Fast-Acting Biodegradable Compound Overview

UNIVERSITAS INDONESIA
FAST-ACTING BIODEGRADABLE COMPOUND FOR

METAL TREATMENT, PROTECTION, AND RESTORATION
Report Assignment 1
GROUP 12
GROUP PERSONNEL:
ANDREAS EXA SAPUTRA (1606834522)
DANDY FADHILAH (1606890233)
KANTIA SIDIQ PERMANA (1606905361)
KIRANA WIDIANI LESTARI (1606826880)
RIEDO DEVARA YUSHARYAHYA (1606895354)
TETRA MUTIARA AFIFAH (1606828841)
CHEMICAL ENGINEERING DEPARTMENT

ENGINEERING FACULTY
UNIVERSITAS INDONESIA
FEBRUARY 2019
EXECUTIVE SUMMARY
Corrosion costs around 170 billion in industrial costs. The oil industry
with complex and demanding product techniques, and environmental challenges
of failing components takes the average portion of these costs. A study revealed
that corrosion of piping and pipeline in the oil and gas industry was a major
problem. Preventing corrosion is vital in every step in the production of oil and
gas (Denis, 1994).
Treatment, protection, and restoration metal has been studied and conducted
but there still has not been found the true cure for all this problem. The problem
that often occurs at this time is caused by the presence of microbes that are carried
along by the fluid, as well as the components of the fluid that are corrosive (H2S
corrosion). To overcome this corrosion, the most commonly used
countermeasures are cutting the part of the pipe that has been corroded, but the
disadvantage is that the costs will be very large. As for the use of cathodic
inhibitors but cannot optimally protect the pipe from corrosion and its use is done
continuously. Lastly, with coating but it’s difficult for the inside of the pipe.
Therefore, a survey was conducted to determine the needs of oil and gas
industry producers. A series of questions are submitted to the respondent directly
and indirectly; through online forms. From the data, we get the specifications
desired and expected by the oil and gas industry producers in this new product.
Each question is classified based on product aspects. The four main aspects
are expected to be core decisions in the final product specifications. Each need is
sorted to identify the most important customer needs and choose which ones need
to be prioritized and which ones do not. The first most important aspect is
performance protection against corrosion, including the frequency of use,
protection of metal, protecting from acid and microbes, place of use, durability,
and taking a short period of time to start acting. The second aspect is retailing, it is
expected that existing products have relatively affordable prices. The third aspect
is handling, the product is expected to be easy to use both in terms of maintenance
and post-corrosion handling. The last aspect is the expected value of the product,
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which is biodegradable, so that the finished product will not be an impurity to the
environment.
Product specifications describe the things that must be done by a product
and are intended to quantify consumer needs so that they can provide direction for
product design. Specifications consist of metrics and metric values whose values
are always followed by the appropriate unit.
After defining and quantifying the needs and specifying every aspect in
quantitative data, then benchmarking is done to clearly see the position of own
product and to find an opportunity based on quantitative data of the existing
products. To do that, benchmarking the similar products that exists in the market,
like corrosion inhibitor product (NALCO 2833, GORCARD 566, Z50-Fluid) and
coating product (Hempacore) has been done. By comparing those data, own
product finds the excitement inside of it, including the cheaper price, the cleaner
raw material, and so on.
Based on benchmarking data, anti-corrosion product ideally has the
retention time and curing time of 120-240 minutes, film persistency of 28-32
N/m2s, corrodent diffusivity of 4.8 x 10-10 m2/s, neutral acidity, room
temperature vapor pressure, good compatibility in the system, fast-acting,
biodegradable, with the price of 700-800 USD/ L.
The proposed product is targeted to piping and pipeline corrosion, this
specification are proved to be better than benchmarking data, therefore proposed
product is forecasted to satisfy the needs of market.
In conclusion, fast-acting biodegradable compound for metal treatment is
strongly suggested to become the solution of corrosion problems in piping and
pipeline.
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LIST OF CONTENT
EXECUTIVE SUMMARY ................................................................................... ii

LIST OF CONTENT ........................................................................................... iv
LIST OF FIGURES ............................................................................................. vi
LIST OF TABLES .............................................................................................. vii
CHAPTER 1 INTRODUCTION ......................................................................... 1
1.1 Background Idea .................................................................................... 1
1.1.1 Economic Losses Due to Corrosion .................................................. 2
1.1.2 Waste of Natural Resources .............................................................. 5
1.1.3 Corrosion Can Harm the Human....................................................... 5
1.1.4 Decreasing Aesthetics ....................................................................... 5
1.1.5 Material Contamination .................................................................... 5
1.2 Product Usage (Formulation of Problem) ............................................ 6
1.3 Identification of Problem ....................................................................... 7
1.4 Limitation of Problem ............................................................................ 7
CHAPTER 2 REVIEW OF LITERATURE ...................................................... 8
2.1 Corrosion in Oil and Gas Piping and Pipeline..................................... 8
2.1.1 Causes of Corrosion in Oil and Gas Field ......................................... 8
2.1.2 Corrosion Treatment in Oil and Gas Piping and Pipeline ............... 10
2.2 The Properties of Biodegradable Compound .................................... 11
2.3 Fast-Acting Criteria for Metal-Treatment Compound..................... 11
2.4 Basic Principle of Metal Treatment Compound ................................ 12
2.4.1 Corrosion Inhibitor .......................................................................... 12
2.4.2 Coating ............................................................................................ 13
2.4.3 Cathodic protection ........................................................................... 9
2.4.4 Rust Remover .................................................................................. 12
2.4.5 Rust Converter ................................................................................ 13
2.5 Product Trends ..................................................................................... 15
2.5.1. Corrosion Inhibitor .......................................................................... 15
2.5.2. Coating ............................................................................................ 17
2.5.3. Cathodic Protection ......................................................................... 19
2.5.4. Rust Remover .................................................................................. 20
2.5.5. Rust Converter ................................................................................ 20
2.6 Environmental Issues ........................................................................... 22
2.6.1 Cathodic Protection ......................................................................... 22
2.6.2 Corrosion Inhibitor .......................................................................... 23
2.6.3 Rust Remover and Rust Converter .................................................. 23
2.6.4 Coating Pigments ............................................................................ 24
2.6.5 Phosphate Coatings ......................................................................... 24
2.6.6 Phosphate Coatings ......................................................................... 25
2.7 Product Risk ......................................................................................... 26
CHAPTER 3 MARKET NEEDS ANALYSIS.................................................. 28
3.1 Methods of Needs Identification ......................................................... 28
3.1.1 Market Analysis .............................................................................. 28
3.1.2 Customer Requirement.................................................................... 28
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3.1.3 Customer Needs Interpretation ....................................................... 34
3.1.4 List of Needs ................................................................................... 38
3.1.5 Category of Customer Needs and Needs Rank ............................... 38
CHAPTER 4 PRODUCT SPECIFICATIONS ................................................ 40
4.1 List of Metrics ....................................................................................... 40
4.2 Metric Needs ......................................................................................... 42
4.3 Benchmarking of Similar or Existing Products ................................. 48
4.4 List of Specifications ............................................................................ 48
CHAPTER 5 CONCLUSION ............................................................................ 60
REFERENCES .................................................................................................... 61
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LIST OF FIGURES
Figure 1.1. Pie Chart of Metallic Corrosion Cost in the United States ................... 4
Figure 2.1. Schematic of How Inhibitor Film Prevents Water Contacting a Metal
Surface................................................................................................................... 12
Figure 2.2. A Typical Coating System for Marine and Industrial Applications ..... 8
Figure 2.3. Impressed Current Cathodic Protection System ................................. 12
Figure 2.4. Surface Before and After Commercial Rust Conversion Treatment .. 13
Figure 2.5. Molecular Structure of Tannic Acid ................................................... 14
Figure 2.6. Schematic of Action of Oil Field Corrosion Inhibitor ........................ 16
Figure 2.7. Coating Global Market Trend in 2016 ............................................... 19
Figure 2.8. Synthesis Procedure of Rust Converter .............................................. 22
Figure 3.1. Respondents’ Frequency..................................................................... 29
Figure 3.2. Respondents’ Common Types of Corrosion ...................................... 30
Figure 3.3. Grouping Types of Corrosion ............................................................. 30
Figure 3.4. Respondents’ Corrosion Site in Pipes ................................................ 31
Figure 3.5. Respondents’ Corrosion Protection Methods ..................................... 31
Figure 3.6. Respondents’ Choice of Corrosion Protection Product’s Notable
Aspects .................................................................................................................. 32
Figure 3.7. Respondents’ Corrosion Countermeasure .......................................... 33
Figure 3.8. Respondents’ Corrosion Restoration Method ..................................... 33
Figure 3.9. Respondents’ Choice of Corrosion Restoration Product’s Notable
Aspects .................................................................................................................. 34
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LIST OF TABLES
Table 1.1. Diagram of Metallic Corrosion Cost in the United States ..................... 4
Table 2.1. Organic Coating ................................................................................... 17
Table 2.2. Local Toxic Level in Phosphating System .......................................... 25
Table 3.1. Customer Needs Interpretation ............................................................ 35
Table 3.2. List of Customer Needs........................................................................ 38
Table 3.3. Category of Customer Needs and Needs Rank .................................... 38
Table 4.1. List of Specification Metrics ................................................................ 40
Table 4. 2 List of Metrics ...................................................................................... 43
Table 4.3. Benchmarking table ............................................................................. 49
Table 4. 4 Specifications list table ........................................................................ 55
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LIST OF APPENDICES
APPENDIX A. SURVEY QUESTIONNAIRE .................................................... 75
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CHAPTER 1
INTRODUCTION
1.1 Background Idea

A lot of things in day-to-day life nowadays require this basic material we
call as metal. Metal-based tools support human daily life and still have such an
enormous role in every industrial process. However, there are still some common
problems associated with metal such as corrosion, scratching, denting, and
decaying because of high temperature. The discussion on this assignment will be
mainly focused on corrosion, as it has always been the most common yet
potentially most dangerous metal problems.
Corrosion is a serious scientific problem. Even in developed countries, this
problem has not been fully scientifically resolved. Apart from being a surface
science problem, which is a study that deals with in physics, corrosion also
involves reaction kinetics; a study area of chemists and process engineers.
Corrosion can also become an economic problem because it affects the
age, shrinkage and efficiency of the use of materials and equipment in industrial
activities. Billions of US dollars have been spent annually to treat bridges, office
equipment, motor vehicles, industrial machinery and other electronic equipment
so that the construction age can last longer.
Many countries have tried to calculate national corrosion costs in different
ways, generally falling in values ranging from 1.5 to 5.0 percent from GNP (Gross
National Product) / PNB (Gross National Product). Practitioners today tend to
agree to set a cost of corrosion of around 3.5 percent of GNP. The losses that can
be caused by corrosion are not only direct costs such as changes in industrial
equipment, bridge maintenance, construction and so on, but also indirect costs
such as disruption of industrial production processes and smooth transportation
which are generally greater than direct costs. Of all the losses incurred, it is
deemed necessary so that we can know what steps can prevent or suppress
corrosion rates.
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Metal losses that occur due to corrosion in manufacturing facilities are

categorized as technical loss which contributes to depreciation, decreased
efficiency, decreased strength of construction, poor performance of equipment,
and increased maintenance costs.
1.1.1 Economic Losses Due to Corrosion
A Corrosion of metals costs the U.S. economy almost $300 billion per
year at current prices. Approximately one-third of these costs could be reduced by
broader application of corrosion-resistant materials and the application of best
corrosion-related technical practices. These estimates result from a recent update
of findings of the 1978 study Economic Effects of Metallic Corrosion in the
United States. The study was performed by Battelle Columbus Laboratories and
the National Institute of Standards and Technology (NIST) and published in April
1995.The original work, based upon an elaborate model of more than 130
economic sectors, found that in 1975, metallic corrosion cost the United States
$82 billion, or 4.9% of its gross national product (GNP).It was also found that
60% of that cost was unavoidable. The remaining $33billion (40%) was incurred
by failure to use the best practices then known. These were called “avoidable”
costs.
Over the last two decades, economic growth and price inflation have
increased the GNP more than fourfold. If nothing else had changed, the costs of
metallic corrosion would have risen to almost $350 billion annually by 1995,
$139 billion of which would have been avoidable. However, 20 years of scientific
research and technological change, much of which was initiated because of the
1978 study, have affected these costs.
The Battelle panel updated the earlier results by judgmentally evaluating
two decades of corrosion-related changes in scientific knowledge and industrial
practices. In the original study, almost 40% of the 1975 metallic corrosion costs
were incurred in the production, use, and maintenance of motor vehicles. No other
sector accounted for as much as 4%of the total, and most sectors contributed less
than 1%. The aircraft sector, for instance, was one of the next largest contributors
and accounted for just more than 3%. Pipelines, a sector to which corrosion is a
recognized problem, accounted for less than 1% of the total cost.
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The panel estimates that 15% of previously unavoidable corrosion costs

can be reclassified as avoidable. The industry is estimated to have eliminated
some 35% of avoidable corrosion by improved practices.
Corrosion can be highly insidious to economy. Industry estimates have
indicated that the annual direct cost of corrosion to an industrial economy in the
past 30 years is approximately 3.1% of the country's Gross National Product
(GNP). In the United States, this amounts to over $1 ton per year. It is startling
that corrosion is causing a loss of $5000 billion USD to the global economy every
year. The Department of Defense in US alone has corrosion costs of $20 billion
because of the significant economic, safety, and historical impact of corrosion on
society.
According to a recent report (NACE, India chapter) the corrosion cost in
any developing country is predicted by 5% of the GDP. For India the cost of
corrosion is estimated to be 36,000 Crores INR in 2008.This is about half of its
defense budget and perhaps double of its total annual expenses on education. This
is, therefore an enormous sum, which needs immediate attention and future
strategy to minimize it and make its industry safer and accident-free.
Some common economic losses occur in its everyday lives include the
replacement of corroded equipment, preventive maintenance like painting,
overdesigning, shutdown of equipment due to corrosion failure, contamination of
a product, loss of valuable product, inability to use otherwise desirable materials.
Social consequences of corrosion can involve safety, for example, sudden failure
of an equipment due to corrosion can cause fire, explosion, release of toxic
product, and construction, health, for example, pollution due to escaping product
from corroded equipment or due to corrosion, collapse, depletion of natural
resources, including metals and the fuels used to manufacture them, an unpleasant
appearance etc.
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Table 1.1. Diagram of Metallic Corrosion Cost in the United States

