grade build: constructed with high-quality materials, the HighMate Prepper is built to withstand the rigors of industrial environments, ensuring long-term reliability and reduced maintenance costs.
Magnetic wheels: the robot is equipped with 4 permanent magnetic wheels. This allows the robot to clamp itself securely to the surface to be pre-treated. The robot can operate completely vertically or upside down. All 4 wheels are electrically driven for precise control.
“The HighMate Prepper offers numerous advantages that make it a valuable ally in the surface preparation process,” highlights Doddema.
“First and foremost, efficiency stands out as one of its primary strengths. By utilizing this robot, users can significantly reduce the time required for surface preparation while maintaining highquality results. With the capability to treat up to 3 m² per hour, the HighMate Prepper clearly distinguishes itself from traditional methods used for weld cleaning and repair work (Table 1).
Cleaning
Consumables & Waste
Table 1: Comparison between HighMate Prepper and traditional technologies.
Moreover, precision and consistency are assured, thanks to its ability to deliver surface profiles of at least 50 microns. This level of precision is critical for ensuring strong adhesion in subsequent coating or treatment processes. Versatility is another key aspect; this device features automated routines and customizable settings, allowing it to adapt to a wide range of surface preparation tasks, thereby saving time and reducing the risk of human error.
UTILIZING THIS ROBOT, USERS CAN SIGNIFICANTLY REDUCE THE TIME REQUIRED
When it comes to cost-effectiveness, this system translates into significant savings for industrial operators, as it improves efficiency and decreases the need for manual labour.
It represents not only a smart investment but also a solution that yields considerable economic returns over the long term.
Finally, the HighMate Prepper is a cutting-edge solution born from the collaboration between MontiPower and Robot++. This partnership merges expertise in surface preparation and robotics, resulting in an innovative product that effectively meets the modern industry’s challenges.”
“In terms of price, we must think of the Prepper as a smart long-term investment,” Doddema continues. “While the upfront cost might seem significant, it quickly pays for itself by reducing labour expenses, cutting down on rework, and boosting overall efficiency. In the long run, this leads to a much higher return on investment (ROI). As for complexity, customers can rest easy knowing that the Prepper is designed with userfriendliness in mind. Its intuitive interface makes it easy to operate, and MontiPower goes the extra mile by providing comprehensive support, from training to after-sales service, ensuring a smooth experience from start to finish. When it comes to compatibility, the Prepper shines with its flexibility. It can be easily adjusted to work with different surface types and meet a variety of preparation needs. This makes it an incredibly versatile tool, suitable for a wide range of applications.” With its advanced features, automation capabilities, and robust construction, the HighMate Prepper is set to become an essential asset in any industrial setting for surface cleaning and preparation. ‹
Jeremy Thomas, Lawrence Livermore National Laboratory - Livermore (CA), United States
Research conducted at the Lawrence Livermore National Laboratory (LLNL), located in the San Francisco Bay Area, identified the material properties that cause or initiate pitting corrosion in 3D-printed stainless steel.
Like a hidden enemy, pitting corrosion attacks metal surfaces, making it difficult to detect and control. This type of corrosion, primarily caused by prolonged contact with seawater in nature, is especially problematic for naval vessels.
In a recent paper published in Nature Communications1, Lawrence Livermore National Laboratory (LLNL)2 scientists delved into the mysterious world of pitting corrosion in additively manufactured (3D-printed) stainless steel 316L in seawater. Stainless steel 316L is a popular choice for marine applications due to its excellent combination of mechanical strength and corrosion resistance. This holds even more true after 3D printing, but even this resilient material isn’t immune to the scourge of pitting corrosion.
The LLNL team discovered the key players in this corrosion drama are tiny particles called “slags,” which are produced by deoxidizers such as manganese and silicon. In traditional stainless steel 316L manufacturing, these elements are typically added prior to casting to bind with oxygen and form a solid phase in the molten liquid metal that can be easily removed post-manufacturing. Researchers found these slags also form during laser powder bed fusion (LPBF) 3D printing but remain at the metal’s surface and initiate pitting corrosion.
1 https://www.nature.com/articles/s41467-024-45120-6
2 https://www.llnl.gov/
“Pitting corrosion is extremely difficult to understand due to its stochastic nature, but we determined the material characteristics that cause or initiate this type of corrosion,” said lead author and LLNL staff scientist Shohini Sen-Britain. “While our slags looked different than what had been observed in conventionally manufactured materials, we hypothesized that they could be a cause of pitting corrosion in 316L. We confirmed this by taking advantage of the impressive materials characterization suite and modelling capabilities we have at LLNL, where we were able to prove without a doubt that slags were the cause. This was extremely rewarding.”
While slags also can form during traditional stainless steel manufacturing, they are typically removed with chipping hammers, grinders or other tools. Those post-processing options would defeat the purpose of additively manufacturing (AM) the metal, said the researchers, who added that prior to their study, there was almost no information on how slags are formed and deposited during AM.
To help address these unanswered questions, the team used a combination of advanced techniques including plasma-focused ion beam milling, transmission electron microscopy and X-ray photoelectron spectroscopy on AM stainless steel components. They were able to zoom in on the slags and uncover their role in the corrosion process in a simulated ocean environment, finding they created discontinuities and allowed the chloride-rich water to penetrate the steel and wreak havoc. Additionally, the slags contain metal inclusions that dissolve when exposed to the seawater-like environment, further contributing to the corrosion process.
“We wanted to do a deep-dive microscopy study to figure out what could potentially be responsible for corrosion when it does happen in these materials, and if that’s the case, then there may be additional ways of improving them by avoiding that particular agent,” said principal investigator Brandon Wood. “There is a secondary phase that’s formed that contains manganese — these slags — that appeared to be what was most responsible. Our team did some additional detailed microscopy looking at the neighbourhood of those slags, and sure enough, we were able to show that in that neighbourhood you have enhancement — a secondary indicator that this is probably the dominant agent.”
Using transmission electron microscopy, the researchers selectively lifted small samples of 3D-printed stainless steel from the surface — about a few microns — to visualize the slags through the microscope and analyse their chemistry and structure at atomic resolution, according to lead investigator Thomas Voisin.
The characterization techniques helped shed light on the complex interplay of factors that lead to pitting corrosion and enabled the team to analyse slags in ways never done before in AM.
“During the process, you locally melt the material with the laser, and then it solidifies very rapidly,” Voisin said. “The rapid cooling freezes the material in a none-equilibrium state; you’re basically keeping the atoms in a configuration that is not supposed to be, and you’re changing the mechanical and corrosion properties of the material. Corrosion is very important for stainless steel because those are used a lot in marine applications. You could have the best material with the best mechanical properties, but if it cannot be in contact with seawater, this is going to significantly restrict the applications.”
Researchers said the study marks a significant step forward in the ongoing battle against corrosion, not only deepening scientific understanding of corrosion processes, but also paving the way for developing improved materials and manufacturing techniques. By unravelling the mechanisms behind the slags and their relationship to pitting corrosion, engineers and manufacturers
can strive to create stainless steel components that are not only strong and durable, but also highly resistant to the corrosive forces of seawater, with implications extending beyond the realm of marine applications and into other industries and kinds of harsh environments.
“When we 3D print the material, it’s better for mechanical properties, and from our research, we also understand that it’s better for corrosion as well,” Voisin said. “The surface oxide that forms during the process is developing at high temperature, and that also gives it many different properties. What’s exciting is understanding the reason why the material corrodes, why it’s better than other techniques and the science behind it. It is confirming, again and again, that we can use laser powder bed fusion AM to improve our material properties, way beyond anything we can do with other techniques.”
Now that the team understands the causes behind pitting, Sen-Britain and Voisin said the next steps to enhancing the performance and longevity of 3D-printed stainless steel 316L would be altering the formulation of the powder feedstock
to remove manganese and silicon, to limit or eliminate slag formation. Researchers also could analyse detailed simulations of the laser’s melt track and melting behaviour to optimize the laser’s processing parameters and potentially prevent the slags from reaching the surface, Voisin added.
Funding for the project came from a Lab Strategic Initiative3 on corrosion led by Wood, which sought to combine modelling and detailed experimental characterization to predict lifetimes of materials and potentially improve on them.
