Corrosion under insulation is a significant and costly challenge for various industries, particularly in regions with harsh environmental conditions. This study introduces an innovative approach to alleviate the corrosion problem by employing SiO2-nano composite coatings. These coatings not only prevent corrosion but also serve as effective insulators due to their low thermal conductivity, adhering to the ASTM C-518 standard with a heat transfer coefficient of approximately 0.017 W/mK. The coating, comprising 30% water-based acrylic resin and 70% SiO2 composite, adheres directly to surfaces, providing protection through its hydrophobic properties that prevent moisture from reaching metal surfaces. This is crucial as humidity is a primary cause of rust on metals. The nano-composite coatings form a thin, hydrophobic film that insulates oil and gas pipelines, while remaining semi-transparent to allow visual inspection. The effectiveness of this coating was demonstrated using the GM9540P environmental corrosion test, where coated surfaces showed no corrosion after 24 test stages, unlike uncoated surfaces. This study highlights the dual benefits of insulation and anti-corrosion properties offered by the SiO2-nano composite coating.

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