(Source: https://jindalstainless.com/)
Increased corrosion costs are often realized when higher-performance
specifications and more hostile environments are encountered. Finally, increased
corrosion costs result from government regulations that prohibit the use of time-
honored methods of protection because of safety or environmental damage. For
example, in an effort to reduce smog, the elimination of lead-based paints on
houses and bridges, chromate inhibiting paints on aircraft, and oil-based paints
throughout industry has had severe repercussions. Substitute water-based paints
have not, in many cases, afforded equivalent corrosion protection.
Figure 1.1. Pie Chart of Metallic Corrosion Cost in the United States
(Source: https://sellmyhou.se/)
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1.1.2 Waste of Natural Resources

Corrosion process can also be defined as the process of returning technical
metal to its original form in nature. The original form of metal in nature is mineral
compounds that are enduring in the bowels of the earth. In general, these metal
mineral compounds are chemical bonds between metal elements and metal
elements with halogen elements such as oxygen and sulfur. With the process of
corrosion in building structures in places scattered throughout the world, the
mineral resources that were originally in the form of technical metals have turned
into corrosion products which are scattered without being recycled to become
technical metal again.
1.1.3 Corrosion Can Harm the Human
Corrosion can lead to accidents that claim dozens of casualties and even
hundreds of lives or injure humans due to failure of building construction due to
corrosion. In the world of shipping, the number of human victims who have died
due to ship crashes is very large.
1.1.4 Decreasing Aesthetics
Corrosion can reduce the aesthetic value of a material. This is because
corrosion can damage the surface layer of the material so that the material looks
less attractive to look at.
1.1.5 Material Contamination
Rust formed in the corrosion process will dissolve in the material. In
applications where there is a lot of contact with materials, for example in water
pipes, this rust can enter the circulatory system, make it polluted, and make the
water unhealthy to use. In addition, if the material has been contaminated but the
product contaminated by corrosion has been circulating in the community, it will
cause even greater losses both in terms of the economy and the aspect of product
safety.
Despite corrosion being one big cause of economic loss in every aspect of
life, the problem of this discussion will be focused on piping and pipeline in oil
and gas industry as they possess the highest risk of corrosion next to water
treatment facility.
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Oil and gas industry deals with high number of metals corrodent, such as
H2S and CO2. As oil and gas may contain corrodents, it is necessary to control the
composition of those acid chemicals so that the quality of metal in the piping and
pipeline can be maintained.
There are many methods available to control corrosion on metal piping
and pipeline, for example by doing routine checking in a certain period of time or
by applying metal protection compound like coatings as primary mitigation, and
cathodic protection method as the secondary mitigation.
As countermeasures of dealing with corrosion, science continues to
develop today to create new innovations in corrosion protection products, ranging
from protective coating technology as metal pre-treatment before usage, material
selection of corrosion inhibitors, remote real-time maintenance and checking, and
other efforts to reduce the corrosion rate.
1.2 Product Usage (Formulation of Problem)
In overcoming the problems that occur due to corrosion, metal treatment
routine can be done continuously. However, some treatments may possess specific
disadvantages according to the chemical used as the anti-corrosion compound. For
example, by giving a metal anti-rust coating, there are shortcomings such as anti-
rust coating base compounds are not so environmentally friendly. So that if the
anti-rust layer is in contact with the environment, it will have a negative impact on
the surrounding environment, especially when they are difficult to decompose and
considered toxic to the health of living things. Easy-peel-off coatings can also
become an issue as they have the potential to get exposed to environment and will
be contaminate the surroundings.
One effort that can be done to reduce the above problems is to do metal
treatment with materials that are environmentally friendly or often called
biodegradable. Biodegradable is one method that is being explored by research to
preserve the environment and reduce waste that is harmful to the environment due
to the biodegrable nature this is easily broken down by the environment and also
microorganisms and also does not pollute the environment so it is safe for health.
The next characteristic possessed by biodegradable is that it is easy to react when
used so it does not need to wait long until the material contained is active.
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1.3 Identification of Problem

The followings are problem identifications for this report:
a. What are the problems of metal?
b. What are the causes of corrosion?
c. How much is the impact of corrosion?
d. What are the corrosions in oil and gas industry?
e. What is the meaning of biodegradable?
f. How is the treatment of corrosion in metal?
g. What do people expect from anti-corrosion product?
h. What are the specifications of anti-corrosion product will be?
1.4 Limitation of Problem
Based on the background and problems that has been described, the
limitation of the problem in the process of creating the product will be based on
the needs survey, the specification of the product, the comparison with other
existing product, and its market analysis as the solution to give metal treatment,
protection, and restoration.
CHAPTER 2
REVIEW OF LITERATURE
2.1 Corrosion in Oil and Gas Piping and Pipeline

According to J. S. Manke (1990), corrosion is one of the leading causes of
pipeline failure in the U.S. Gulf of Mexico. Therefore, treatment corrosion is one
of the important things because the cost of handling corrosion will be very
expensive when compared to treatment corrosion in the supply of equipment in
the industry, especially in the corrosion of the oil and gas piping and pipeline
industry. According to NACE International (2008), the total annual cost of
corrosion in the oil and gas production industry is estimated to be $1.372 billion,
broken down into $589 million in surface pipeline and facility costs, $463 million
annually in downhole tubing expenses, and another $320 million in capital
expenditures related to corrosion.
2.1.1 Causes of Corrosion in Oil and Gas Field
The problems encountered in oil and gas field, mainly are:
2.1.1.1 Carbon Dioxide
Carbon dioxide has been a problem in oil and gas industry for many years
(Mehdi et al, 2015). Dry carbon dioxide gas itself is not corrosive at the
temperatures encountered within oil and gas industry systems, but when carbon
dioxide dissolved in an aqueous phase, it can promote an electrochemical reaction
between steel and the contacting aqueous phase. Carbon dioxide will mix with the
water, forming carbonic acid, making the fluid acidic (Jom, 2013). Carbon dioxide
corrosion can appear in two principal forms: pitting (localized form
of corrosion by which cavities or "holes" are produced in the material) and mesa
attack (common type of corrosion where low alloy steels and carbon are exposed
to conditions of wet carbon dioxide at elevated temperatures).The best known
mechanism was postulated by de Waard et al(1995) given as follows:
𝐻2 𝐶𝑂3 + 𝑒 − → 𝐻 + 𝐻𝐶𝑂3 − (2.1)
2𝐻 → 𝐻2 (2.2)
With the steel reacting:
𝐹𝑒 → 𝐹𝑒 2+ → 2𝑒 − (2.3)
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And overall
𝐶𝑂2 + 𝐻2 𝑂 + 𝐹𝑒 → 𝐹𝑒𝐶𝑂3 + 𝐻2 (2.4)
2.1.1.2 Hydrogen Sulfide
According to Oilfieldwiki Inc, Hydrogen Sulfide is another problem in oil
and gas industry. Hydrogen sulfide forms a weak acidwhen dissolved in water, it
is a source of hydrogen ions and turns corrosive. The forms of this corrosion are
uniform, pitting, and cracking.
2.1.1.3 Oxygen
Oxygen is a strong oxidant that reacts with the metal very quickly and may
acceleratethe anodic destruction of metal. The presence of oxygen magnifies the
corrosive effects of the acid gases (H2S and CO2). The forms of corrosion
associated with oxygen are mainly uniform corrosion and pitting-type corrosion
(Satyendra, 2015).
2.1.1.4 Two Metal Galvanic Action
According to Mckey and Worthington (1936), contact between two metals
that have a difference potential and exposed to the electrolyte environment will
cause the metal to corrode. In this situation, metal with a negative potential
becomes the anode and begins to rust. Anodes lose metal ions to balance the flow
of electrons, because metals are made up of crystals, many of such cells are set up,
causing intergranular corrosion. In addition, electrochemical potential differences
can also produce crevice and cause pitting corrosion. This crevice will be where
oxygen dissolves in the liquid which is stagnant and causes corrosion destruction
under the pipe.
2.1.1.5 Fluid Flow
The presence of turbulence fluid flow with solids which are carried in the
fluid can cause erosion corrosion. This corrosion is caused by damage to the
protective layer in the pipe. The protective layer is a thin film that serves to
stabilize the corrosion reaction and slow it down. This form of corrosion is
recognized as being caused by wear on the pipe walls (Lecan et al, 2013).
2.1.1.6 Biofilm
A biofilm is a complex aggregation of microorganisms growing on a solid
substrate. Biofilms are characterized by structural heterogeneity, genetic diversity,
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complex community interactions, and an extracellular matrix of polymeric

substances. Biofilm will produce waste products such as organic acids that
damage the pipes by increasing the toxicity of the liquid flowing in the pipe.
These microorganism usually colonize and form mucus to attach to one another,
forming larger bacteria so that it can cause problems in blocking the pipe
(Helsinki, 2005).
2.1.2 Corrosion Treatment in Oil and Gas Piping and Pipeline
In corrosion treatment there are several methods that have been widely
recognized in maintaining corrosion maintenance in the oil and gas piping and
pipeline industry. This method can be classified as follows:
2.1.2.1 Use of Inhibitors
According to Amitha and Bharathi (2011), inhibitors are chemicals that
can protect metal surfaces from corrosion. Inhibitors can act in several ways,
limiting the rate of anodic or cathodic processes on metal surfaces or can act to
increase the potential of metal surfaces so that an oxide film will be formed on the
metal surface.
Factors to be considered before using a corrosion inhibitor are toxicity,
availability and cost. Miksic et al. (2005) had evaluated several types of inhibitors
and concluded that organic inhibitors are more effective than inorganic inhibitors
for the protection of steel in acidic media in the oil and gas industry.
2.1.2.2 Use of Protective Coatings
A protective layer or barrier on the material to avoid the direct contact
with the process media will enhance the material and equipment life. According
Denis et al (2013), mechanism of coating can be differentiated into three, namely;
barrier creation between substrate materials and environments, inhibition of the
corrosion processes, and coating acting as sacrificial materials.
2.1.2.3 Cathodic Protection Technique
Cathodic protection is a technique to reduce corrosion by minimizing the
difference in potential between anode and cathode. It is normally used in
conjunction with coatings and can be considered as a secondary corrosion control
technique. The cathodic protection system can be designed to prevent both
oxygen-controlled and microbiologically controlled corrosion.
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According to Araujo (2013), there are two methods of applying cathodic