“I think there’s a real pathway to actually co-designing these alloy compositions and the way they are processed to make them even more corrosion resistant,” Wood said. “The long-term vision is to go back to a prediction-validation feedback cycle. We have an idea that the slags are problematic; can we next leverage our composition models and process models to then figure out how to change our base formulations, such that what we get is basically an inverse design problem. We know what we want, now we just have to figure out how to get there.” ‹
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3 https://ldrd-annual.llnl.gov/ldrd-annual-2022/project-highlights/advanced-materials-and-manu facturing/predicting-and-controlling-corrosion
By unravelling the mechanisms behind the slags and their relationship to pitting corrosion, engineers and manufacturers can strive to create stainless steel components that are not only strong and durable, but also highly resistant to the corrosive forces of seawater, with implications extending beyond the realm of marine applications and into other industries and kinds of harsh environments.
By RIO - Research and Innovation Office,
The Hong Kong Polytechnic University
Hong Kong
The Hong Kong Polytechnic University’s researchers introduced biomineralization as a sustainable strategy against the marine corrosion on concrete.
Microbially induced corrosion (MIC) is a prevalent issue in marine environments, leading to structural damages such as cracking in concrete infrastructure. This corrosion poses a persistent challenge, significantly reducing the lifespan of marine structures and resulting in substantial economic losses. In response to the need for an effective solution to combat the marine corrosion on concrete, researchers of the Hong Kong Polytechnic University have developed a biomineralization approach to protect marine concrete from MIC.
Prof. Xiang-dong LI, Dean of Faculty of Construction and Environment, Director of Research Institute for Sustainable Urban Development, Chair Professor of Environmental Science and Technology, and Ko Jan Ming Professor in Sustainable Urban Development, has led the research that successfully introduces a novel biomineralization strategy, which effectively isolates marine concrete from MIC, thereby contributing to the achievement of sustainable coastal
structures. MIC on concrete usually occurs in harsh environments with the presence of corrosive microorganisms, such as sewage structures, wastewater treatment plants, and marine structures. The formation of a biomineralized film on concrete surfaces is typically considered to be the major anticorrosion mechanism as it can provide a barrier to inhibit corrosion.
Prof. LI said, “The biomineralization technique serves as an environmentally friendly coating method for controlling concrete corrosion, with minimal impact on the overall biofilm communities. Also, it utilises carbon dioxide to produce mineral precipitates, enhancing the durability of concrete structures. This process not only reduces the carbon footprint and energy consumption of marine infrastructure throughout its lifespan, but also makes a valuable contribution to carbon neutrality and sustainability.”
The study showed the biomineralization treatment effectively prevents corrosion by reducing the total and relative abundance of sulphate-reducing bacteria (SRB). SRB is a type of anaerobic bacteria and can produce hydrogen sulphide, which is corrosive and can lead to material deterioration. The biomineralized film acts as a protective layer, controlling sulphate diffusion and isolating the concrete from the corrosive SRB communities. This protective mechanism significantly extends the lifespan of concrete structures. Moreover, this technique has no negative impact on the native marine microbial communities.
Prof. LI added, “If the biomineralized film remains intact, repainting the concrete structures is unnecessary. The utilisation of a single coating treatment eliminates the need for multiple treatments, further minimising the cost and carbon footprint.”
This biomineralization strategy has strong potential for applications in corrosive environments, such as marine environments, sewage environments, and water cooling utilities, where concrete corrosion is induced by corrosive microorganisms. The research, titled “Biomineralization to prevent microbially induced corrosion on concrete for sustainable marine infrastructure” was published in Environmental Science &
Technology1. The study employed a combination of chemical and mechanical property measurements of concrete, along with an analysis of the microbial community of biofilms, to evaluate the effectiveness of biomineralization techniques in inhibiting corrosion of marine concrete. These assessments aimed to enhance understanding of MIC development. The results contribute to the development of new techniques for inhabiting corrosion to achieve sustainable marine concrete structures.
In a sulphate chemical attack, calcium hydroxide and calcium aluminate hydrate will be consumed to form gypsum and ettringite, resulting in expansion stress and matrix fracture (Fig. 1a). In an MIC attack, bacteria can colonise the corroded layer, which provides an excellent medium for microorganisms to grow. Microbial activity can extend beyond the corrosion layer near to the surface and spread across the deterioration zone (Fig. 1b).
Compared with chemical corrosion, MIC causes more severe damage to marine concrete structures. However, the formation of the biomineralized film on the concrete surfaces led to higher surface pH (potential of hydrogen) and lower surface sulphate concentrations, which also acted as a protective layer to control the diffusion of sulphate and isolate the concrete from SRB communities, decreasing internal sulphate levels (Fig. 1c).
Considering that the type of colonised surface also affects the treatment effect of biomineralization, the effectiveness of biomineralization will be further investigated for different types of concrete to expand its applicability potential. In addition, the functional prediction can be used in future studies to obtain a mechanistic understanding of the possible metabolic capability of microbial action on concrete corrosion. This understanding is beneficial for uncovering the mystery between SRB and the lifespan of marine concrete structures. ‹
1 https://pubs.acs.org/doi/10.1021/acs.est.3c04680
Corrosion mechanism for (a) chemical corrosion; (b) biofilm corrosion; (c) biomineralization for corrosion inhibition.
by Gianmaria Guidi, Germedia Srl – Brescia, Italy - gianmaria.guidi@germedia.it
In this article, Giammaria Guidi, who has over thirty years of experience in the industrial and corrosion protection coating sector, addresses one of the most complex and delicate topics in the application phase of coatings: the calculation of the coverage of coating products, analysed here as a cost factor that directly impacts the economic aspect of the coating project.
Unfortunately, and increasingly often in the coating industry too, our society fails to anticipate and avoid the loss of knowledge, skills, and expertise levels. In 1974, Kaufman called this phenomenon “the obsolescence of skills”, referring to the lack of up-to-date knowledge or proficiency a worker needs to continue to perform their current or future job properly. More and more often in our professional activities, major problems arise precisely from the failure to compensate for physiological information asymmetries between contractual parties, which can no longer be adequately compensated due to a lack of specific technical expertise. In recent decades, market dynamics have favoured economic and financial aspects to the detriment of investment in technical training, taking it for granted that the necessary technical elements were simply ingrained in the common consciousness. The case described below attempts to refocus attention on a calculation method that helps define the economic impact of paint products in a coating project.
Every coating project requires a thorough feasibility analysis that considers various factors and constraints, e.g. time-related, technological, regulatory and, last but not least, economic. In particular, this article analyses paint coverage as a cost item directly affecting the coating project’s economic factor. To reach a coating treatment’s expected performance and durability as defined in the design phase, it is necessary to achieve and maintain the specified dry film thickness (DFT) value. That ensures the coating acts as a protective barrier, preventing corrosive agents such as water, salts, and oxygen from reaching the metal surface. Insufficient DFT can indeed leave vulnerable areas, exposing the metal to corrosion. In contrast, adequate DFT increases the coating’s resistance to mechanical and chemical stress, prolonging its service life and protective action and reducing the need for frequent maintenance and repairs. A sound coating project should also use the appropriate terminology to
define the desired DFTs, also considering that, in the context of coating treatments, nominal quantities translate into actual measures conditioned by wide tolerances, which are absolutely necessary and unavoidable.
Various international standards can be used to determine the dry or wet thickness of a coating. This article focuses on dry thicknesses as an objective parameter for qualitatively evaluating the applied cycle. The coating work can be divided into two main macro-phases: design and execution. In the design phase, the designer defines the coating’s nominal dry film thickness (NDFT), the required sampling plan, and the measurement tolerances (e.g. +/- 20%).
In the execution phase, the applicator applies the coating and strives to meet and maintain the set standards, initially measuring the applied wet film thickness (WFT) and then checking the final dry film thickness (DFT) achieved after the polymerisation step. It is important to emphasise that the terminology and acronyms used to define the desired values are not universal but strictly depend on the technical regulations adopted by the designer. For example, in ISO 2808 and ISO 19840, the acronym DFT may refer to two different measurements, one of which rules out surface roughness after shot blasting. These differences are of fundamental importance when calculating the coverage of a coating treatment.
