Term 252

Self-Healing Protective Coatings for Corrosion Mitigation in Oil & Gas Production Systems

Project Type: Self-Initiated

Project Description

This project addresses the critical challenge of material degradation in the Saudi Arabian oil and gas sector caused by severe corrosive environments. Traditional protective coatings often fail due to microcracking and mechanical wear, leading to accelerated corrosion in sour and high-salinity conditions. The primary objective of this work is to design, formulate, and experimentally validate a self-healing protective coating to withstand these specific field challenges. The methodology involves developing a coating system integrated with specialized healing agents or microcapsules designed to trigger autonomous repair upon the formation of micro-defects. To evaluate performance, coated steel coupons will be subjected to simulated field conditions, including exposure to carbon dioxide dissolved sulfides, and high-salinity brines. Testing will be conducted in accordance with ASTM and NACE standards to assess corrosion resistance, adhesion strength, abrasion resistance, and thermal cycling stability. Healing efficiency will be quantified by intentionally inducing micro-defects and measuring the subsequent recovery of the coating barrier properties when exposed to corrosive media. The expected outcome of this project is a field-applicable, environmentally compliant coating capable of achieving at least 90% recovery of mechanical integrity following damage. It is expected that the system will maintain a corrosion rate below 0.10 mm/year under harsh reservoir temperatures and pressures. Ultimately, this project seeks to demonstrate a modern solution for extending the operational lifespan of production systems, thereby reducing maintenance frequency and overall costs in high-risk environments.