protection include, Sacrificial Anode Cathodic Protection (SACP) and Impressed
Current Cathodic Protection (ICCP). The main difference between this two
methods is that ICCP uses an external power source with inert anodes and SACP
uses the naturally occurring electrochemical potential difference between different
metallic elements to provide protection.
2.2 The Properties of Biodegradable Compound
The term biodegradable is used to describe substances that are capable of
being damaged, or decayed, by the action of bacteria, fungi, and other
microorganisms. Temperature and sunlight can also play a role in the
decomposition of biodegradable materials. When substances are not
biodegradable, they remain in the environment for a long time, and, if toxic, can
contaminate soil and water, causing losses to plants and animals that live in that
environment. Humans can also be affected by the consumption of food
contaminated with toxic substances. General, everyday substances that are
biodegradable include food waste, tree leaves, and grass pieces. Many people now
encourage people to compost these ingredients and use them as humus (decaying
organic matter in the soil) for gardening. Because plants and animals are
biodegradable, this is one way for cities and towns to reduce solid waste. In an
effort to control the use of non-biodegradable materials, the government and
industry have taken various steps, one of which is the handling of corrosion
problems in the oil and gas industry pipeline. In an effort to control the use of
non-biodegradable materials, the government and industry have taken various
steps; one of them is the handling of corrosion problems in the oil and gas
industry pipeline using green materials and assuring the waste composition is
consistent with environmental regulation.
2.3 Fast-Acting Criteria for Metal-Treatment Compound
Fast acting can be seen as the easiness for a product to react when used
and how instant the process of the reaction it. The use of this kind of compound in
metal treatment is vital in the industry, especially oil and gas.
By applying fast-acting compound, they do not need to experience
production shutdown in the event of metal treatment from corrosion maintenance.
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Othercriteria for fast acting is how effective the performance of our product is
when used in emergency.
2.4 Basic Principle of Metal Treatment Compound
2.4.1 Corrosion Inhibitor
Corrosion inhibitors are chemical compounds that are added to a fluid to
reduce the rate of corrosion in materials in contact with the fluid. For example, an
inhibitor will be injected into the stream of hydrocarbons (oil or gas) near to the
wellhead to reduce corrosion in the steel of the pipeline. The composition of the
flow from the wellhead can vary greatly, with the water content varying from
between 1 and 99%, for example, and this has a significant effect on the natural
corrosion potential in the untreated system. Other factors, such as temperature and
pressure also affect corrosion rates (Hobbs, 2014). While corrosion inhibitors are
effective against 𝐶𝑂2 𝑎𝑛𝑑 𝐻2 𝑆,if oxygen is present they are either ineffective or
require very high concentrations to achieve the desired inhibited corrosion rate
(Winning, et al, 2010). In these conditions, scavengers are used to remove the
oxygen. Also, any water injected into the well would be treated to remove oxygen
before injection.
The main mechanisms for internal corrosion of pipelines are aqueous
corrosion caused by soluble corrosive gas, such as carbon dioxide, hydrogen
sulphide, or oxygen, and corrosion influenced by microorganisms. The water can
arise from being part of the original reservoir products (formation water) or from
water injection used to increase pressure. Corrosion Inhibitor are adsorbed on the
surface of the corroding metal, creating in this way a tight protective film as
illustrated in Figure 2.1.
Figure 2.1. Schematic of How Inhibitor Film Prevents Water Contacting a Metal Surface
(Source: Hobbs, 2014)
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Another method of creating a protective layer is passivation, which is

based on chemical interaction of the surface of the corroding metal with a
potential inhibitor. In this way, the metal surface is covered with an insoluble
protective layer whose main components are oxides. This group of compounds
comprises e.g. organic phosphates and chromates (Brzeszcz, et al , 2015).
Corrosion inhibition, both continuously and batch applied, is one of the
common methods used to control internal (process) corrosion of metal in oil and
gas production, transportation and processing facilities. For existing, aging
installations, treatment of produced fluids with corrosion inhibiting chemicals is
often the only feasible option.
This type of corrosion protection product has many factors affecting the
corrosion rates and inhibitor efficiency, which are flow rates and type of flow,
amount of water, presence of oxygen, carbon dioxide, and hydrogen sulphide,
temperature, welds, pH, and pre-existing corrosion (McMahon et al, 1995).
2.4.2 Coating
Corrosion-resistant coating is applied on metal parts for the purpose of
preventing corrosion. The functioning of any protective coatings is based upon
three basic mechanisms, which are Barrier Protection, Chemical inhibition,
Galvanic (sacrificial) protection. Barrier protection is achievable only when the
coating completely isolates the metal substrate from the corrosive environment.
Chemical inhibition refers to the ability of a coating system to release inhibitors to
retard corrosion such as anodic corrosion protection.
Galvanic or sacrificial corrosion protection refers to an active metal coated
on a substrate that corrodes at a faster rate due to the lower oxidation potential of
the active metal than the substrate itself. The coating therefore acts as a sacrificial
anode and the substrate is cathodic in the corrosion cell (Makhlouf, 2014). The
lifetime of anti-corrosion coating is influenced by oxygen permeability, water
vapor permeability, liquid water uptake, ionic permeability, coating porosity,
surface contamination, and surface profile. (www.sealxpert.com, 2017)
Coatings can be broadly classified into three types. There are Metallic
coatings, Inorganic coatings, and Organic coatings.
5
2.4.2.1 Metallic Coatings

Metallic coatings are applied to a metal surface by using following
methods: electroplating, electro-less plating, hot dipping, thermal spraying,
cladding, vapor deposition, ion implantation, laser processing a metallic coating
can function either as noble coatings or as sacrificial coatings.
Electroplating are produced by the electrodeposition of an adherent
metallic coating upon a metal or alloy which is to be protected. This is carried out
by immersing a metal or part of the metal to be coated in a solution of the metal to
be coated and passing direct current between the metal and another electrode.
Several metals commonly coated on steel are noble to iron. These noble coatings
act as an effective barrier to deny access for any corrosive species and to ensure
this the noble coating should be pore free and flawless.
Electro-less metal coatings are prepared without the help of electric
current. Electro-less nickel coatings are achieved by the autocatalytic chemical
reduction of nickel ions from aqueous solution. Generally, nickel-phosphorous
and nickel-boron coatings are produced. These coatings are amorphous in nature
and provide excellent corrosion resistance in a wide range of environments
Hot-dip coating is a process in which a low melting point metal is applied
as a protective coating on steel wherein the material to be coated is immersed in a
molten bath of the coating metal. Although hot dipping method can be applied
over a wide variety of materials, it is commonly used to protect steels. Hot-dip
coating can be applied by continuous or batch process. Aluminum and zinc are
most commonly used metals to be coated to steel. Hot-dip zinc coated steels are
generally known as galvanized steels.
Thermal spraying consists of a group of processes including flame
spraying, plasma spraying, arc metallization, detonation gun, high velocity
oxyfuel, and cold spray and that can be used to apply a variety of coating
materials for corrosion prevention. The coating materials can be powder, rod, wire
or liquid. The coating materials are heated to a plastic or molten state and
propelled by a stream of compressed gas onto the substrate. When these particles
strike the metal surface, they flatten and form thin platelets and adhered to the
6
prepared surface. Generally, a spray gun is used to generate the required heat for
melting through combustion of gases, electric arc or plasma.
Cladding is the bonding together of dissimilar metals. It is achieved by
rolling of two sheets of metal together. The principle of cladding includes hot-roll
bonding, cold roll bonding, explosive bonding, and weld cladding. For example, a
nickel and steel sheets 21 are hot rolled to get a composite nickel-steel sheet.
Similarly, high strength aluminum alloys are clad with commercially pure
aluminum to have a good barrier to corrosion.
Vapor deposited coatings are accomplished in a high vacuum chamber.
There are mainly two types of vapor deposition: physical vapor deposition (PVD)
and chemical vapor deposition (CVD). Usually, the coating material is vaporized
by heating electrically and the vapors are allowed to deposit on the part to be
protected. The major vapor deposition method are sputtering, evaporation, ion
plating (all of which are PVD processes) and CVD. The species to be deposited is
transferred and deposited in the form of individual atoms or molecules. The most
important advantage of vapor deposited thin coating is that it is pore free and
highly dense. However, its application in corrosion protection is limited since this
method is more expensive compared to other methods.
Ion implantation and laser processing are two surface modification
methods accomplished using high-energy or particle beam. High-energy ion
beams are used to modify surfaces to combat issues related to corrosion and wear.
By ion implantation, it is possible to enhance the passivation characteristics or
create a novel material. Ion implantation commonly finds its application in
semiconductor industry. Lasers with output power 0.5 to 10 kW can be employed
to engineer the metallurgical structure of a surface and tailor its surface property
by leaving its bulk properties intact. Laser processing helps to produce corrosion
resistant surface layers. Transformation hardening, surface melting, and surface
alloying achieve laser processing
2.4.2.2 Inorganic Coatings
Nonmetallic inorganic coatings include ceramic coatings, conversion
coatings, and anodized coatings. One of the most widely used ceramic coatings is
zinc silicates. These Sol-gel based silica and titania coatings are another type of
7
inorganic coatings. The inorganic particles in the sol gel coatings generally act as
a good barrier against corrosive species. But, the sol gel coatings cannot be
prepared in the thickness required for very high corrosion resistance since it is
prone to have cracks in the coating.
Next, Phosphate coating and chromate conversion coatings are two largely
used inorganic conversion coatings. Phosphate coating is produced on the metal
surface by immersion the metal in a bath mainly contains phosphoric acid and
other chemicals. During the immersion, the metal reacts with phosphoric acid and
other chemical contained in the bath and produce a crystalline insoluble protective
phosphate layer. Phosphate conversion coatings are generally used to improve the
corrosion resistance and the adhesion of paints. Commonly used phosphate
conversion coatings are zinc phosphate, iron phosphates, and manganese
phosphates. The basic principle involves in any phosphate coating is the
precipitation of a divalent metal and phosphate ions (𝑃𝑂43− ) on a metal surface.
The phosphate conversion coatings can be applied either by spraying or by
immersion.
Chromate conversion coatings are produced on the metal surface by a
chemical or electrochemical treatment of the metals or metallic coatings in
solutions containing hexavalent chromium (𝐶𝑟 6+ ) and other components.
Chromate conversion coatings are primarily applied to improve the corrosion
resistance of the metal and to improve the adhesion of paints on the metal surface.
Chromate conversion coatings are applied by both spraying and immersion
methods. However, various governments and regulatory bodies recommend the
replacement of chromate conversion coating with some other green alternative
since hexavalent chromium is carcinogenic and toxic.
Anodizing is one of the most important surface modifications carried out
for aluminum alloys for improving the corrosion resistance and other purposes.
Aluminum oxide (𝐴𝑙2 𝑂3) films are formed on the surface when aluminum and
aluminum alloys are polarized anodically in electrolyte solutions. Since all of the
anodic process form porous 𝐴𝑙2 𝑂3films, it is required to seal the pores by
immersion the coated materials in hot water. The hot water treatment would
hydrate the coating and seal the pores by forming 𝐴𝑙2 𝑂3 . 𝐻2 𝑂.
8
2.4.2.3 Organic Coatings

Usually, an anticorrosive coating system is multifunctional with multiple
layers with different properties. A typical multifunctional coating can provide an
aesthetic appearance, corrosion control, good adhesion, and abrasion resistance.
Figure 2.2. shows a typical multifunctional multiple coating system used for
highly corrosive industrial and marine environments.
Figure 2.2. A Typical Coating System for Marine and Industrial Applications
(Source: https://www.steelconstruction.info, .n .d)
Prior to the application of a primer, the substrates to be coated should be
cleaned neatly and pretreated to improve the adhesion of the subsequent coatings.
Generally, sand blasting, polishing with emery sheets and pickling are employed
for surface finishing. Next, the primer is the base coat on which the rest of the
coating system is applied and hence it should have strong adhesion to the surface
of the substrate. The primer generally contains some inhibitive pigments and these
pigments used to passivate the metal surface and improve its corrosion resistance.
A primer should protect the surface for many days or months prior to the
application of top coats and thus the primer coat should be highly adherent and
inert.
The next layer is intermediate coating which is to increase the thickness of
the coating system and resist the infiltration of corrosive species to the metal
surface. The major use of intermediate coats is to build up the thickness of the
coating, Improve the chemical resistance of the coating, Retard the moisture vapor
transfer, Increase the electrical resistance of the coating, Improve the adhesion
between the primer and topcoat.
9
The topcoat is the final finish coat it is always exposed to the external
environment. The topcoat should have required colour and gloss to please the eyes
of an observer. It is the first line of defense against corrosion in a coating system
and hence it should have enough barrier property to impede the transport of
aggressive species through the coating system. The important function of a
topcoat is to provide A resistant seal for the coating system, Initial barrier to the
external environment, Good resistance to water, chemicals, and weather, Strong
and wear resistant surface, Aesthetic look to the coating system, High resistance
to ultraviolet radiation. The above-mentioned coating system is not necessary for
all applications.
Different combinations of coating system can be obtained depending upon
the corrosive situations. Even a single coat can function satisfactorily for some
corrosive environment. Sometimes a single coating formulation applied in more
than two coats can provide required protection for metals and alloys.
2.4.3 Cathodic protection
Cathodic protection is an electrical method of control or preventing
external corrosion of pipeline steels and other metallic structures buried in soil or
submerged in water (Bushman, 2012). The cathodic protection principle is based
on reversibility of electron flow to prevent current leaving the corroding area or
moving the equilibrium potential of the structure to be protected to a more
electron negative value (lower potential) and supply external source of current to
flow into the structure (Talbot, 1998). The principle of cathodic protection can be
explained with electrochemical reactions. In corrosion of iron, the metal ion enters
solution at the anodic areas in a quantity equals to cathodic reactions and flow to
the cathodic areas so that electrons on both sides are balanced.
At the anodic areas, atoms of metal release electron to become metal ions
as shown below
2𝑀 → 2𝑀+ + 2𝑒 − (2.5)
M is the metal atom, 𝑀+ is the metal ion and 𝑒 − is electron.
A general reaction at the anode where iron is corroding in non-acidic
environment such as water or soil electrolyte is represented as:
𝐹 → 𝐹 2+ + 2𝑒 − (2.6)
10
The reaction released free electron that remains in the structure of the
metal and the metal ions move away from the metal structure and enter the
environment where it is consumed at the cathodic area.
At cathodic area in acidic solution in the presence of water, the reaction is
represented as:
2𝐻 + + 2𝑒 − → 𝐻2 (2.7)
The reaction produced two hydrogen ions to form two atoms of hydrogen.
Another possible cathodic reaction in aerated water or soil that is non-acidic
where oxygen is dissolved in a solution and consumed but still corrosion occur at
the anode and not at the cathodic is represented as:
𝑂2 + 2𝐻2 𝑂+4𝑒 − → 4𝑂𝐻 − (2.8)
The whole of equations (2) to (4) which are electrochemical reactions that
occur during corrosion process can be summarized into one equation as shown:
2𝐹𝑒 + 2𝐻2 𝑂 + 𝑂2 → 2𝐹𝑒(𝑂𝐻)2 (2.9)
There are basically two techniques of applying cathodic protection to
protect structures, namely sacrificial anode and impressed current techniques.
2.4.3.1 Sacrifial Anode
Sacrificial anode system involves connection of a more negative
electrochemical metallic anode with the intended structure to be protected via a
wire to complete the circuit. The method of protection requires no external power
source but based on the natural potential existing between sacrificial anode and
protected structure. For sacrificial anode system, the metallic anode dissolves, get
consumed gradually and the current flow from the anode through the soil
(electrolyte) down to the protected structure because of natural potential
difference between the protected structure and the metallic anode (Ameh, et al,
2017).
Metallic anodes commonly used in the protection of steel structures are
magnesium, zinc and aluminum and their selection depend largely on electrolyte
conductivity or resistivity. Thus, magnesium is most suitable in seawater;
aluminum in freshwater but zinc can be used in both seawater and land. It is less
expensive to install, lower maintenance cost and the current distribution to the
intended structure is quite uniform and therefore pose no risk of overprotection
11
and potential coating damage. However, the current output delivery is small
compared to impressed current system, so it is only effective for smaller structure.
One other obvious disadvantage of the protection system is that the sacrificial
anode gradually gets consumed, thus needing replacement after depletion (Ameh,
et al, 2017).
2.4.3.2 Impressed Current
Impressed current cathodic protection system uses highly energized (inert)
anodes such as silicon cast iron, graphite, platinum clad, silicon mixed metal
oxide, and niobium coated wire which are then connected to positive terminal of
the power source (rectifier) and to the anode while structure intended to be
protected is connected to the power source negative terminal. The original power
source which is alternative current is converted to direct current by a rectifier
(Bushman,2012). The inert anode for the impressed current system remained
undissolved and non-consumed throughout the protection period but in the
process the inert anode causes hydrogen gas evolution reaction at the anodic
region. For structures’ potential to be lowered or cathodically protected, the
structures must be in contact with power source and in electrolytic environment.
The impressed current cathodic protection system delivers adequate
power output and therefore used for protection of larger structures and several
kilometers of pipelines. Above all, the inert anodes are not consumed, hence
requires no replacement. But the current distribution is usually not uniform
leading to overprotection and coating damages of structures that are in closed
proximity to the power source if not insulated. It has become necessary to
critically evaluate design processes of cathodic protection system due to rising
corrosion and increasing pipelines construction and installation in very harsh
environment owing to remote oil and gas exploitation and exploration (Ameh, et
al, 2017).
12
Figure 2.3. Impressed Current Cathodic Protection System