To achieve the specified NDFT, the applicator must calculate the coverage of the products that make up the coating system by taking into account at least the following aspects:
The theoretical coverage of a paint product (fig. 1), considering its dry solid by volume (S.V.) and the possible dilution required for its application, which increases the value of volatile organic compounds (VOCs) and decreases the DRV, with a direct impact on the final DFT.
The correction factor for shot-blasted surfaces, which takes into account the fact that part of the paint is deposited within the surface irregularities, creating a so-called “dead volume” (fig. 2). Although such volume is filled by the product, it does not contribute to the effective protection of the substrate, as it does not increase the thickness of the dry film covering the exposed areas. Therefore, it is crucial to consider this correction factor when calculating product coverage, as it directly affects the effectiveness of the protection provided by the coating treatment. Ignoring the dead volume could lead to underestimating the amount of paint required to achieve the necessary degree of protection.
The necessary overconsumption factor (NOC), representing an amount of paint product that does not disperse into the environment but rather is deposited on the surface to ensure compliance with the required NDFT values (fig. 3): such overconsumption is not due to the applicator’s lack of skill but is an unavoidable discontinuity in the coating process. Any application method inevitably generates variations in the thickness of the organic film deposited on the surface. Therefore, a larger volume of paint must always be applied to ensure compliance with the minimum DFT value defined in the sampling plan.
The loss factor due to the geometry of the object to be coated mainly affects spray application operations, but it should be considered that, to a lesser extent, it can also affect brush or roller application ones, depending on the complexity of the part’s geometry itself.
The loss factor due to overspray affects spray application and can be influenced by various elements, such as the distance from the surface, the complexity of the part’s shape, the presence of air currents, the type of atomisation used, and the spray pressure set by the operator.
Any advance estimate cannot be exact and must be confirmed or denied after completion of the process. However, since it is necessary to calculate the economic impact of paint consumption at the quotation stage, it can be useful to resort to computational formulas using theoretical correction coefficients. If a company is consistent in using these formulas and in subsequently verifying the theoretical coefficients initially applied, it will be able to reduce its error margins, thus consolidating its position in the market with a high level of qualitative-economic competitiveness.
The theoretical coverage of a paint product expressed in square metres (m2) per litre (l) applied is generally determined using the following formula:
Any advance estimate cannot be exact and must be confirmed or denied after completion of the process. However, since it is necessary to calculate the economic impact of paint consumption at the quotation stage, it can be useful to resort to computational formulas using theoretical correction coefficients.
On the other hand, a paint product’s consumption expressed in litres per square metre applied is determined using the following formula: Where:
TC = Theoretical Consumption
SV = Solid by Volume, the percentage of product remaining on the surface after evaporation of the solvent DFT = Dry Film Thickness, the required thickness expressed in microns.
The formula assumes ideal conditions and does not take into account factors such as overconsumption, dead volume, or losses due to overspray that may reduce the product’s actual coverage.
The correction coefficient for the dead volume (fig. 2) is essential to compensate for the loss of paint product that is deposited within surface irregularities and, therefore, does not contribute to effective protection.
This coefficient helps estimate the actual amount of paint required to achieve the desired result.
ISO 19840, in accordance with ISO 8503-1, provides guidance on how to apply this coefficient. Table 1, provided by these standards, simplifies the practical application of this coefficient, allowing the product coverage calculation to be adapted by considering surface discontinuities and their associated losses.
Therefore, in the case of a shot-blasted surface, it is necessary to define its type of surface profile and consequently increase the NDFT of the first layer by the correction value.
As this article introduces a new factor to balance the interests of all parties involved in a coating project, the following considerations will be based on empirical data collected experimentally during inspection activities (fig. 3). It should be noted that this factor is affected by multiple conditions, such as the type of application process, the complexity of the object geometry, the method used, and the tolerances indicated in the DFT sampling plan. In this article, specific guidance is given according to the geometry of the part to be treated, leaving the reader to adapt the coefficient according to their past and future experience.
This factor reflects the actual paint amount deposited on the treated surface, and although it relates to geometry, it does not directly imply the loss of material due to the part’s geometry itself, which will be treated separately. To distinguish these two coefficients, we will use here the acronym NOC followed by the type of object geometry.
NOC for linear geometry:
Linear geometry refers to large, flat-surfaced sheets, profiles, and tubular structures where the spray paint application does not involve frequent direction changes. This application process allows the operator to maintain a constant dispensing position over at least 90% of the surface to be treated. The stripe coating technique is not mandatory, and if used, it should be limited to a maximum of 5% of the total surface area.
NOC for complex geometry:
Complex geometry refers to sheets, profiles, and tubes assembled to form complex structures. In such cases, the spray application of the paint product requires numerous changes of direction,
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preventing the applicator from maintaining a constant dispensing position over more than 50% of the surface to be treated. Stripe coating is necessary but should cover a maximum of 15% of the surface.
NOC for intricate geometry:
Intricate geometry refers to sheets, profiles, and tubes assembled to form intricate structures. In such cases, the spray application of the paint product requires numerous and frequent changes of direction, preventing the applicator from maintaining a constant dispensing position over the entire surface to be treated. Stripe coat application is therefore necessary and should cover more than 15% of the surface.
Conducting a thorough preliminary economic analysis is essential to ensure durable coating results. The project variables and their correction coefficients should be discussed and agreed upon in specific meetings between the customer and the contractor. Corrective factors such as the necessary overconsumption, if not adequately considered, can have significant economic consequences.
Table 2 also provides values for roller and brush application.
Actual paint loss correction coefficient
The actual paint loss must be related to transfer efficiency (TE), which represents the amount of applied paint that actually reaches the surface to be coated (figs. 4 and 5). Two main factors influence such efficiency: the object’s geometry and the application method. Based on the previous definitions, we will use the term “loss” similarly to the acronym NOC, to differentiate the required correction coefficients (table 3).
Loss for linear geometry:
This refers to large, flat-surfaced sheets, profiles, and tubular structures where the spray paint application does not involve frequent direction changes, allowing the operator to maintain a constant dispensing position over at least 90% of the surface to be treated. Under these conditions, almost all the applied paint is deposited on the surface. However, factors such as the type of atomisation technology, the distance from the surface, the
geometry of the workpiece, the presence of air currents, and the delivery pressure set by the operator can affect the final result.
Loss for complex geometry:
This refers to sheets, profiles, and tubes assembled to form complex structures, where the spray application of the paint product requires numerous changes of direction and prevents the applicator from maintaining a constant dispensing position over more than 50% of the surface to be treated. In these circumstances, part of the paint is not deposited on the surface due to the geometry of the workpiece, which facilitates the dispersion of the applied product. Additional factors, such as the type of atomisation technology, the presence of air currents, and the dispensing pressure set by the operator, can further aggravate dispersion.
Loss for intricate geometry:
This refers to sheets, profiles, and tubes assembled to form complex structures, where the spray application of the paint product requires continuous direction changes and prevents the applicator from maintaining a constant dispensing position over the entire surface to be treated. In this situation, a significant amount of paint is not deposited correctly on the surface due to the highly complex geometry of the workpiece, which facilitates the dispersion of most of the applied product. Additional factors, such as the type of atomisation technology, the presence of air currents, and the dispensing pressure set by the operator, can further aggravate dispersion.
For computational calculations related to a spray coating project on a structure with linear or intricate geometry and a “coarse” roughness profile, in order to achieve an NDFT of 200 microns with a paint product (PP) with 80% DRV, the following calculation scheme is suggested as per the two examples.
Conducting a thorough preliminary economic analysis is essential to ensure durable coating results. The project variables and their correction coefficients should be discussed and agreed upon in specific meetings between the customer and the contractor.
Project NDFT adaptation scheme Values in µm
NDFT as per design 200
Dead volume correction factor (for the primer only) + 40
NOC correction factor (linear geometry =15%) + 30
Actual paint loss correction factor (linear geometry =10%) + 20
Total NDFT adjusted by the coefficients = 290
Theoretical and practical consumption and coverage analysis
Theoretical
Project NDFT adaptation scheme
NDFT as per design
Values in µm
200
Dead volume correction factor (for the primer only) + 40
NOC correction factor (intricate geometry =40%) + 80
Actual paint loss correction factor (intricate geometry =50%) + 100
Total NDFT adjusted by the coefficients = 420
Theoretical and practical consumption and coverage analysis
Theoretical coverage in m2/l 4.0 m2/l Practical coverage in m2/l 1.90 m2/l
Theoretical consumption in l/m2
Corrective factors such as the necessary overconsumption, if not adequately considered, can have significant economic consequences. These costs cannot be overlooked in the design phase nor entirely attributed to the applicators, assuming unrealistic execution skills. All the parties involved should consider and concretely agree on the mentioned correction factors to meet the required treatment performance standards.