(Source: http://faculty.kfupm.edu.sa/, n.d )
2.4.4 Rust Remover
Rust Remover removes rust from an object completely and leaves behind
bare. To use this product requires the object to be completely submerged and
soaked. There are three type of rust remover.
First, Acid-based rust removal products normally contain an acid or
caustic solution such as oxalic acid as an active ingredient to strip the rust from
the metal surface. Unfortunately, oxalic acid is a harsh and toxic chemical which
could pose a health risk to anyone who gets into contact with it. Due to the
numerous disadvantages of acid, not least the health and safety concerns, it is
rarely used except where it's low chemical cost and fast acting nature are needed
to sustain the demands of the business.
Second, Alkaline based rust removal or hot alkali solutions such as caustic
soda (sodium hydroxide) and caustic potash (potassium hydroxide) will remove
rust from iron and steel, and when combined with sequestering agents to hold the
dissolved iron in solution, they can be very effective, particularly at near boiling
temperatures. However, since hot alkali is very corrosive, dissolving soft metals
such as aluminum, its use is restricted to iron and steel parts only. It is commonly
used in automotive restoration on body panels and cast-iron engine parts where its
ability to remove oil and grease as well as paint residues is beneficial.
13
Third, Aqueous rust removal is aqueous based with a completely neutral

pH. It utilizes iron's multivalent nature and its ability to form stable complexes
with specific tailored chelating molecules. Put simply, the solution converts the
red rust to a completely different form of iron compound which is lifted from the
surface of the part and into the aqueous solution. In doing so it does not attack the
base metal, and as a neutral aqueous solution it does not attack any other surfaces
or materials either. This rust removal is safe on almost all surfacest, need low
energy cost and very low maintenance costs as a result.
2.4.5 Rust Converter
According to Viswanathan S. Saji (2019), in principle, a rust converter is
designed for application on a rusty surface to convert rust (iron oxides, that cannot
be easily removed from the surface) to a harmless adherent protective layer where
overcoat painting is feasible.
Figure 2.4. Surface Before and After Commercial Rust Conversion Treatment
(Source: Viswanathan, 2019)
Rust converter reduces the corrosion rate of rusted metals either when used
alone or in combination with a primer . In practical applications, an initial rust
converting coating will be followed by a topcoat. For performance improvement,
additives such as active agent, catalytic agent, corrosion inhibitor, penetrating
agent and wetting agent, are added in commercial rust converting paint
formulation (Marco et al, 1994).
2.4.5.1 Tannins-Based
Tannin and its derivatives are the major group of chemicals investigated
for rust converter applications. On reaction with iron oxides, tannin-based
14
compounds can form iron tannates that appear as a blue/ black protective layer on
the surface. The performance of these compounds depends on several parameters
such as the type of tannin used, concentration, pH, time of exposure, reaction
time, nature of co-additives, application method, the extent of corrosion happened,
electrolyte aggressiveness and contamination grades of the rusted steel.
(Viswanathan S.Saji, 2019)
Tannins (hydrolysable and condensed tannins) are high molecular weight
polyphenolic compounds. Tannic acid, the most widely investigated tannin (Fig.
2.5) is a hydrolysable tannin (ß-1,2,3,4,6-digalloyl-O-D-glucose) with
approximate empirical formula 𝐶76 𝐻52 𝑂46. Due to the presence of ortho −OH
groups on the aromatic rings, tannic acid can chelate with metal ions forming a
highly crosslinked network of ferric tannates.
Figure 2.5. Molecular Structure of Tannic Acid

(Source: Okuda, 2005)
Martinez investigated the mechanism of the adsorption of mimosa tannin
onto low-carbon steel in sulphuric acid solutions. At pH 1 and 2, the value of the
free energy of adsorption suggested a chemisorption mechanism due to the
formation of an adsorption bond between the oxygen lone-pair electrons of the
tannin−OH group and the metal surface. At pH≥3, ferric tannate was formed and
the value of the free energy of adsorption suggested a physisorption mechanism
for ferric tannate adsorption onto steel surface.
At high concentrations or pH (3 and 5), tannins reacted to form insoluble
blue-black amorphous complexes of mono-and bis-type tannate complexes, with a
relative amount of bis-ferric tannate generally increasing with pH. At pH 7 (and
15
even higher) a partially hydrolyzed ferric tannate complex and some 𝐹𝑒 2+ in the
form of hydrated polymeric ferrous tannate are obtained. These phases do not
provide corrosion protection (Jaen et al, 2011)
2.4.5.2 Phosphoric Acid-Based
Leonard said, 𝐻3 𝑃𝑂4 insufficient amount can act as a rust remover,
converter, and inhibitor in paint compositions. The use of 𝐻3 𝑃𝑂4in rust converter
formulations is based on its ability to form water-insoluble iron phosphate
(𝐹𝑒3 (𝑃𝑂4 )2 ) on steel surface. A waterborne epoxy ester resin rust converting
primer containing TiO2, bentonite, and 𝐻3 𝑃𝑂4 showed good physical and
corrosion-resistant properties.
Almeida et al. explained the mechanism of phosphoric acid pretreatment
for rusted surfaces. On reaction with rust, phosphoric acid can give amorphous or
crystalline iron phosphates and that depends strongly on the concentration of the
phosphoric acid solution. For a surface that corroded for 10 months in an
atmosphere with low level of contamination, phosphoric acid solutions of ca.
7.5wt.% not converted residual rust eficiently whereas at a higher concertation
(14.6%), formation of a less adherent bluish-white film was formed corresponding
to the formation of vivianite [𝐹𝑒3 (𝑃𝑂4 )2.8𝐻2 𝑂]. At concentration > 33.2%, a
vitreous dark brown film was formed which exhibited more and more cracks,
discontinuities and higher acidity as the concentration increased.
Phosphoric acid can react with different components of rust and can give
rise to various iron phosphates [𝐹𝑒(𝐻2 𝑃𝑂4 )2 , 𝐹𝑒(𝐻2 𝑃𝑂4 )2 and𝐹𝑒3 (𝐻2 𝑃𝑂4 )8].
The dihydric phosphates formed can be converted into indissoluble phosphates
(FeHPO4, 𝐹𝑒3 (𝑃𝑂4 )2, and FPO4 ) with time (Burtnieks, 1975)
2.5 Product Trends
2.5.1. Corrosion Inhibitor
Typical corrosion inhibitors used in oil and gas industries revolve around
organic compounds and are employed in small concentrations (less than 0.1 %).
Often categorized as mixed inhibitors, they adsorb on steel surfaces and inhibit
anodic and cathodic reactions. It also displaces adsorbed water molecules from the
surface and are referred as filming inhibitors. (Palmer, Hedges and Dawson,
2004).
16
Almost all organic inhibitors are highly polar functional compounds, with
many being based on nitrogen, such as amines, amides, imidazolines or
quaternary ammonium salts, and include salts of nitrogenous molecules with
carboxylic acids, poly-oxyalkylated nitrogen containing compounds, nitrogen
heterocyclics and compounds containing P, S, and O (Palmer, Hedges and
Dawson, 2004).
Furthermore, the molecules also have a hydrocarbon chain attached, at
which the length varies (carbon numbers between 12 and 18). The active group
provides the ability to displace water and cause adsorption onto the metal surface.
The hydrocarbon causes the molecule to be partially oil soluble and attracts crude
oil molecules from the process stream. The inhibitor molecule protects metal the
surface by providing a barrier from the corrosive water phase. (Palmer, Hedges
and Dawson, 2004).
Figure 2. 6. Schematic of Action of Oil Field Corrosion Inhibitor

(Source: Palmer, Hedges and Dawson, 2004.)
According to Palmer, Hedges and Dawson (2004), Common commercial
products of oil-field corrosion inhibitors can contain up to six surface active
organic compounds dissolved in a carrier solvent, which can be water, alcohol, or
hydrocarbon. A low freezing point solvent (e.g. ethylene glycol) is required for
products at extreme cold weather. Demulsifier may also be included to reduce
impact on water/oil separation in the field.
Oil and gas corrosion inhibitors are classified based on their solubility as:
a. Oil or water soluble
b. Oil or water dispersible
c. Oil and water insoluble
d. Gas Phase
17
Water-soluble inhibitors used in continuous injection of water containing

systems are typically quaternary amines, amine salts or salted imidazolines. Oil-
soluble inhibitors tend to be long chain primary amines, imidazolines, fatty acids,
and phosphate esters. Gas phase inhibitors are usually low molecular amines that
have a high vapor pressure (Palmer, Hedges and Dawson, 2004).
2.5.2. Coating
Applying an anti-corrosion coating to oil and gas pipelines and piping
protects it from corrosive environment and decreases the corrosion rate.
Commonly, coatings are classified onto 2 major classifications, which is organic
and inorganic coating.
Organic coatings are known for their relatively better acid and corrosion
resistance and are widely used. Here are several examples of organic coatings
with their set of advantages and disadvantages,
Table 2.1. Organic Coating
No Coating Advantage Disadvantage
Good acid and alkali
Low mechanical and
resistance, water resistance,
Coal Tar thermal stability, easily
1 and the ability to prevent
Coating damaged by plants and
surface from peeling. Cheap
bacteria, and ages fast
and high insulative properties
Good insulative property and
Petroleum and
does not easily eroded by Low mechanical and
2 Asphalt
bacteria. Low absorption rate thermal stability
Coating
and strong adhesion
Epoxy Compact and fine adhesion.
3 High water absorption rate
Coating Salt and alkali resistant
18
Table 2.1. Organic Coating (Continued)