Everything stated and reported here is intended for the benefit of the industry. ‹
Dr. Gianmaria Guidi has over thirty years of experience in the industrial and corrosion protection coating sector.Over the years, he has specialised in the management of technical-legal disputes and is regularly registered with the Official Register of CourtAppointed Experts (C.T.U.) of the Italian Ministry of Justice, further enhancing his previous NACE and FROSIO certifications.
Jotun responds to Ignazio Messina’s challenging trade with customized solutions, and signs an agreement for the next “Jolly Oro” and “Jolly Argento” drydocks.
Given the common commitment to sustainable operations, Ignazio Messina selects Jotun as a partner for the incoming drydocks. “By continuously developing and innovating sustainable products and solutions, our Clean shipping commitment1 contributes to protecting biodiversity, preserving fuel, and reducing carbon emissions. Our customers reduced emissions by 10.4 million tonnes of CO₂ in 2023, based on ISO 19030 calculations. We are thrilled that Ignazio Messina has selected us to protect their vessels” said Giulia Nebbia, Marine Area Manager in Jotun.
Jotun’s customized solution responds to Messina’s challenging trade in warm waters with moderate speed in an uncertain geographical scenario. Tailored hull coatings system with SeaQuantum (Silyl Acrylate antifouling) and SeaQuest Endura (FRC Biocidal antifouling) will protect Messina vessels granting the best hull performance and cooperating with the sustainable target required.
Jotun Hull Performance Solutions (HPS), of which the two products are part, combines state-of-the-art antifouling and application technologies with high-end technical service. The performance and impact on vessel energy efficiency can be tracked and measured with transparent methods (ISO 19030), and additional highperformance guarantees that can secure return on investment. “Jotun coating systems selected by Ignazio Messina & C. for vessels “Jolly Oro” and “Jolly Argento” will reduce emissions by about 20,000 tonnes of CO₂ during the vessels’ service period,” Giulia Nebbia says and adds: “We are proud to support Ignazio Messina & C. in in-service hull control with the Jotun Hullkeeper program2.”
Digital monitoring is an essential element of hull performance to maintain a clean hull. The ability to identify fouling risks before will help to save fuel, reduce GHG emissions, and protect biodiversity.
The HullKeeper program utilizes Jotun’s in-house developed fouling risk algorithm and combines data from different sources to make fouling control and efficiency predictable enabling ship owners to take hull control by enabling better decisions faster.
Vessels “Jolly Oro” and “Jolly Argento” will join the Hullkeeper program after the drydockings enabling Ignazio Messina & C. to monitor the fouling pressure on the hulls maximizing the coatings performance results.
For further information: www.jotun.com and www.messinaline.it ‹
1 https://www.jotun.com/ph-en/industries/shipping
2 https://www.jotun.com/ph-en/industries/solutions-and-brands/hullkeeper/the-hullkeeper-program
Ignazio Messina & C. provides regular line services that connect the Mediterranean to Africa, the Middle East, and the Indian subcontinent, reaching more than 50 ports and supplying over 40 different countries. In addition to the headquarter in Genoa, Italy, the company has:
commercial offices in Italy: Modena and Naples;
representation commercial offices in Europe: London, Barcelona and Valencia;
controlled agencies in Europe: Marseille;
controlled agencies in Africa: South Africa (Durban, Cape Town, Johannesburg), Côte d’Ivoire (Abidjan), Senegal (Dakar), Kenya (Mombasa, Nairobi), Tunisia (Tunis), Uganda (Kampala), and Mozambique (Maputo).
Company’s shipping consists of a 21-ship fleet, both owned and leased ships, for a total capacity of 40,200 TEU and 62,500 line meters. It directly own 8 Ro/Ro vessels, while all the leased ships are full containers.
by Monica Fumagalli, ipcm®
Thanks to its favourable location in the port of Ravenna (Italy), Donelli Eos, a Donelli Group company specialising in anti-corrosion coating and fireproofing of offshore structures, has become a benchmark supplier not only for shipbuilding businesses in the port but also for firms throughout Italy that need to adequately protect their structures against corrosion before they are exposed to the harsh environmental conditions caused by the salinity of the sea.
The offshore industry, including sectors such as petrochemical and renewable energy, especially the wind power field, accounts for a significant part of the world economy. In 2022, the offshore oil and gas sector achieved record profits, generating approximately 1.4 trillion US dollars in free cash flow globally1 – an increase driven by high energy prices and strong demand for hydrocarbons. The offshore wind market is also experiencing rapid growth, stimulated by industry-wide efforts to reduce carbon emissions. By 2030, it is expected to play a critical role in the transition to renewable energy, with potential revenues set to grow as countries such as the United States, China, and parts of Europe, including Italy, ramp up offshore wind projects.
1 https://www.deloitte.com/global/en/Industries/energy-chemicals/analysis/gx-oil-and-gas-industryoutlook.html
An example of a re-coating operation on a helipad flight deck.
In Italy, the offshore sector is growing significantly in the field of floating wind power. The Italian market has great potential and can become the third largest in the world in this segment, with the prospect of creating up to 1.3 million jobs and generating an economic value of over 255 billion Euros2 while also maintaining a significant presence in the oil and gas sector.
One of the Italian infrastructures that is most focussing on transitioning to more sustainable energy technologies in both the petrochemical and wind power areas is the port of Ravenna. Considered one of Europe’s main commercial ports, thanks to its favourable geographical location for trade with the Eastern Mediterranean, the Black Sea, and the Middle and Far East markets, it is currently one of the most dynamic hubs in the energy supply industry as well.
2 https://quifinanza.it/green/eolico-offshore-italia-ha-potenziale-per-diventare-terzo-mercatomondiale/744323/
Indeed, it has yards equipped for constructing platforms to be installed worldwide, shipyards for building tugboats and support vessels for drilling rigs, and areas for services such as submarine pipeline, offshore platform, and diving support vessel laying. “Precisely because of their direct impact on a country’s economy and industrial development, all these structures must function perfectly and safely. To do so, they must be protected with the most effective anti-corrosion solutions available, as they operate in the harshest conditions and in continuous contact with seawater,” explains Luca Biserna, plant manager at Donelli Eos Srl, the Donelli Group company based right in Ravenna and specialising in corrosion protection and fireproofing coatings and linings, in-shop insulation and thermal insulation, and infrastructure maintenance. “The critical conditions in which they operate can accelerate their structural degradation, potentially leading to serious safety incidents for both facilities and personnel and to significant financial losses.”
In the oil and gas sector, costs for corrosion management and prevention are expected to reach 6.53 billion US dollars by 20323; in the wind energy sector, some figures estimate that the investment for maintenance work on wind turbines, including corrosion prevention, accounts for 30% of total operating costs4 “As applicators of corrosion protection coatings,” states Alessio Trisolino, the CEO of Donelli Alexo, another company of the Donelli Group, “our job is vital to extend the service life of structures and ensure their perfect functioning. Our long-standing history started in 1911, the profound expertise that distinguishes us, and the solid corporate structure we have built over time, currently consisting of 5 companies, enable our Group to present itself as a truly reliable partner in the highly competitive offshore and onshore corrosion protection market.”
The Donelli Group: five sites, one soul ‘5 sites, one soul’ is the motto Donelli has chosen to express its corporate strategy. “Speaking of ‘soul’”, emphasises Trisolino, “seems appropriate because that is precisely what can be found at our five locations, two of which (CX in Cuggiono, in the province of Milan5, and MXP in Ferno, in the province of Varese) recently opened and perfectly consistent with our corporate identity –technologically advanced and characterised by largely automated process management but also by strong attention to detail, a trait that has always been one of our flagships.”