No Coating Advantage Disadvantage
Expensive and complex to
Good adhesion, penetration
3-Layered be manufactured.
resistant, and high mechanical
4 Polyethylene Temperature hard to
and soil resistance.
Coating control and inconsistent
Environmental-friendly
thickness
Epoxy Coal Water-proof and good
Long curing period and
5 and Asphalt insulative property. Heat and
hard to apply to surface
Coating wear resistant. Good life span
Rubber Anti- Good insulation and salt
6 Corrosion resistant. Inexpensive and Soft and easily damaged
Coating environmental-friendly
(Source: Reproduced from Mirza, Rasu et al. 2018.)
On the other hand, inorganic non-metallic coatings are very corrosion,
heat, and wear resistant. And as a result, using inorganic materials in the
manufacture of anti-corrosion coatings have become more prominent in the past
few years. These are several inorganic coatings present in the oil and gas industry,
a. Cement Mortar Coating
Cement mortar is rich in alkali which produces a passive film inside the
pipeline, preventing it from corroding. It is non-toxic, safe, cheap, and
easy to apply.
b. Enamel Coating
Currently considered the best material, as it can resist all kinds of acid and
salt in a reasonably inexpensive price.
c. Ceramic Coating
Great corrosion-resistant material which can resist oxidation and have high
thermal stability.
Despite the many applications of organic and inorganic coatings, the
current trend in coating as of 2016 are: 3-Layered Polyethylene, Fusion Bonded
Epoxy, Coal Tar Enamel, and Asphalt Enamel. The figure below shows the
market trend of coatings used throughout the world (Mirza, Rasu et al. 2018).
19
100
80
60
40
20
0
North America South America Middle East Europe North Africa Asia
FBE 3-LPE Other
Figure 2. 7. Coating Global Market Trend in 2016

(Source: http://www.journalrepository.org/)
2.5.3. Cathodic Protection
Cathodic protection is the only foolproof method of protection in
inaccessible areas like underground pipelines and marine structure like offshore
platforms. Throughout the year, two method is available to apply this kind of
protection, which are sacrificial anode and impressed current (Khan, Kakar et al.
2018).
Sacrificial anode is a protection that involves protecting a metal surface of
a piece of equipment using another metal that is more reactive. The more reactive
metal is called sacrificial anode. The anode has a less negative electrochemical
potential compared to the metal being protected, hence it undergoes oxidation
rather than the metal and protecting the piece of equipment. It is usually used on
offshore pipelines, offshore oil platforms, and onshore oil casing when other types
of corrosion protection can’t reach the metal (Khan, Kakar et al. 2018).
Impressed current is another form of cathodic protection, which is applied
by coupling the metal to be protected to the negative pole of a direct current
source, while the positive pole is coupled to the auxiliary anode. Since the driving
voltage is provided by the DC source, there is no need for the anode to be more
active than the structure to be protected. Impressed current usually protects large
metallic structure or long pipelines because it economically more beneficial and
20
when the current requirement is high, and an external DC source is required

(Ameh, Ikpeseni et al. 2017).
2.5.4. Rust Remover
The global rust remover market is segmented by the product type into
Acid Rust Removers, Neutral Rust Removers, and Alkaline Rust Removers. Acid
Rust Removers is the largest segment with an estimated market share of more than
60% throughout the forecasting period. Neutral Rust Removers segment is
projected to become 1.7x of its current value by the end of the period of
assessment (Anon, 2017).
According to Anon (2017), Rust remover is mainly used on Automotive,
Aviation and Aerospace, Oil and Gas, Marine, Petrochemical, Metal Machining,
Construction and Infrastructure, and others. Oil and Gas is anticipated to remain
one of the largest segments in terms of value, expected to reach US$ 112.5
Million by the end of 2027.
Based on the report of “Rust Remover Market: Global Industry Analysis
2012 – 2016 and Opportunity Assessment 2017 – 2027,” the historical trend
suggests that the global rust remover market is projected to grow owing to the
increasing demand for corrosion removal, metal cleaning, and surface pre-
treatment chemicals. The global rust remover market is estimated to be worth US$
411.6 Million in 2017 and this is expected to increase to US$ 638.9 Million by the
end of 2027, registering a CAGR of 4.5% in terms of value during the forecast
period. Globally, the usage of rust removers reached 180598 tons in 2016 and this
is forecasted to increase to reach 258227 tons by the end of 2027 (Anon, 2017).
2.5.5. Rust Converter
Several recent patents regarding rust converter coatings were published
that have a low pollution environmental rate, strong weather and corrosion
resistance. Patents during 2008 – 2018 period are mainly based on water-dilatable
resin system as they are economic and environmental-friendly (Reinhard 1990).
Rust converters can be produced from three types: tannins-based,
phosphoric acid-based, and tannins-phosphoric acid synergistic combination
(Reinhard 1990). Tannins-based rust converter was patented by Vysotskaya that
comprises of tannin extract, oxalic acid, silver nitrate, oxyethylideniphosphonic
21
acid, and water. Phosphoric acid-based is essentially H3PO4 in sufficient amount,

which uses its ability to form water-insoluble iron phosphates on steel surface.
(Reinhard 1990). Pan et al. patented cleaning, converting, and anti-rust treatment
agent for coating on inner wall of acrylic acid reactor for nuclear power stations
that includes: H3PO4 (85%) and zinc oxide, citric acid, tartaric acid, nickel nitrate,
potassium dichromate, ammonium molybdate, triethanolamine, and ethylene
glycol (15%) (Ocampo, Margarit et al. 2004). Tannins-phosphoric acid synergistic
based is mixed phosphoric acid and tannin acid-based. Bolivar et al. studied the
conversion properties of 15 different combinations of rust converters, based on a
combination of 3, 5, and 10% tannic acid, 35% phosphoric acid, and five different
mixtures of isopropyl and terbutilic alcohol. (Reinhard, 1990)
There are also innovations regarding rust converters. Wang et al patented a
coating process that is similar with the industrial coating procedure followed by
many coating companies. The steps involve: pre-treating the substrate with rust,
coating waterborne rust converting material, spray coating waterborne
anticorrosive primer, flash/surface drying or baking, and spray coating waterborne
texture topcoat. The steps include adding tannic acid (rust converter), wetting
agent, dispersing agent, antifoaming agent, flash rust proof agent and thickening
agent into distilled water, stirring to obtain intermediate material, and processing
it to create the corrosion-resistant rust converting materials. (Szauer, Bordzilowski
et al. 1990)
Feng et al. also reported a rust converter, 3, 4, 5-trihydroxy-2-
hydroxyimino methyl benzoic acid. The gallate obtained by reacting gallic acid
with magnesium methoxide was subsequently reacted with formaldehyde to
produce the product. (Zuo, Li et al. 2017)
22
Figure 2.8. Synthesis Procedure of Rust Converter

(Source: Reinhard, 1990)
2.6 Environmental Issues
Metal surface treatment increases its durability and reduces the rate of
corrosion in metal. However, this operation could produce hazardous chemical
waste that contributes to environmental damages. Ecological issues about every
metal treatment method will be explained below.
2.6.1 Cathodic Protection
Sacrificial zinc anodes are cathodic protection are one of the most
common metal corrosion prevention method. It is known that despite being
necessary for human health, a high concentration of zinc can be harmful to
human. According to Hinton (2011), water from industrial area is often considered
toxic as it contains high amount of zinc. High concentration of zinc in water can
be a result of waste from galvanizing system that produces a high amount of zinc
in the process.
According to Birds (1996), zinc level in the environment coming from
metal equipment that is exposed to seawater could numbered up to 25𝜇𝑔𝐿−1 ,
depending on the tide exposition. This fact is considered as ecological damage, as
zinc is recognized to be toxic up to 5𝜇𝑔𝐿−1 according to OSPAR Convention
ecotoxicological assessment criteria (1997). Moreover, zinc has the potential to
contaminate food chain since it is bio-accumulable.
Dissolved anodes also can be transferred into sediment phase via
adsorption or absorption phenomena. Not just contaminated by zinc, sediments in
area near cathodic-protected metal facility in seawater can be considered
moderately polluted by Cu and Pb, according to Rousseau (2008).
23
2.6.2 Corrosion Inhibitor

Coatings and metal protective spray usually doped by volatile corrosion
inhibitor (VCI). The VCI crystals then will slowly vaporize . However, VCIs
contain hazardous chemicals from aromatics and aliphatic amines, chromates, to
phosphonates. To control the vapor pressure of VCIs to be low, usually solvents
are added. Solvents may include alcohols, acetates, glycols, and others. A review
on TOXNET, a database maintained by the National Institutes of Health on
chemical safety, shows nearly all VCI and solvent chemicals to be hazardous by
OSHA (Occupational Safety and Health Administration) definition. A study by
German Workers Safety Association also found that VCIs posed carcinogenic
threat from mixture of amines and nitrites contained in the product. The outcome
resulted in the German government issuing a regulation (TRGS-615) banning
throughout Germany certain VCI formulations and restricting certain other VCI
chemical concentrations.
Conventional corrosion inhibitors are usually chromate-based, which is
considered toxic and has been declared restricted by government regulations.
However, recent ‘green’ alternatives usually do not have comparable performance
than chromate-based ones, particularly on corrosion-prone aluminum alloys such
as the 2000 and 7000 series. A study by Costa and Klein (2006) of chrome
chemical production worker found that excess lifetime risk of dying from lung
cancer to be 255,000 per million, massively larger than acceptable risk of 1 death
per million.
A study by Ezemonye (2006) shows that corrosion inhibitor (Norust CR
486) possesses more threat than detergent if exposed to the environment. This data
is supported by considering the mortality of earthworms, Aporrectodea longa that
indicates early warning signs of future soil deteriorations by indiscriminate
disposal in the environment.
2.6.3 Rust Remover and Rust Converter
Both rust remover and rust converter mainly used acids as the main
ingredient. However, the low pH of acid possesses high threat to the environment
also creates serious health and safety risks. Industry spends billions trying to
prevent damage by these damages and their removal.
24
Mineral acids such hydrochloric acids, sulphuric acid, and phosphoric acid
are usually used for surface finishing process. Exposure usually is accidental and
often is due to inadequate use of protective measures. Acid burns are a unique
clinical entity. Dilute solutions deeply penetrate before dissociating, thus causing
delayed injury and symptoms.
Organic acid such as tannic acid is another type of corrosion inhibitor,
however tannic acid and water expectably reduces the pH level below 7, leading
to a far more acidic environment which has adverse consequences. The shift in the
pH is often too sudden to sustain a constant population.
Another example of chemical rust removing agent is hydroxyethane
diphosphonic acid (HEDPA). According to Rao et al (2012), chemical processing
of HEDPA (>5vol.%) at high temperature (> 40oC-55oC) produces strong pungent
smell and unpleasant cleaning environment. In contrast of what usually chemical
contributes to living beings’ mortality, low concentration (<0.5wt.%) of HEDPA
improved seeds germination and plants growth. However high concentration of
HEDPA produces reverse effect.
2.6.4 Coating Pigments
Pigments are inorganic or organic compounds that provide colors to the
coating. Color and visible opacity is necessary to observe coating flow and
durability. However, pigments often contain heavy metals such as cadmium, lead,
zinc, chromium and cobalt. According to Porwal (2015), The World Health
Organization (WHO) has reported a 20%-40% increased risk of certain types of
cancer for those who come into regular contact with, or work with paint.
2.6.5 Phosphate Coatings
There are several operations to be done as surface preparation to give
protective coatings to the metal. The most common one is phosphate coating
which promotes adhesion of organic coating onto metal surface and retard
corrosion. The process consists of a series of chemicals and rinse baths and most
of the hazardous waste produced in a metal finishing facility comes from waste
water generated by the rinsing operations that follow cleaning and plating.
The mechanism of phosphate of processing is to coat metal with phosphate
containing mixture of hopeite and phosphophyllite layer after immersion in a
25
dilute phosphoric acid solution using phosphating bath or spraying techniques

(Weng, 1998).For zinc phorphate coating, the normal reaction can be described as
follows:
3 𝑍𝑛2+ + 2𝐻2 𝑃𝑂4− + 4 𝐻2 𝑂 → 𝑍𝑛3 (𝑃𝑂4 )2 ⋅ 4𝐻2 𝑂 + 4𝐻 + (2.10)
or:
2 𝑍𝑛2+ + 𝐹𝑒 2+ + 4 𝐻2 𝑃𝑂4 + 4 𝐻2 𝑂 → 𝐹𝑒𝑍𝑛2 (𝑃𝑂4 )2 ⋅ 4𝐻2 𝑂 + 4𝐻 + (2.11)
The waste outlet contains wastewater from processing steps, solid rust
residue from steel sheet during pre-degreasing operation, sludge precipitate from
phosphating, and slime from neutralization process for wastewater treatment.
According to Weng (1998), Total calculated of wastewater may numbered up to
20,800 𝑔/𝑚2 and solid residue up to 49.0 𝑔/𝑚2 . Unlike the wastewater
discharge, solid residue cannot be absorbed by the environment. A single-factor
analysis of LTL (Local Toxic Level) is conducted from wastewater, and the
results are listed in Table 2.2. The average LTL value is 1.6 ppm/ppm, which
demonstrates wastewater must be treated before disposal.
Table 2.2. Local Toxic Level in Phosphating System
Substance 𝐹 𝑃𝑂43− 𝑆𝑂42+ 𝑍𝑛2+ 𝑀𝑛2+ 𝑁𝑖 2+ Oil Suspended Average
Solids
LTL 1.3 2.9 1.5 2.1 1.3 1.4 1.1 1.3 1.6
(Source: Reproduced from Weng et al, 1998)