In addition to its sites in the Lombardy region, i.e. Cuggiono (two plants), Ferno, and Voghera, and the one in Ravenna, the
3 https://www.reportsanddata.com/report-detail/offshore-corrosion-protection-market
4 https://www.icorr.org/wp-content/uploads/2024/08/Offshore-Wind-Turbine-Coatings_IsbelisLopez-ACF-27-08-24-Aberdeen.pdf
5 https://www.ipcm.it/en/open/corrosion-protection/2024/6/16-21.aspx
Donelli Eos organised a training course in the field to include new professional, highly motivated employees in its staff.
other companies that complete the Group are Impresa Donelli (Legnano, Milan, with a site also in Ravenna), BerSud (Brindisi), Donelli Sh.p.k. (Albania), and Donelli Mozambique (Maputo, Mozambique). “Our Group’s strength lies in the flexibility and interchangeability of its plants, which are all equipped to perform any application process, although each with its own specialisation. This allows our customers to interface with a single company, which can, however, offer different services as if it were a set of different suppliers. The connections between our sites are immediate and efficient because they have been in operation for many years. At the same time, our staff is highly specialised and continuously trained.”
The critical conditions in which infrastructure operates can accelerate their structural degradation, potentially leading to serious safety incidents for both facilities and personnel and to significant financial losses.
Indeed, the Donelli Group places great importance on training to ensure maximum application performance.
“Recently, in cooperation with employment agency Randstad, we organised very special training courses in the field at our Ravenna site,” describes Biserna, Donelli Eos’s plant manager. “We offered a temporary work contract to about twenty workers: the most motivated ones stayed and became permanently part of our team. We know that the commitment required by this profession is burdensome and that the job characteristics are complex, as working in this sector calls for uncommon mental flexibility to handle even the most complex situations. We sometimes carry out corrosion protection operations in our factory, but it is more often the case that we are required to work at our customers’
premises, especially when the structures’ size and tasks’ delicacy do not allow for material handling. For example, these days, we are finalising an important project at the yard of Rosetti Marino, the long-standing industrial Group providing engineering and construction services in several sectors, including energy, petrochemical, chemical, power, and shipbuilding, that is currently in charge of the revamping of the Ravenna regasifier.”
The construction of the new floating storage and regasification unit (FSRU) is among the main projects involving the port of Ravenna, resulting in hectic shipbuilding activities. “The construction of the new regasifier, which is already nearing completion, is taking place in parallel with the dismantling of
the Petra platform, which will be replaced by the new docking platform for the LNG carrier,” says Marco Fincato, technical director at Donelli Eos, to describe the project that his company has been supporting. “Rosetti Marino entrusted us with the coating of the new structures that will form the docking platform at its yard and the revamping of some parts of the old structures of the Petra platform that could be recovered at our workshop. Specifically, this entails applying fireproofing coatings to parts of this structure – with which we are familiar, having treated and coated the lower part of its main deck since 2010. When placing this order, Rosetti Marino was looking for a reliable partner capable not only of managing its three shot blasting and coating plants (which will soon become four thanks to our technical consultancy) with adequate skills but also of handling on-site application operations. These are perhaps one of the most undervalued but certainly most complex phases of our work: the touch-up phases at sea once the structures have been installed.”
We know that the commitment required by this profession is burdensome and that the job characteristics are complex, as working in this sector calls for uncommon mental flexibility to handle even the most complex situations.
Donelli Eos specialises in fireproofing coatings that can delay or limit fire damage.
The insulation of a structure intended to be subjected to high temperatures.
“We implement different application cycles depending on the conditions under which the metal structure to be protected is intended to operate, in accordance with ISO 12944,” indicates Biserna. “If the structure will operate in atmospheric service, we adopt a tried and tested standard cycle; when the structure is to be subjected to very high temperatures, we physically and thermally insulate it to counteract corrosion. One of the specialisations that have helped us establish ourselves in this sector is the application of fireproofing coatings that can delay or limit fire damage: we have even formed a specially trained team for this type of operation. These are high-thickness coatings suitable for counteracting and delaying the adverse effects of a potential fire: especially in refineries, petrochemical plants, and offshore infrastructures, the characteristics of a possible fire are of such a magnitude and temperature that conditions are very severe. Contrary to civil fires, also called cellulosic fires, i.e. fuelled by flammable materials such as wood, paper, furniture, or textiles, hydrocarbon fires involve liquids such as solvents and gases and are characterised by very fast propagation and very high temperatures. It is, therefore, easy to understand how important it is to apply the most suitable, effective, and long-lasting fireproofing coating.”
Finally, Donelli Eos performs thermal spray treatments on stainless steel, which are essential for preventing corrosion under insulation (CUI).
The Ravenna-based company is currently completing the installation of a new automatic shot blasting machine supplied by OMSG Officine Meccaniche San Giorgio (Villa Cortese, Milan). “Unlike the Group’s other sites,” notes Biserna, “our factory is not equipped with a conveyor. To limit manual handling, especially in the case of small parts that require a lot of effort in the shot blasting booth despite the limited size of the task, we decided to invest in an automatic system that facilitates the work of our operators because they remain outside the plant with considerable advantages in terms of safety, time, and labour reduction.” Such a requirement underlines the great variety of metalwork fabrications handled by the Donelli Group in part size and geometry.
“Most of the structures transported along the north and northeast of the Italian Peninsula and destined for offshore facilities are handled by us,” emphasises Fincato. “We protect against corrosion vital parts of offshore platforms and wind turbines, including highpressure pipelines for the transport of gas from underground sources or jacked support structures for wind blades, but also containers, compressor cabinets and bases, buried pipelines that we treat with a cold wrapping tape application process, and transformer cabinets. In the case of orders with large batch quantities, we can distribute these processes among the Group’s various plants – a testament to the flexibility of our company’s structure.
“Another operation in which Impresa Donelli and Donelli Eos
specialise is the re-coating of helipad flight decks, including horizontal markings in compliance with AIMo regulations, related to the maintenance of facilities and equipment, and ENAC ones. We also carry out friction tests with special equipment to certify the helipads’ suitability and determine the deadline for the following inspection, which can be annual, biannual, or sixmonthly. Finally, we also carry out reflectance measurements of both onshore and offshore tanks containing hydrocarbons according to European emission abatement regulations.”
One of the most complex aspects of being a protective coating applicator is logistics, in terms of both equipment and personnel. “Managing these operations at sea is even more complex because they are affected by weather conditions, and problems to be solved are around the corner more frequently than with onshore works since the intensity of the waves, the strength of the currents, and the speed of the wind are not predictable,” explains Biserna. “Furthermore, on offshore facilities, space is limited in terms of staff accommodation and material storage, transport is very slow, and the environment is highly corrosive. Given all these variables, whereas a repair on land may take a few hours, it could take weeks at sea.”
“However, this is where our strength lies,” Trisolino concludes. “We have several years of experience in this field, which have allowed us to refine our techniques and procedures and, above all, choose
Equipment ready to be shipped to its destination.
our staff carefully, training and integrating only highly motivated people into our team. We are a benchmark applicator for this industry and have a solid corporate structure: this has enabled us to serve major companies in the offshore industry and beyond, such as ENI, even for long-term projects all over the globe. The flexibility-based strategy that distinguishes us and that we have emphasised with our motto is the key element that enables us to meet the needs of any customer, even with the most complex tasks. We are aware of the importance of our work, which has a major impact on infrastructure operation and, therefore, has a significant influence on the global economy.” ‹
One of the most complex aspects of being a protective coating applicator is logistics, in terms of both equipment and personnel.
A study on the importance, impact, and investment in corrosion management was launched by Jotun, one of the world’s leading experts in paints and coatings, at ONS, the leading energy conference and exhibition, which took place from August 24-27 in Stavanger, Norway. Here follows a brief summary.
The integrity of steel infrastructure is directly linked to the safety, security and environmental impact and reliability of energy supplies. Effective corrosion management minimizes the risk of failure and damage. It can also extend the lifespan of existing infrastructure, reduce the need for steel replacement, and limit associated environmental impact. Furthermore, corrosion-related failures are expensive to repair and result in costly disruptions and potentially serious safety risks. From an environmental perspective, failing to maintain steel integrity can be harmful too. According to a report published in Nature in 20221, steel production represents around 10.5% of total global CO2 emissions, but by 2030, as much as 9.1% of the total CO2 emissions will be associated only with steel produced to replace corroded steel.
1 https://www.nature.com/articles/s41529-022-00318-1
by Cecilie Skeie Melberg, Jotun A/S – Sandefjord, Norway
This, combined with an industry where in many cases assets and infrastructure are well into their life cycle, or if newly built will be required to last long-term, means that effective corrosion maintenance is a vital element of oil and gas production. Across the world, countries are looking at how they can transition to cleaner energy to support net zero goals, while also ensuring access to reliable energy supplies. Throughout this transition, oil and gas will continue to be a key element of our energy systems.
There are several challenges faced by companies producing oil and gas, including ensuring that infrastructure is fit
for purpose. A key part of this is effective corrosion maintenance, which is vital in protecting the integrity, safety, and operational efficiency of infrastructure.
Corrosion management in oil and gas is important as the infrastructure, often operates in harsh environments where the risk of material degradation is high. This includes, but is not limited to, the likes of high temperature operations, the challenge of identifying and managing corrosion under insulation and the use of chemicals which weaken the integrity of materials. Any failures in the infrastructure bring with it a high risk of an incident which causes damage to people, assets and the environment – from methane and chemical leakages, to the risk of fires and explosions, loss of integrity, and fallen objects.
As a vital element of an asset’s lifecycle, corrosion maintenance programs require significant investment from companies, both direct costs from expenses in relation to inspection, maintenance and repair, and indirect costs accrued during any downtime for assets or environmental clean-up required should corrosion impact an asset’s operations.
As far back as 2016, a study by the National Association of Corrosion Engineers (NACE) estimated corrosion costs in the [oil and gas] industry to be a staggering $1.372 billion annually2. With another study published in Nature3 where researches speculate that between 14 and 33% of the costs could be prevented by implementing current best practices.
When you consider this in the context of the wider challenges globally around energy, with the world facing an energy trilemma – how to balance energy security, sustainability and affordability - it becomes clear that effective corrosion maintenance is one element required to meet these challenges.
2 https://www.ampp.org/technical-research/what-is-corrosion/corrosion-reference-library/oil-gas
3 https://www.nature.com/articles/s41529-022-00318-1
As a sector, there must be a focus on making sure companies are getting this right and developing plans which ensure any work completed is going to be what is best for the asset, safety, and the environment.
To develop a global picture of the oil and gas industry’s maintenance strategies, Jotun carried out research which explores the attitudes of senior decision-makers and those who are responsible for maintenance at both on and offshore oil and gas assets. Those surveyed also claimed to have an acceptable to very good understanding of their ESG goals and ambitions. Working with Censuswide, the survey collected the views of 1,017 senior professionals in the onshore and offshore oil and gas sectors across 10 countries, exploring the industry’s attitudes to maintenance management and the near-term outlook for the sector.
Survey respondents own or operate oil and gas assets in the following regions:
“Effective maintenance is not just a technical issue anymore; it’s a strategic imperative that impacts every facet of the industry’s
operations, from safety to environmental sustainability,” said Ekaterina Mezhentseva, Global Solutions Manager at Jotun.
“Our report clearly shows that the industry is moving towards greater investment in maintenance, driven by the need to meet ESG criteria and ensure long-term operational success, but budgets need to be future-proofed to allow for effective longterm maintenance planning.” The report also emphasizes the importance of knowledge sharing and improving competence in corrosion management, suggesting that companies can enhance their internal capabilities through external third-party partnerships and support. Indeed, the survey data revealed that as many as one in four (24%) oil and gas asset owners outsource all their maintenance to external providers, with as little as 6% of companies surveyed managing all maintenance in-house.
“We believe this report delivers valuable insights, enabling the industry to understand the importance, impact and investment of corrosion management,” added Ekaterina. “Our long-term commitment, to support the industry by delivering high-quality corrosion management solutions and expertise empowers oil and gas operators to improve the safety, reliability, and profitability of their operations.”
This research has shed light on key industry trends relating to maintenance and corrosion management across the global oil and gas sector. Derived from a survey of over 1,000 senior professionals, the report reveals a significant shift in the perception and prioritization of maintenance, particularly in the context of Environmental, Social, and Governance (ESG). The survey reveals increasing strategic importance of maintenance in oil and gas industry operations. Key findings include 88% of respondents anticipate an increase in maintenance
budgets over the next five years and 75% say that the requirement to report on environmental performance has led to increased investment in maintenance. In addition to the increased focus on environmental performance, improving safety (78%) and reducing risks of fire-related incidents (76%) were mentioned as important drivers behind maintenance strategies. This underlines the crucial role that maintenance, and corrosion management, plays in improving the safety, profitability, and environmental sustainability of oil and gas operations. However, three quarters of senior decision makers in the oil and gas industry (74%) said maintenance budgets are the first to be cut when cost savings need to be made. Survey respondents highlighted that this is making it difficult for those in charge of maintenance strategies to plan. ‹
As a vital element of an asset’s lifecycle, corrosion maintenance programs require significant investment from companies, both direct costs from expenses in relation to inspection, maintenance and repair, and indirect costs accrued during any downtime for assets or environmental clean-up required should corrosion impact an asset’s operations.
Cathodic corrosion protection is a widely used technique for protecting steel-based infrastructure from corrosion. ETH researchers have now clarified the detailed mechanisms involved, thereby resolving a controversial issue that had preoccupied the engineering community for decades.
Corrosion is a chemical reaction to which even the strongest structures fall victim. Metals such as steel react with oxygen and water, going on to rust and decay. Cathodic protection plays a key role in combatting corrosion. It protects steel structures by slowing down or preventing the processes that lead to corrosion.
Cathodic protection was first described in a scientific context in England two centuries ago and has since played a valuable role in maintaining modern infrastructure such as buried gas pipelines and reinforced concrete structures. “However, despite its widespread use, the underlying working principle behind cathodic protection has remained unclear and controversial,” says Ueli Angst, Professor of Durability of Materials at ETH Zurich.
A team of researchers led by Angst has now made significant progress in clarifying the principle behind it, particularly in the case of steel in porous media such as soil or concrete. Their study1, published in the journal Communications Materials in the Nature portfolio, sheds light on the complex processes involved in cathodic corrosion protection at the interface between the metal and the porous medium. To illustrate the interplay, it is worth taking a look at the history behind the method.
Cathodic corrosion protection goes back to British chemist and inventor Sir Humphry Davy, who described the principle just over two hundred years ago. Back then, the Royal Navy was facing a problem: it had clad the wooden hulls of its ships with copper sheeting to prevent fouling and rotting – but the copper hulls were quickly attacked and subject to corrosion in the salty seawater. Sir Humphry Davy, then President of the Royal Society, took up the search for a solution in the name of science.
In northern Italy, Luigi Galvani and Alessandro Volta had recently discovered the phenomenon that an electric current flows when different precious metals are joined together. Inspired by this, Davy was able to show in the laboratory that small samples of base metals such as zinc or iron can protect relatively large copper sheets from corrosion, namely by acting as a sacrificial anode and corroding themselves.
In 1824, the Royal Navy transposed Davy’s technique virtually directly from the laboratory to its entire fleet – too hastily, as it turned out. Although the copper hulls were now protected against corrosion, they lost their effectiveness against marine fouling: the ships became increasingly heavy and barely manoeuvrable.
1 https://www.nature.com/articles/s43246-024-00454-y
The Royal Navy had to remove the cathodic corrosion protection again, and Davy’s episode went down in history as a significant lesson in failure due to the premature transfer of knowledge into practice.
“Today we know that the cathodic protection current has the side effect of promoting the deposition of minerals on the metal, which allows the growth of mussels and other marine organisms,” says Angst. Despite the failure two centuries ago, Davy’s work laid the foundation for later applications.
However, it was another hundred years or so before Robert James Kuhn revived the technology in the USA, this time to make buried pipes durable. Kuhn’s notes show that he already had a much better understanding of corrosion processes in the 1920s than had been the case in Davy’s time. Kuhn also carried out extensive test series “in the field”, i.e. under real-life conditions. The technology has since developed into a standard method for corrosion protection and today ensures that water and gas pipes, tanks and ships, as well as bridges and car parks, have a longer and corrosion-free life.