The other influence to the environment of phosphating operation,
according to Weng (1998), is the level of GWP (Global Warning Potentials). The
process discharges 400.0 𝑔/𝑚2 CO2-equivalent mass to the environment which
contributes to green-house effect.
2.6.6 Coating Solvent
Solvents work to decrease coating viscosity and dissolve the binders.
Organic solvents used in coatings include aliphatic hydrocarbons, aromatic
hydrocarbons, esters, ketones, glycol ethers, and alcohol. Solvents used in coating
formulations are hazardous as they contain carcinogenic, flammable, explosive,
and high level of VOCs.
26
The ozone layer forms a gaseous shield, between 10 and 50 km altitude,

protecting the Earth from ultraviolet rays. A new study attempts to evaluate the
damage caused by solvents for paints and varnishes. According to this research,
the level of DCM in the stratosphere has almost doubled since 2004. If this
growth were to continue, it could delay the recovery of ozone over Antarctica by
more than a decade – where the “hole” was most alarming.
2.6.6.1 Solvent Stripping
Chemical or mechanical coating removal is conducted when a metal
surface requires recoating, repair, or inspection. The most common chemical
coating removal method is solvent stripping, using phenol, methylene chloride,
and organic acid to dissolve the coating from the coated surface. However, this
could generate a large quantity of wastewater as a the result of water wash to
remove the chemicals, especially when the wastewater contains a great amount of
toxic compound and cannot be degraded easily.
2.6.6.2 Curing
Curing, according to Corrosionpedia Inc., is a chemical reaction or a
physical action which results adhesive bond. Curing is performed to convert the
coating binder into hard, tough, surface. Binders include a variety of oils, resins,
rubbers and polymers. Curing usually generates significant VOCs from solvent-
based coatings and becomes explosive. Air pollution control is required as a
countermeasure of high-level pollutant VOCs.
Alternative formulations of coating with non-hazardous constituents is a
solution to answer environmental and health concerns, strict regulations, high cost
of solvent, and its climacteric disposal.
2.7 Product Risk
Many aspects of product can be used to assess its performance to meet all
the customer’s requirement. For the protection of metal, the existing products
widely use in the market are coating, corrosion inhibitor, cathodic protection, etc.
Despite of its affordable price for the multiple use of treatment, by significantly
improving the quality of coating, it is possible to produce a diversed coating that
has multiple function in one product. However, it is important to understand that
in development of coating, there are approximately two phenomena that need to
27
be considered. Those are weathering and loss of adhesion. In weathering, the

primary parameters are UV radiation, temperature, and moisture. Meanwhile, for
loss of adhesion, it is caused by moisture penetration and its interaction with the
substrate. The loss of adhesion can also be influenced by pollutants (Wypych,
2018). These two phenomena are actually risky, if product is going to be
developed in form of coating, keeping in mind that the average annual humidity
percentage of Indonesia is around 55-100%, a very humid air (BMKG, 2018). In
addition, using corrosion inhibitor as a metal protection agent is a right way to
prevent the internal corrosion. Unfortunately, the use of inhibition to control
corrosion presents a risk to future operation. Corrosion inhibition is also less
effective in old, corroded and pitted pipelines/facilities and in systems that contain
large amounts of debris. Dosages may have to be increased or the system need to
be cleaned. The inhibitor may not perform as anticipated in the field or there may
be poor management of the dosage leading to lower than required inhibitor
availability. Beside that, another type of metal protection technology is cathodic
protection that is proven as an alternative solution in moist and corrosive soils.
Cathodic protection should be considered wherever the system is exposed to an
aggressive surrounding (Bahadori, 2014). Despite all of advantages that it has, this
technology also has some risks in operational, consist of the increasing of noise
level because of water turbulence around the hull, the increasing of fuel
consumption, the uncontrollable of anode current, and etc (Bahadori, 2014).
In restoration of metal, before the product is going to be made in form of
rust converter and rust remover, there are some considerations that need to be
noted. For restoration, the rust converter is harmful for rusted samples with high
chloride contamination (Ocampo et al., 2004). When applying this product into
metal, both of vapors from rust converter and rust remover are similar to latex
paints and are not dangerous for healthy. But, it is recommended that it is applied
only in well ventilated areas.
CHAPTER 3
MARKET NEEDS ANALYSIS
3.1 Methods of Needs Identification

In designing chemical or bio-based product, several steps need to be done.
The first step is performed by market research.
3.1.1 Market Analysis
Market analysis is conducted by two ways, there are indirect and direct
analysis. For developing concept for fast acting biodegradable compound for
metal treatment, protection, and restoration application, we need to do interview
or spread questionnaire about new ideas of what customer needs to improve the
existing product. From that data, we can know what consumers needs and rewrite
the needs into a table.
There are two type of method for knowing what consumer’s needs. First,
Direct Market Analysis is type of method which include such as sending email
survey to consumers, doing a telephone survey, or interviewing the consumers. In
this method, we do face-to-face interview with people who have knowledge,
expertise or experience in piping and pipelines field. The answers we obtained are
varied and more comprehensive. Second, there is Indirect Market Analysis. We
gather information by spreading online questionnaire to social media where the
piping and pipeline engineer or oil and gas engineer communities exists. By doing
so, we can get more answer from anywhere. After that we can process the
respondent's data by grouping and interpreting their needs, so we can create idea
for innovations needed in accordance with existing problems or needs.
3.1.2 Customer Requirement
Based on literature and discussion, we know that almost all the existing
products of metal protection, treatment, and restoration still have some
weaknesses. Therefore, based on this reason we will expose and analyze the
consumer needs for the product. Then, we will formulate the product’s
specification by analyzing the consumer requirements.
The customer requirement is based on the target market’s ideas and
opinions that have been obtained and analyzed from the questionnaires and
29
interviews. We also obtain additional literature from the interviews with some
experts and professionals that interacts with piping and pipelines in oil and gas
field. Those customer voices are affecting the sustainability of product design and
development.
To understand what customer needs, first we ought to define our customer
specifically. The customers include both those who will buy the product and those
who will use the product. Therefore, we gather information from, industry
professionals as user of the product and experts related to this field. Here are the
results of the survey.
3.1.2.1. Usage Frequency of Anti-Corrosion Protection
Continues (remote)
monitoring
(Tentative) Depends on
22%
the case
34%
Once in a month
11%
Twice in a month
11%
22%
3 bulan sekali
Figure 3. 1. Respondents’ Frequency

(Source: Reproduced from Questionnaire)
Most of the respondents use Anti-corrosion protection product
continuously, specifically 34 % of the total respondents and followed by the
second largest 22% respondents use product quarterly and tentatively. tentatively
here means that the frequency carried out depends on the case. For example, is if
there is a change in composition of the fluid entering the pipe with increasing
number of corrodents (such as 𝐻2 𝑆 𝑎𝑛𝑑 𝐶𝑂2), then the frequency of product
usage is increased.
3.1.2.2. Common Types of Corrosion Encountered
30
Stress Corrosion
Cracking
Localised Corrosion
12%
25%
6%
Crevice Corrosion
6%
13% 13% Pitting
25% H2S Corrosion
CO2 Corrosion
Figure 3. 2. Respondents’ Common Types of Corrosion

25%
37% general corrosion
acidic corrosion
microbial corrosion
38%
Figure 3. 3. Grouping Types of Corrosion

As seen above, the largest corrosion occurred in piping and pipeline are
caused by 𝐻2 𝑆 𝑎𝑛𝑑 𝐶𝑂2. This is reasonable because the oil extracted from the
ground still contains CO2 and H2S. These compounds are acidic which make
meterial easily corroded. The percentage of the occurrence stress corrosion
cracking and microbial corrosion are 12% and 25%, respectively. Then
followed by, 6% localized corrosion, 13% pitting, and 6% crevice corrosion. In
conclusion, it can be seen in figure 3.3 that usual type of corrosion in oil and gas
are acidic corrosion, general corrosion and microbial corrosion.
31
3.1.2.3. Pipe Corrosion Sites
Internal flowline
41% 41%
Pipe Support
external flowline
18%
Figure 3. 4. Respondents’ Corrosion Site in Pipes

Based in figure 3.4, Most, pipe section that more often gets treatment are
outer flowline and inner flow. They both get the same percentage,41%. Then
followed by pipe support, which is 18%. This indicates the leakage that occurs in
the pipe often in the flowline so it becomes priority in preventing corrosion. Leaks
cause a very detrimental effect, namely loss of product, increase in costs, and can
endanger the environment
3.1.2.4. Corrosion Protection Methods
Brushing
27%
40% Sprinkle
Painting
Spraying
13%
injection
13% 7%
Figure 3. 5. Respondents’ Corrosion Protection Methods

32
As seen above, about 40% of respondents apply anti corrosion treatment

by brushing. Then followed with injection whose percentage is 27%. Injection is
method for applying corrosion inhibitor. Brushing is the easiest for applying
coating for metal protection. This is done by the manufacturer of the pipes. Then
to maximize the protection, adding corrosion inhibitor is done by oil and gas
company.
3.1.2.5. Corrosion Protection Product’s Notable Aspects
Fast-Acting
21% Durable
28%
3% Heat Resistant
7% Non-Volatile
No Smell
17% 24%
Economic
Figure 3. 6. Respondents’ Choice of Corrosion Protection Product’s Notable Aspects

Based on Figure 3.6, it can be seen, there are 3 top priority considerations
for purchasing product. The priority consideration mostly chosen by 28% of
respondents is fast acting. Fast acting means must take a short period of time to
start acting. In other word, the product is instantly active. Then followed by
economic which means the product the price is affordable. Nowadays, the cost
range for oil and company paid to anti corrosion product is usually 5% from total
cost for pipe installation. So, cost less than 5% from total cost is preferable. The
third priority consideration mostly chosen by of 20% respondents, which means
this product should have long lifetime.
3.1.2.6. Corrosion Countermeasure on Piping and/or Pipeline
33
Cutting off part of the

6% 6%
pipe
Blasting
22% 44%
Coating
rust converter
22%
rust remover
Figure 3. 7. Respondents’ Corrosion Countermeasure

Based on the data obtained, it can be seen, there are 3 steps preferred by
oil and gas companies. The first is cutting of part of the pipe. the percentage of
this answer is 44%. This is done to reduce the cost of repairs. If the inner pipe is
corroded, it will be difficult to apply coating unless the size of the pipe diameter
is large. Then, the second preferred step is blasting with coating. The percentage
of both of them is 22%. From the results of this survey, it can be concluded that
oil and gas companies are looking for the easiest and lowest cost ways to be able
to cope with existing corrosion
3.1.2.7. Corrosion Restoration Method
17%
brushing
spraying
25% 58%
roll on
Figure 3. 8. Respondents’ Corrosion Restoration Method

34
As expected, it is shown in figure 3.10, Most of respondents apply

coating by brushing and the percentage is 58%. This type of method is used for
bigger pipe. Meanwhile, spraying is done to coat smaller metal and the percentage
is 25%. It can be concluded that protection for bigger pipe is preferred.
3.1.2.8.Corrosion Restoration Product’s Notable Aspects
9%
Fast-acting
18%
46% Durable
Odorless
Non-volatile
27%
Figure 3. 9. Respondents’ Choice of Corrosion Restoration Product’s Notable Aspects

Based on Figure 3.9, it can be seen, there are 2 top priority considerations
for purchasing product. The first priority consideration mostly chosen by 46% of
respondents is fast acting. Fast acting means must take a short period of time to
start acting. For now, the time usage of product to start working is less than 1
hour. In order to get the fast-acting property, the time usage must be not more than
1 hour. Then followed by durability which means the product has long lifetime.
3.1.3 Customer Needs Interpretation
After doing interviews and spreading the questionnaires, the next step is
interpretation of customers’ needs. The result of interviews and questionnaires
obtained is then converted into a list of customers’ needs which is used as a
standard of design concept our product.
35
Table 3.1. Customer Needs Interpretation

No. Questions Answers Needs
How often Continues (remote)
corrosion- monitoring
control Once in a month
Anti-Corrosion Treatment that
1 maintenance is Twice in a month
can be used continuously
done on piping
or pipeline Once in 3 months
inspection?
Stress Corrosion
Cracking Anti-Corrosion Treatment
Localized Corrosion Compound that can prevent
Crevice Corrosion general types of corrosion
Pitting
Which kind of
𝐻2 𝑆 Corrosion Anti-Corrosion Treatment that
corrosion usually
2 can protect metals from
occurs on piping
𝐶𝑂2 Corrosion corrosion in an acidic
or pipeline?
environment
can protect metals from
Microbial Corrosion
corrosion in a microbial
environment
Based on your Internal Flowline
observations, Pipe Support
which part of Anti-Corrosion Treatment that
3 pipe usually can be applied on any part of
undergoes anti- External Flowline the pipeline and/or piping
corrosion
treatment?
For years, anti-
corrosion
treatment
contains Some Anti-corrosion is
4 hazardous not safe to be disposed
is biodegradable
substances. to the environment
What is your
opinion about
this fact?
36
Table 3.1. Customer Needs Interpretation (Continued.)

How do you Brushing
apply your Sprinkle
choice of Painting
corrosion Anti-Corrosion Treatment that
5
prevention is easy to be applied
compound on Spraying
piping or
pipeline?
Fast-Acting takes a short period of time to
start acting
Durable
is durable
What Anti-Corrosion Treatment that
characteristics Compatible with the
is compatible with the fluids
in corrosion fluids carried by the
carried by the pipeline and/or
6 prevention pipeline and/or piping
piping
compound are
you looking Anti-Corrosion Treatment that
Heat Resistant
for? resists heat
Non-Volatile
does not easily vaporize
Anti-Corrosion Treatment
Economic Compound that has a
relatively affordable price
How much is 20-30% from total cost
the budget of pipe installation
usually 10-20% from total cost
provided to Anti-Corrosion Treatment
of pipe installation
7 purchase your Compound that has a
choice of relatively affordable price
corrosion <5 % from total cost of
treatment pipe installation
method? (range)
How long will it more than 1 hour
take for your
choice of Anti-Corrosion Treatment that
8 corrosion takes a short period of time to
Instantly active
prevention start acting
compound to
start working
Table 3.1. Customer Needs Interpretation (Continued.)
As Cutting off part of the
countermeasure(s) pipe
of corrosion on Blasting
pipe, which
that uses mechanical handling
9 method(s) listed
as post corrosion
below are usually
Coating countermeasure
used?
how do you apply Brushing

your choice of Spraying
metal restoration
10 Compound that is easy to be
compound on
Roll on applied
piping or
pipeline?
Fast-acting that takes a short period of
what
time to start acting
characteristics in
Anti-Corrosion restoration
11 metal restoration Durable
that is durable
compound are
Anti-Corrosion restoration
you looking for?
Non-volatile Compound that does not
easily vaporize
How long will it
take for your
choice of metal
12 Less than 1 hour that takes a short period of
restoration
compound to start
working?
Do you have any
suggestions Anti-Corrosion Restoration
Make the compound
13 regarding metal Compound that can withstand
last longer in storage
restoration that long duration of time
we can develop?
38
3.1.4 List of Needs
Table 3.2. List of Customer Needs

No Needs
1 Anti-Corrosion Treatment that can be used continuously
Anti-Corrosion Treatment that can protect metals from general types of
2
corrosion
Anti-Corrosion Treatment that can protect metals from corrosion in an
3
acidic environment
Anti-Corrosion Treatment that can protect metals from corrosion in a
4
microbial environment
Anti-Corrosion Treatment that can be applied on any part of the pipeline
5
and/or piping
6 Anti-Corrosion Treatment that is biodegradable
7 Anti-Corrosion Treatment that is simple to be applied
8 Anti-Corrosion Treatment that takes a short period of time to start acting
9 Anti-Corrosion Treatment that is durable
Anti-Corrosion Protection Compound that is compatible with the fluids
10
carried by the pipeline and/or piping
11 Anti-Corrosion Treatment that resists heat
12 Anti-Corrosion Treatment that has a relatively affordable price
Anti-Corrosion Treatment that uses mechanical handling as post-corrosion
13
countermeasure
3.1.5 Category of Customer Needs and Needs Rank

Table 3.3. Category of Customer Needs and Needs Rank
No Needs Needs Rank
Product Performance
1 Anti-Corrosion Treatment that can be used continuously 5
Anti-Corrosion Treatment that can protect metals from 5
2
common types of corrosion
3
corrosion in acidic environment
4
corrosion in microbial environment
Anti-Corrosion Treatment that can be applied on any 5
5
part of the pipeline and/or piping
9 Anti-Corrosion Treatment that is durable 4
Anti-Corrosion Protection Compound that is compatible 5
10
with the fluids carried by the pipeline and/or piping
11 Anti-Corrosion Treatment that resists heat 4
39
Table 3.3. Category of Customer Needs and Needs Rank (Continued.)

No. Needs Rank
Anti-Corrosion Treatment that takes a short period of
8 4
Retailing
Anti-Corrosion Treatment that has a relatively
12 5
affordable price
Added Value
6 Anti-Corrosion Treatment that is biodegradable 2
Handling
7 Anti-Corrosion Treatment that is simple to be applied 5
Anti-Corrosion Treatment that uses mechanical
13 2
handling as post-corrosion countermeasure
40
CHAPTER 4
PRODUCT SPECIFICATIONS
4.1 List of Metrics

Needs grouping has been done based on the literature and the next step of
product design is making the specs of our desired product. All the qualitative
needs demanded by consumer will be converted into numerical and measurable
metric unit which makes comparison with existing products can be defined easier,
as well as providing more technical directions.
Table 4.1. List of Specification Metrics
No Needs Specification Metric Unit Rank
Product Performance / Functionality
Anti-Corrosion Treatment Retention time of
minutes
Compound that can be corrosion inhibitor
1 used continuously curing time of coating minutes 5
Film persistency of
corrosion treatment N/m2s
compound
Compound that can protect
metals from various types
Corrodent diffusivity
of corrosion that generally
2 caused by the difference of from the fluid to the 5
m2/s
metal (on the protection
electrode potential
film)
between two metals and
operating condition of
working fluid
pH level of the anti-
3 Compound that can protect corrosion treatment [H+] (mol/L) 5
metals from corrosion in
compound
acidic environment
Anti-Corrosion Treatment Local oxygen
4 Compound that can protect concentration on the 5
mol/L
metals from corrosion in protection film of anti-
microbial environment corrosion compound
41
Table 4.1. List of Specification Metrics (Continued.)

Compound that can be Wettability of corrosion
5 N/m 5
applied on any part of the prevention compound
pipeline and/or piping
Toughness of anti-
J/m3
corrosion agent
Vapor pressure of anti-
corrosion protection Pa
Anti-Corrosion Treatment compound
6 5
that is durable Life time of anti-
years
corrosion coating-type
Life time of anti-
corrosion corrosion days
inhibitor
Anti-Corrosion Protection
Compound that is
7 compatible with the fluids Reactivity with fluids keff 5
carried by the pipeline
and/or piping
Heat resistance of anti-
Anti-Corrosion Protection o
8 corrosion protective C/Watt 4
Compound that resists heat
compound
Compound that takes a Anti-corrosion compound
9 Minutes 5
short period of time to start respond time to corrodent
acting
42
Table 4.1. List of Specification Metrics (Continued.)

Retailing
10 Compound that has a Price USD 5
relatively affordable price
Added Value
Anti-Corrosion Treatment Charge
Hydrolytic activity
11 Compound that is (electron) 2
biodegradable Degradation rate %
Handling
Anti-Corrosion Protection
12 Method that is simple to Application duration Minutes 5
do
that uses mechanical Pressure exerted to pipe
13 Pa 2
handling as post-corrosion by mechanical treatment
countermeasure
4.2 Metric Needs

Needs with similar metric units will be grouped to display the correlation
between market needs and specifications. Table 4.2 showing relations for the
needs and following metric units will be shown in the next page.
42
Univers
itas Indonesia
Table 4. 2 List of Metrics
Metrics
Com-
Film Diffu Con- pound Wet-
Tough- Pre- Reacti- Heat Hydrolytic Degradation
No List of Needs Time Persis- sivi- centra- res- tabi- Price
ness ssure vity Resistance activity rate
tency ty tion pond lity
time
mi Charge
days years N/m2.s m2/s mol/L [M]/s N/m J/m3 Pa keff o
C/Watt USD %
n (electron)
Anti-Corrosion
Treatment
1 • •
Compound that can
be used continuously
Anti-Corrosion
Treatment
Compound that can
2 •
protect metals from
various types of
corrosion
Anti-Corrosion
Treatment
Compound that can
3 •
protect metals from
corrosion in acidic
environment
Table 4.2. List of Metrics (Continued.)
Metrics
Com-
Con-
Film pound Wet-
Diffus cen- Tough- Pre- Reacti- Heat Hydrolytic Degradation
No List of Needs Time Persis- res- tabi- Price
-sivity tra- ness ssure vity Resistance activity rate
tency pond lity
tion
time
mol/ Charge
min days years N/m2.s m2/s [M]/s N/m J/m3 Pa keff o
C/Watt USD %
L (electron)
Anti-Corrosion
Treatment
Compound that
4 can protect metals •
from corrosion in
microbial
environment
Anti-Corrosion
Treatment
Compound that
5 can be applied on •
any part of the
pipeline and/or
piping
Anti-Corrosion
6 Treatment that is • • • •
durable
Metrics
Com-
Con-
Film pound Wet-
ivi-ty tra- ness ssure vity Resistance activity rate
tency pond lity
tion
time
mol/ Charge
C/Watt USD %
L (electron)
Anti-Corrosion
Protection
Compound that is
7 compatible with •
the fluids carried
by the pipeline
and/or piping
Anti-Corrosion
Protection
8 •
Compound that
resists heat
Anti-Corrosion
Treatment
Compound that
9 •
takes a short
period of time to
start acting
Metrics
Com-
Con-
Film pound Wet-
tency pond lity
tion
time
mol/ Charge
C/Watt USD %
L (electron)
Retailing
Anti-Corrosion
Treatment
10 Compound that •
has a relatively
affordable price
Added Value
Anti-Corrosion
Treatment
11 • •
Compound that is
biodegradable
Handling
Anti-Corrosion
12 Protection Method •
that is simple to do
Metrics
Com-
Con-
Film pound Wet-
tency pond lity
tion
time
mol/ Charge
C/Watt USD mol/g.day
L (electron)
Anti-Corrosion
Treatment that
uses mechanical
13 •
handling as post-
corrosion
countermeasure
(Source: Private Data, 2019)
48
4.3 Benchmarking of Similar or Existing Products

After defining and quantifying the specifications of the product, then
benchmarking of the similar product (Anti Corrosion Treatment Compound) in
the market is done. Benchmarking is a way of evaluation of the existing product
by analyzing its specification in measurable aspects, and in the same time,
comparing these with our own product in order to get spot of opportunities. This
can be an indicator that shows the position of own product compared to the other
competitors in the similar segments. It can be better, similar, or even worse. By
doing this, product owner can finally find what is called as ‘unique selling point’
or the excitement of the product. That is why, benchmarking product is necessary
to done. For the purpose of benchmarking, there are some existing products in the
market that have been evaluated in some aspects. Those products are NALCO-
2833, CORGARD 566, Z50- Fluid, and Hempacore. For more, it can be seen in
Table 4.3.
4.4 List of Specifications

By going through a benchmarking process, own product will surely get a
comparison data among any existing products in quantitative manner. By sorting
it out, there will be the best value in each specifications. This actually is called as
ideal value. Reaching all of ideal values in own product will undoubtedly satisfy
the customer’s desires. However, to make it happened, it’s important to consider
many aspects, like technical, economical, safety, et cetera. Because of that, it does
not really that matter if all of the ideal values of own product can not be fulfilling
those requirements. The most important thing is that all of the basic needs can be
implemented and all of the spesifications are in tolerable value by consumers.
This accepted range can be defined as marginal value. Marginal value derived
from the specification of an existing products circulating in the market. Marginal
value is expected to get as close as it can to the ideal value, as it is needed for
making a product with maximum performance and specification. Regarding to
own product about anti corrosion treatment compound, the list of ideal value and
marginal value of each needs specification is shown in Table 4.4.
49
Table 4.3. Benchmarking table
Scores
Needs Metric Needs Competitor
No. Needs Description Specification Own
Group Unit Rank NALCO CORGARD Z50- Hempacor
Product
2833 566 Fluid e
Anti-Corrosion
Performa
Product
Retention time
Treatment Compound
nce
1 of corrosion minutes 5 240 180 210-220 130 -

that can be used
inhibitor
continuously
Curing time of minutes 120 - - - 120
coating
Film
persistency of
corrosion N/m2.s 30 - - - 26,4
treatment
compound
Anti-Corrosion
Treatment Compound
Corrodent
that can protect metals
diffusivity
from various types of
from the fluid
corrosion generally m2/s
2 to the metal 5 2.10-10 2.10-9 N/a 1,6.10-9 4,8.10-10
caused by the
(on the
difference of electrode
protection
potential between two
film)
metals and operating
condition of working
50
fluid
Table 4.3. Benchmarking table (continued)
Scores
Needs Metric Needs Competitor
No. Needs Description Specification Own
Group Unit Rank NALCO CORGARD Z50- Hempacor
Product
2833 566 Fluid e
pH level of the
Product Performance
anti-corrosion
Anti-Corrosion treatment
[H+]
(continued)
Treatment compound
Compound that can Local oxygen (mol/L) 10-14-10- 10-10-
3 5 10-7 12,5 10-8-10-6 10-9-10-6
protect metals from concentration on 10-9
corrosion in acidic the protection mol/L
environment film of anti-
corrosion
compound
Anti-Corrosion
Treatment Corrodent
Compound that can diffusivity from
4 protect metals from the fluid to the m2/s 5 2.10-10 N/a N/a N/a N/a
corrosion in metal (on the
microbial protection film)
environment
51
Scores
Needs Needs Metric Needs Competitors
No. Specification Own
Group Description Unit Rank NALCO CORGARD Z50-
Product Hempacore
2833 566 Fluid
Anti-Corrosion
Performance
Treatment
(continued)
Wettability
Product
Compound that
of corrosion 5
5 can be applied N/m ••• •• • ••• ••
prevention
on any part of
compound
the pipeline
and/or piping
52
Scores
Needs Needs Metric Needs Competitors
product Hempacore
2833 566 Fluid
Product
Anti- Toughness of
Performan
Corrosion anti-
ce 6 J/m3 5 ••• ••• •• •• ••
Treatment that corrosion
(continued
is durable agent
)
Vapor
pressure of
anti- 3.10-4 at 1,3.10-4 4,84.10-3 at
MmHg N/a N/a
corrosion 27oC at 21oC 25,3oC
protection
compound
Life time of
anti-
years 3 - - - 3
corrosion
coating-type
Life time of
anti- minutes 240 180 210-220 130 -
corrosion
53
(corrosion
inhibitor)
Scores
Needs
Needs Needs Metric Competitor
Product Hempacore
2833 566 Fluid
Anti-Corrosion
Protection
Performance
(continued)
Compound that
Product
is compatible Reactivity 5
7 keff <1 N/a N/a 0,8 -
with the fluids with fluids
carried by the
pipeline and/or
piping
Thermal
Anti-Corrosion resistance of
Protection anti- o 4 0,085-
8 C/Watt 0,09 0,042 0,067 N/a
Compound that corrosion 0,091
resists heat protective
compound
Anti-Corrosion Anti- 5 2 for CI
9 minutes 5-6 2 3-5 180
Treatment corrosion 60 for
54
Compound that compound CT

takes a short respond time
period of time to to corrodent
start acting
Need Scores
Needs Specificat Metric Competitors
No. Needs Description s Own
Group ion Unit NALCO CORGA
Rank Product Z50- Fluid Hempacore
2833 RD 566
Anti-Corrosion
Retailin
Treatment Compound USD/