However, despite its widespread use in engineering practice, the underlying mechanisms of action of cathodic corrosion protection are still the subject of controversial debate. For decades, there have been two opposing theories: one being the view that the protective current directly influences the rate of corrosion through a purely kinetic mechanism, and the other being that it leads to an increase in the pH value in the medium at the interface, which protects the steel from corrosion – an idea first postulated by Kuhn as early as 1928.
Sir Humphry Davy.
According to Angst, the lack of a consistent scientific understanding is hindering the development of sound engineering practices. One example is the protection criterion postulated by Kuhn in the 1920s, which is still used in standards today and requires a potential of -850 millivolts in relation to the saturated copper sulphate electrode: “This is an empirical criterion,” says Angst.
The inconsistent state of knowledge also means that standards are contradictory and it is not always possible in practice to fulfil all the relevant standard specifications at the same time.
“This is a serious problem in engineering and is all the more worrying given that cathodic protection can be considered a key technology for tackling the challenge of infrastructure ageing and is used in safety-relevant systems such as high-pressure gas pipelines,” continues Angst.
For their study, the ETH researchers focused on the interface between steel and the electrolyte and characterised the spatial and temporal changes in detail.
For the first time, they were able to demonstrate the formation of a thin metal oxide film on the steel surface and show that this layer is a direct result of the increase in pH due to the electrochemical processes taking place.
Federico Martinelli-Orlando, first author of the study, adds: “We were also able to show that these chemical changes on the steel surface and in the electrolyte lead to changes in the speed and progression of the anodic and cathodic reactions.”
The researchers propose a mechanism of action that resolves the apparent contradictions between previous hypotheses and
For the first time, the ETH researchers were able to demonstrate the formation of a thin metal oxide film on the steel surface and show that this layer is a direct result of the increase in pH due to the electrochemical processes taking place.
brings the two theories together in a complementary way. “We conclude that we should consider the two debated theories as complementary rather than contradictory in order to fully explain the working mechanism of cathodic protection,” says Martinelli-Orlando.
Based on the measurements carried out, the researchers have developed a mechanistic model that takes all electrochemical processes into account.
The consistent understanding gained can help to improve corrosion protection technologies and operate critical steelbased infrastructures in a safe, economical and environmentally friendly manner. The results can subsequently “validate” existing empirical concepts and form the basis for consistent approaches, for example, to develop well-founded standard criteria for the effectiveness of cathodic corrosion protection.
Close up of the cathodic protection on the hull of the vessel.
Scientifically supported technologies for corrosion protection currently play an important role, particularly in the context of ageing infrastructure, as they can delay or prevent the replacement of old structures.
“If we avoid unnecessary dismantling and replacement of structures, this ultimately also benefits the environment,” says Angst.
The underlying publication is part of a larger research project on corrosion and ageing infrastructure2 that was supported by the Horizon2020 research programme of the European Research Council (ERC)3. ‹
2 https://ifb.ethz.ch/research/research-durability-of-engineering-materials/ongoing-projects/ercgrant-taming-corrosion.html
3 https://cordis.europa.eu/project/id/848794
References
Martinelli-Orlando F, Mundra S, Angst UM. Cathodic protection mechanism of iron and steel in porous media. Communications Materials 5, 15 (2024). https://www.nature.com/articles/s43246-024-00454-y
Angst UM. A Critical Review of the Science and Engineering of Cathodic Protection of Steel in Soil and Concrete, Corrosion 75 (2019) 1420-1433. https://meridian.allenpress.com/corrosion/article/75/12/1420/445383/A-Critical-Review-of-the-Science-and-Engineering
InnoTrans breaks all records - the world’s leading trade fair draws a successful balance sheet
InnoTrans, the world’s largest trade fair for transport technology, set several records at its 14th edition from 24 to 27 September 2024. It occupied all the exhibition halls and the entire outdoor and track area of the Exhibition Grounds of Messe Berlin and offered the largest exhibition space since InnoTrans was founded in 1996. ‘InnoTrans 2024 was a real record-breaking trade fair - both in terms of exhibition space and visitor numbers. Around 170,000 visitors from 133 countries came to the Exhibition Grounds of Messe Berlin this year - so we were once again able to increase the pre-corona level in terms of visitor numbers and internationality. InnoTrans has impressively demonstrated that it is the world’s leading trade fair for transport technology and mobility,’ says Dirk Hoffmann, Chief Operating Officer of Messe Berlin.
‘InnoTrans was once again the event of the global railway industry,’ said InnoTrans Director Kerstin Schulz. ‘With a firework display of innovations and 226 world premieres, the trade fair attracted visitors from all over the world.’ The 2,946 exhibitors from 59 countries presented their latest products and services in the five trade fair segments Railway Technology, Railway Infrastructure, Public Transport, Interiors and Tunnel Construction. The trade fair became even more international this year. Around 600 new exhibitors took part - and with them new countries such as Morocco, Malaysia, Indonesia and South Africa. Exhibitors from all over the world presented 133 vehicles on the 3,500 metres of track. In the Bus Display in the Summer Garden, trade visitors were able to experience eleven buses in live operation on a 500
metre long circuit.
The main topics at this year’s trade fair were sustainability, electrification, digitalisation and, above all, artificial intelligence. ‘AI is also becoming increasingly important in the transport industry,’ says InnoTrans Director Kerstin Schulz. InnoTrans took this development into account with the new exhibition area, the AI Mobility Lab. ‘This was exactly the right decision. The demand for AIbased solutions and cybersecurity was enormous,’ reports Schulz. 42 exhibitors from 17 countries presented their expertise in AI, robotics, data protection and cybersecurity. The next InnoTrans will take place at the Exhibition Grounds of Messe Berlin from 22 to 25 September 2026.
What exhibitors had to say about InnoTrans 2024:
Michael Peter, CEO of Siemens Mobility: ‘We are delighted with this year’s InnoTrans in Berlin - the trade fair was a great success. We were able to show thousands of visitors and customers how Siemens Xcelerator uses standardised interfaces to digitally connect data from our products, operators and ecosystem partners in new ways. In this way, we are promoting ground-breaking innovations that make rail transport the most sustainable, convenient and cost-efficient transport solution. InnoTrans offers us the perfect setting for personal dialogue and joint progress.’
Henri Poupart-Lafarge, CEO of Alstom: “This InnoTrans 2024, we saw how the industry is actively responding to
the rapidly evolving transportation needs of the world. I am grateful for the many visitors from around the globe, particularly Alstom’s customers and partners, who took the time to exchange with us. We were proud to showcase the innovation from our 84,000 talented employees, working together to make transportation clean, efficient, smart, reliable, enjoyable and accessible for all. The challenges we face – climate change, rapid urbanisation, and a changing technological landscape – need a united approach and we are well are on the way. InnoTrans 2024 has confirmed my optimism about the future.”
Dr Richard Lutz, CEO of Deutsche Bahn AG: ‘More rail in Germany and Europe and therefore more climate protection can only be achieved together. That’s why the dialogue within the industry at InnoTrans is so important. With innovative approaches and digital technologies and with tangible improvements for our passengers in terms of trains, connections and integrated
public transport services, we at DB are taking responsibility for a strong railway.’
Markus Bernsteiner, Group CEO of Stadler: ‘InnoTrans 2024 was a great success for Stadler. At our stand, we were able to present our innovative strength for modern rail vehicles and customised signalling and service solutions to our guests and customers. With eight vehicle concepts, we once again demonstrated our commitment to sustainable, safe and reliable mobility. We look forward to the upcoming projects and partnerships that will emerge from this successful week at the trade fair.’
Ghizlane Aaboud, Head of OPC Planning and Interfaces, ONCF: ‘We were delighted to take part in InnoTrans 2024. The show provided a valuable opportunity to connect with key industry leaders and explore the latest developments in railway technology. For our company, participation in InnoTrans is essential to remain at the forefront of innovation and strengthen
our global partnerships. This event is an important part of our mission to promote sustainable and efficient solutions in the rail industry.’