10 Price 5 750 1167 900 1099 980
g
that has a relatively 200 L

affordable price
Anti-Corrosion
Adde
value
Hydrolytic Charge
11 Treatment Compound 2 • - - N/a -
d
activity (electron)
that is biodegradable
Degradati
on rate in
% • - - • •
microbial
digestion
3-8 for CI Continuous
Handlin
Anti-Corrosion
Applicatio 120 (per when
12 Protection Method Minutes 5 3-12 8-15 120 (per km)
g
n duration km) for operation is

that is simple to do
CT on
55
Anti-Corrosion Pressure 2,0.107 for

Treatment that uses exerted to CI, or
13 mechanical handling pipe by Pa 2 Ambient 1,6.107 2,5.107 2,8.107 ~2.106
as post-corrosion mechanica pressure
countermeasure l treatment for CT
Table 4. 4 Specifications list table
Needs Own Marginal

No. Needs Description Specification` Metric Unit Needs Rank Ideal Value
Group Product Value
Anti-Corrosion Retention
Performa
Product
Treatment Compound time of

nce
1 Minutes 5 240 30-120 120-240

that can be used corrosion
continuously inhibitor
Curing time
Minutes 120 240-300 120
of coating
Film
persistency of
corrosion N/m2.s 30 20-24,6 28-32
treatment
compound
Anti-Corrosion Corrodent
Treatment Compound diffusivity
that can protect metals from the fluid m2/s 4,8.10-10-
2 5 2.10-10 4,8.10-10
from various types of to the metal 2.10-9
corrosion generally (on the
caused by the difference protection
56
of electrode potential film)

between two metals and
operating condition of
working fluid
Table 4.4. Specifications list table (continued)
Needs Metric Own Marginal

No. Needs Description Specification` Needs Rank Ideal Value
Group Unit Product Value
pH level of the
Product Performance
anti-corrosion
treatment
Anti-Corrosion [H+]
(continued)
compound
Treatment Compound
Local oxygen (mol/L)
3 that can protect metals 5 10-7 10-14-10-12,5 10-7
concentration on
from corrosion in acidic mol/L
the protection
environment
film of anti-
corrosion
compound
Anti-Corrosion Corrodent
Treatment Compound diffusivity from
m2/s 1.10-10-5.10-
4 that can protect metals the fluid to the 5 2.10-10 N/a 10
from corrosion in metal (on the
microbial environment protection film)
57
Anti-Corrosion
Wettability of
Treatment Compound
corrosion 5
5 that can be applied on N/m ••• •-••• •••
prevention
any part of the pipeline
compound
and/or piping
Needs Metric Needs Own Marginal

No. Needs Description Specification` Ideal Value
Group Unit Rank Product Value
Anti-Corrosion
nued)
(conti
rman
Perfo
Prod
Toughness of anti-
uct
J/m3 ••• ••-••• •••

ce
6 Treatment that is 5
corrosion agent
durable
Vapor pressure of anti- >10-3 at >10-4 at
3.10-4 at
corrosion protection MmHg room room
27oC
compound temperature temperature
Life time of anti-
years 3 1-2 3-5
corrosion coating-type
Life time of anti-
corrosion (corrosion minutes 240 30-120 120-240
inhibitor)
Anti-Corrosion
Protection Compound 5
7 Reactivity with fluids keff <1 0,7-0,8 0,8<x<1
that is compatible with
the fluids carried by the
58
pipeline and/or piping

Anti-Corrosion Thermal resistance of
8 Protection Compound anti-corrosion o
C/Watt 4 0,09 0,042-0,05 0,091
that resists heat protective compound
Needs Needs Own Marginal

No. Needs Description Specification` Metric Unit Ideal Value
Group Rank Product Value
Anti-
Anti-Corrosion
Performance
corrosion 5-6 for CI

(continued)
Treatment Compound 5 2 for CI 2 for CI

9 compound minutes 120-150 for
Product
that takes a short period 60 for CT 60 for CT

respond time CT
of time to start acting
to corrodent
Anti-Corrosion
Retailing
Treatment Compound USD/

10 Price 5 750 1000-1200 700-800
that has a relatively 200 L
affordable price
Anti-Corrosion Hydrolytic Charge
val
Ad
•• •
de
ue
11 2 0-••
d
Treatment Compound activity (electron)

59
that is biodegradable Degradation

rate in
% • 0 0-•
microbial
digestion
Needs Needs Own Marginal

No. Needs Description Specification` Metric Unit Ideal Value
Group Rank Product Value
Anti-Corrosion 10-12 for CI
Hand
Application 3-8 for CI 2 for CI

ling
12 Protection Method that Minutes 5 180-300 for

duration 120 for CT 120 for CT
is simple to do CT
Anti-Corrosion Pressure 2,0.107 for
107 for CI, or
Treatment that uses exerted to CI, or 2-3.107 for
Ambient
13 mechanical handling as pipe by Pa 2 Ambient CI, or
pressure for
post-corrosion mechanical pressure for 2.106 for CT
CT
countermeasure treatment CT
CHAPTER 5
CONCLUSION
a. Customer needs can be classified into three main categories; product

performance / functionality, retailing, added value, and handling
b. Customer needs can be classified into three main categories; retailing,
product perception, and product performances.
c. Costumer needs are derived into 10 needs, which are frequency, protect
metals (in acidic and microbial environment), high durability, compatible
with the fluids carried, resists heat, that takes a short period of time to start
acting, relatively affordable price, biodegradable, simple to do, and uses
mechanical handling as post-corrosion countermeasure.
d. Based from the market needs, anti-corrosion treatment that is affordable,
compatible with substances that promotes corrosion, and can be used
continuously has a large demand on industries.
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66
APPENDICES
APPENDIX A.
SURVEY QUESTIONNAIRE
1. Informasi Responden
a. Nama Lengkap :
________________________________________
b. Pekerjaan :
________________________________________
c. Region Operasional Perusahaan : Onshore / Offshore
d. Apakah pekerjaan anda berhubungan dengan piping di
industri atau transportasi pipeline?
a) Berhubungan langsung.
b) Tidak berhubungan.
c) Tidak berhubungan langsung, namun memiliki
pengetahuan tentang proteksi dan restorasi bahan
logam.
2. Current Problems
a. Berdasarkan pengalaman anda, seberapa sering upaya

corrosion-monitoring dilakukan pada piping maupun
pipeline?
b. Berdasarkan pengalaman anda, jenis korosi apa yang paling

sering terjadi pada pipeline?
c. Berdasarkan pengamatan anda, dimana saja bagian piping

atau pipeline yang sering mengalami korosi?
d. Selama ini, treatment anti-korosi yang ada biasanya

mengandung logam berat, volatile organic compounds, atau
bahan berbahaya lainnya. Bagaimana tanggapan Anda
mengenai hal ini?
3. Pencegahan Korosi
67
a. Untuk mencegah terjadinya korosi, metode pencegahan apa

yang biasa anda lakukan?
b. Bagaimana metode pengaplikasian dari jenis pencegahan

tersebut pada piping maupun pipeline?
c. Aspek apa saja yang Anda perhatikan dalam pemilihan

pencegahan korosi?
d. Berdasarkan pengalaman anda, berapa harga yang biasanya

dianggarkan untuk jenis proteksi tersebut?
e. Berapa lama waktu yang dibutuhkan sampai produk proteksi

metal yang anda gunakan dapat bekerja?
f. Apakah anda memiliki saran untuk produk pencegahan

korosi yang akan kami kembangkan?
4. Penanggulangan Korosi
Penanggulangan korosi di sini dimaksudkan sebagai upaya restorari
dari logam pada piping maupun pipeline yang sudah berkarat.
a. Untuk menyikapi terjadinya korosi, metode pencegahan apa

yang biasa anda lakukan?
b. Abaikan pertanyaan ini jika restorasi logam tidak dilakukan,

bagaimana metode pengaplikasian dari jenis
penanggulangan tersebut pada piping maupun pipeline?
c. Abaikan pertanyaan ini jika restorasi logam tidak dilakukan,

aspek apa saja yang Anda perhatikan dalam pemilihan
produk restorasi logam?
d. Abaikan pertanyaan ini jika restorasi logam tidak dilakukan,

berdasarkan pengamatan anda, berapa harga yang biasanya
dianggarkan untuk produk restorasi metal tersebut?
68
e. Abaikan pertanyaan ini jika restorasi logam tidak dilakukan,

berapa lama waktu yang dibutuhkan sampai produk restorasi
metal yang anda gunakan dapat bekerja?
f. Apakah anda memiliki saran untuk produk pencegahan

korosi yang akan kami kembangkan?

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UNIVERSITAS INDONESIA

FAST-ACTING BIODEGRADABLE COMPOUND FOR

CHEMICAL ENGINEERING DEPARTMENT

iii Universitas Indonesia

EXECUTIVE SUMMARY ................................................................................... ii

vii Universitas Indonesia

APPENDIX A. SURVEY QUESTIONNAIRE .................................................... 75

viii Universitas Indonesia

1.1 Background Idea

Metal losses that occur due to corrosion in manufacturing facilities are

The panel estimates that 15% of previously unavoidable corrosion costs

Table 1.1. Diagram of Metallic Corrosion Cost in the United States

1.1.2 Waste of Natural Resources

1.3 Identification of Problem

2.1 Corrosion in Oil and Gas Piping and Pipeline

complex community interactions, and an extracellular matrix of polymeric

According to Araujo (2013), there are two methods of applying cathodic

Another method of creating a protective layer is passivation, which is

2.4.2.1 Metallic Coatings

2.4.2.3 Organic Coatings

Figure 2.3. Impressed Current Cathodic Protection System

Third, Aqueous rust removal is aqueous based with a completely neutral

Figure 2.5. Molecular Structure of Tannic Acid

Figure 2. 6. Schematic of Action of Oil Field Corrosion Inhibitor

Water-soluble inhibitors used in continuous injection of water containing

Table 2.1. Organic Coating (Continued)

FBE 3-LPE Other

Figure 2. 7. Coating Global Market Trend in 2016

when the current requirement is high, and an external DC source is required

acid, and water. Phosphoric acid-based is essentially H3PO4 in sufficient amount,

Figure 2.8. Synthesis Procedure of Rust Converter

2.6.2 Corrosion Inhibitor

dilute phosphoric acid solution using phosphating bath or spraying techniques

(Source: Reproduced from Weng et al, 1998)

The ozone layer forms a gaseous shield, between 10 and 50 km altitude,

be considered. Those are weathering and loss of adhesion. In weathering, the

3.1 Methods of Needs Identification

Figure 3. 1. Respondents’ Frequency

13% 13% Pitting

25% H2S Corrosion

Figure 3. 2. Respondents’ Common Types of Corrosion

Figure 3. 3. Grouping Types of Corrosion

3.1.2.3. Pipe Corrosion Sites

Figure 3. 4. Respondents’ Corrosion Site in Pipes

Figure 3. 5. Respondents’ Corrosion Protection Methods

As seen above, about 40% of respondents apply anti corrosion treatment

Figure 3. 6. Respondents’ Choice of Corrosion Protection Product’s Notable Aspects

Cutting off part of the

Figure 3. 7. Respondents’ Corrosion Countermeasure

Figure 3. 8. Respondents’ Corrosion Restoration Method

As expected, it is shown in figure 3.10, Most of respondents apply

Figure 3. 9. Respondents’ Choice of Corrosion Restoration Product’s Notable Aspects

Table 3.1. Customer Needs Interpretation

Table 3.1. Customer Needs Interpretation (Continued.)

how do you apply Brushing

3.1.4 List of Needs

Table 3.2. List of Customer Needs

3.1.5 Category of Customer Needs and Needs Rank

Table 3.3. Category of Customer Needs and Needs Rank (Continued.)

4.1 List of Metrics

Table 4.1. List of Specification Metrics (Continued.)

Table 4.1. List of Specification Metrics (Continued.)

4.2 Metric Needs