Sarah Stark, Managing Director of the German Railway Industry Association (VDB): ‘Every two years, InnoTrans shines the spotlight on an industry that moves the everyday lives of millions of people and makes their mobility future-proof. From innovative regional trains that can replace the office and run on hydrogen and battery power, to high-speed trains that can withstand desert temperatures and sandstorms, to digital information systems for quick orientation or barrier-free railway doors that bridge height differences without steps - InnoTrans 2024 has once again demonstrated the innovative power of the rail industry this year.’
www.innotrans.com
The Pipeline Technology Conference (ptc) is celebrating its 20th anniversary as “The Global Pipeline Event”, set to take place in Berlin from 5 to 8 May 2025. As Europe’s premier conference and exhibition for pipeline professionals, ptc 2025 will offer a dynamic, forward-looking program featuring a wide range of training courses, technical sessions, panel discussions, operator round-tables, award ceremonies, and networking events. This milestone event is set to bring together a diverse array of participants from around the world, including delegations from over 100 pipeline operating companies, making it a flagship platform for the global pipeline industry.
The 20th Pipeline Technology Conference will explore key topics at the forefront of the industry, including pipeline research, renewable fuels like hydrogen and biogas, CO2 pipelines, digital twins in the pipeline industry, and strategies for managing ageing pipeline infrastructures, including modernization, conversion, and decommissioning. The ptc Conference aims to highlight technological excellence and foster meaningful discussions about the future of the pipeline sector.
ptc 2025 will also showcase an expanded international ptc Exhibition, featuring more than 100 key technology providers from across the globe. The exhibition will highlight cutting-edge innovations, products, and services that are shaping the future of the pipeline industry. From advanced line pipe materials and construction techniques to state-of-the-art monitoring, inspection and maintenance solutions, attendees will have the opportunity to engage directly with leading companies driving
the evolution of pipeline technology. The expanded exhibition floor will foster new connections, collaborations, and business opportunities for pipeline operators, service providers, and suppliers alike. Startups are encouraged to join one of the two dedicated areas.
Pipeline experts worldwide are invited to contribute to ptc 2025 by submitting their papers and presenting at one of the 34 technical sessions. The call for papers has been closed as of September 30, providing a unique opportunity to share innovative research, case studies, and new developments with a global audience. An early bird discount applies until the end of 2024. Special rates are applicable for speakers, students and participants from pipeline operators.
www.pipeline-conference.com
Amidst European phased target of achieving zero emissions by 2035 and energy independence, nuclear power industry is playing a vital role in achieving a sustainable and resilient energy future for the continent. Despite facing challenges, opportunities for new nuclear power plant construction are arising in recent years, notably with advanced designs like Small Modular Reactors (SMRs). Many aging nuclear plants present chances for life extension and upgrades. Advancements in fuel cycle & waste management also offer potential for reducing the volume and radiotoxicity of nuclear waste. Therefore, the Organizing Committee is pleased to invite everyone in the industry to the Europe Nuclear Energy & SMR Conference 2024 on November 13-14th, 2024 in Prague (Czech Republic) with the theme of “Elevating Europe›s Energy Landscape with Nuclear Power: Secure, Sustainable, and Innovative”. The conference will provide thorough updates on the civil nuclear industry in Czech Republic, Poland, France, Slovakia, United Kingdom, Netherlands, Hungary, Romania, Bulgaria, Lithuania, Slovenia, Finland. After experiencing delays and cost escalations in some NPP constructions & upgrades, how would the industry
solve key challenges such as lengthy regulatory approval processes, public opposition, financing constraints, human resources and skills shortages? What kind of strategies and approaches are needed for deploying SMRs soon in Europe? How to balance the pros and cons of spent fuel recycling and direct disposal for the sustainable and economical perspective?
The 2-day Europe Nuclear Energy & SMR Conference 2024 is dedicated to fostering engaging discussions and insights aimed at addressing these challenges and implementing strategic measures. With over 240 senior attendees from the Government & Regulators, Utilities & Operators, Large Reactor & SMRs, Fuel Cycle & Waste Management, Institute & Universities, Associations, EPC & Engineering Consulting, Professional Services, Leading Technology Firms, and Other Key Stakeholders, the conference seeks to accelerate nuclear power projects and unlock the full potential of nuclear energy to contribute to European energy transition goals, while ensuring safety, sustainability, and affordability.
https://europe-nuclear-smr.ltsinnovate.com
There are over 10,000 Level I, II and III inspectors in 74 countries worldwide, as large clients consider the qualification of Coating Inspector Frosio as a reference for monitoring the quality of the application of a painting cycle.
There are 367 active Certifications in Italy, of which 109 Level I (white card), 115 Level II (Green card) and 143 Level III (red card). The certification is in accordance with the Frosio Certification SCHEME, which follows the requirements of ISO 17024.
The University of Genova, accredited by FROSIO as a Training Body, is in charge of organising courses in the Italian language exclusively for the Italian territory. To date, 20 courses have been organised.
The Gruppo IspAC Associazione (GIA), accredited by FROSIO as Certifying Body, is in charge of organising the exams for the Qualification and Certification of Coating Inspectors Level I, II and III, renewal of certifications and level ups exclusively for the Italian territory.
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EDITORIAL BOARD
Annalisa Acquesta, University of Naples
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Mehdi Attarchi, Senior Materials & Corrosion Specialist
Andrea Balbo, University of Ferrara
Hadi Beirami, Cathodic Protection Certified Specialist
Maria Bignozzi, University of Bologna
Stefano Caporali, University of Florence
Marco Cattalini, AMPP Italy Chapter Chairman
Jérôme Crouzillac, BAC Corrosion Control
Marina Delucchi, University of Genoa
Sergio Lorenzi, University of Bergamo
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Nov. 13-14th
Elevating Europe's Energy Landscape with Nuclear Power: Secure, Sustainable, and Innovative
(ENES 2024)
Forefront event to explore Europe's Nuclear Energy Landscape covering NPP New Build & Life Extension, SMR Deployment, Fuel Cycle & Waste Management.
Latest Progress update on projects in hot countries such as: Czech Republic, Poland, France, Slovakia, United Kingdom, Netherlands, Hungary, Romania, Bulgaria, Italy, Slovenia, Finland.
Dive into the Small Modular Reactors (SMRs) with a special focus on: Site Selection, Projects Update, Public & Private Financing, Collaboration Across Multiple Industries (including with Renewable Energy), Supply Chain Access, International Cooperation, and more.
Acquire Firsthand Insights into European Civil Nuclear Industry: Policy Incentives & Regulation, Advanced Technology, Financing Mechanisms, Sustainable Local Supply Chain, Talents Training, Digital Twin, Project Management, Legal Frameworks, Infrastructure, etc.
Discover Golden opportunities for Exhibition and enhancement of Connections with Senior Management & Experts drawn from Government & Regulators, Utilities & Operators, Large Reactor & SMRs, Fuel Cycle & Waste Management, Institute & Universities, Associations, EPC & Engineering Consulting, Professional Services, Leading Technology Firms, and Other Key Stakeholders.
European Parliament Member of the European Parliament and a member of the EPP
Wojciech Dabrowski Council for Strategic Development Projects under the President of the Republic of Poland
Member PGE Polska Grupa Energetyczna S.A. Former President of the Management Board
Satu Katajala, Director World Association of Nuclear Operators (WANO) WANO Paris Centre
Ms. Baiba Miltoviča EESC (European Economic and Social Committee)European Union Board Member NACP President TEN section Tatiana Ivanova OECD Nuclear Energy Agency (NEA) Head of the Division of Nuclear Science
Ionut Purica the Advisory Council for Sustainable Development to the Prime Minister of Romania Prof. Dr., Member
Tomas Kovalovsky Czech Nuclear Association Chairman of the Board
Daniel Dean International Bank for Nuclear Infrastructure – IBNI Managing Director Dean Capital Strategies GmbH Chairman Implementation Organization Strategic Advisory Group
Laban Coblentz ITER Organization Head of Communication
Juraj Václav Nuclear Regulatory Authority of the Slovak Republic (UJD SR) Director Division of Nuclear Materials
Attila Hugyecz Paks II. Nuclear Power Plant Zrt, Hungary Chief International Officer
Per Nyström Ministry of Finance, Sweden Special Adviser, Secretariat for Financing New Nuclear Power
Eduard Klobouček State Office for Nuclear Safety (SUJB) Czech Republic Head of the Legal Division
Vladimir Wagner Nuclear Physics Institute of the Academy of Sciences (NPI CAS)
