Environmentally Friendly Anticorrosive Polymeric Coatings
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applied sciences Review Environmentally Friendly Anticorrosive Polymeric Coatings Mirko Faccini 1,* , Lorenzo Bautista 2, Laura Soldi 2, Ana M. Escobar 2 , Manuela Altavilla 1, Martí Calvet 2 , Anna Domènech 2 and Eva Domínguez 2 1 Centro de Excelencia en Nanotecnología (CEN), Leitat Chile, Calle Román Díaz 532, Providencia, Santiago 7500724, Chile; [email protected] 2 Leitat Technological Center, Surface Chemistry Area, Applied Chemistry & Materials Department, Terrassa 08225, Barcelona, Spain; [email protected] (L.B.); [email protected] (L.S.); [email protected] (A.M.E.); [email protected] (M.C.); [email protected] (A.D.); [email protected] (E.D.) * Correspondence: [email protected] Abstract: This paper provides a synthetic and comprehensive overview on environmentally friendly anticorrosive polymeric coatings. Firstly, the economic and environmental impact of corrosion is presented to highlight the need of anticorrosive polymeric coatings as a flexible and effective solution to protect a metal. Secondly, the implementation of regulations together with the consumer awareness for environmental considerations and protection of health are the driving force for a progressive but significant change in the sector. Therefore, within the protective organic coatings market, this article provides a review of the most recent developments in environmentally friendly solutions, including bio-based and water-borne epoxy, hyperbranched polyester for low- volatile organic compounds (VOC) coatings, waterborne polyurethane and non-isocyanate polyurethanes (NIPUs), and graphene or bio-based fillers for acrylics. Moreover, this paper outlines new trends such as smart additives, bio- based corrosion inhibitors, and functional antibiocorrosive coatings as superhydrophobics. Finally, Citation: Faccini, M.; Bautista, L.; industrially relevant applications of environmentally friendly anticorrosive polymeric coatings Soldi, L.; Escobar, A.M.; Altavilla, M.; including solutions for marine and off-shore industries are summarized. Calvet, M.; Domènech, A.; Domínguez, E. Environmentally Keywords: polymeric coatings; anticorrosive; environmentally friendly; protective coating; bio- Friendly Anticorrosive Polymeric based; waterborne; low VOC Coatings. Appl. Sci. 2021, 11, 3446. https://doi.org/10.3390/app11083446 Academic Editor: Mirko Magni 1. Introduction Corrosion Cost and Environmental Impact Received: 28 February 2021 Corrosion is a universal topic, for many accepted as an inevitable process. The Accepted: 5 April 2021 Published: 12 April 2021 penalties of failures from corrosion are highly impactful from a human safety perspective and an economic point of view, including safety hazards or plant interruptions. Publisher’s Note: MDPI stays neutral The conclusion of significant studies undertaken by several countries was that corro- with regard to jurisdictional claims in sion represents a constant charge to the nation’s gross national product (GDP). The National published maps and institutional affil- Association of Corrosion Engineers (NACE International) studied the role of corrosion iations. management in industry and government impact in the US and estimated a global cost of corrosion of US $2.5 trillion, equivalent to 3.4% of US GDP, and from approximately 1 to 5 percent of GDP of each nation. These numbers are considered to be conservative since only well-documented costs can be used for study: corrosion control management as well as maintenance costs, monitoring, inspection and fewer failures are difficult to Copyright: © 2021 by the authors. Licensee MDPI, Basel, Switzerland. measure. Nevertheless, it was observed that indirect costs due to corrosion damage are This article is an open access article often significantly greater than direct costs. Hence, the total cost which should include distributed under the terms and direct plus indirect cost could double the corrosion cost up to six percent of US GDP [1,2]. conditions of the Creative Commons Health hazards and environmental impact of corroded materials, which could be Attribution (CC BY) license (https:// considered as indirect costs, have been widely studied. Especially, the runoff of multiple creativecommons.org/licenses/by/ metal ions (iron, zinc, lead, manganese) causing the contamination of the surrounding 4.0/). environment and drinking water systems were reported [3–7]. Moreover, the iron rust Appl. Sci. 2021, 11, 3446. https://doi.org/10.3390/app11083446 https://www.mdpi.com/journal/applsci Appl. Sci. 2021, 11, x FOR PEER REVIEW 2 of 19 metal ions (iron, zinc, lead, manganese) causing the contamination of the surrounding Appl. Sci. 2021, 11, 3446 2 of 18 environment and drinking water systems were reported [3–7]. Moreover, the iron rust influence on the growth rate of Legionella bacteria [8], chemical emissions from cathodic protection of offshore wind farms (OWF) [9], or the environmental impact of rust removal techniquesinfluence onare the other growth examples rate of of Legionella environmental bacteria concerns [8], chemical [10]. emissions from cathodic protectionAnticorrosive of offshore polymeric wind farms coatings (OWF) have [9 ],gained or the high environmental potential and impact flexibility of rust removalagainst metaltechniques protection are other compared examples to non-polymeric of environmental ones, concerns as they [ 10can]. be designed and formu- lated toAnticorrosive achieve more polymeric than one coatingsprotective have mechanism. gained high This potential review is and focused flexibility on anticor- against rosivemetal polymeric protection coatings, compared paying to non-polymeric special attention ones, ason theyenvironmentally can be designed friendly and formulated solutions ableto achieve to achieve more a proper than one balance protective between mechanism. cost, technical This reviewperformance, is focused and onenvironmental anticorrosive issues.polymeric coatings, paying special attention on environmentally friendly solutions able to achieveTherefore, a proper the balance need to between overcome cost, the technical economic performance, damages generated and environmental by corrosion issues. phe- nomenaTherefore, has been the faced need through to overcome the developm the economicent of damages several generatedcoating technologies. by corrosion This phe- reviewnomena is focused has been on faced anticorrosive through thepolymeric development coatings of as several a flexible coating and technologies.effective solution This againstreview corrosion is focused by on means anticorrosive of different polymeric and simultaneous coatings as amechanisms flexible and of effective corrosion solution inhi- bition.against A corrosioncomprehensive by means vision of of different the topic and is provided, simultaneous together mechanisms with a state of corrosion of the art inhi-for eco-friendlybition. A comprehensive polymeric coatings vision organized of the topic in four is provided, main categories, together according with a state to the of thepoly- art merfor resin eco-friendly type: epoxy, polymeric polyester, coatings polyurethane, organized and in four acrylic. main categories, according to the polymerAbove resin all, the type: present epoxy, work polyester, aims to polyurethane, give an overall and picture acrylic. on how the coating market is evolvingAbove asall, a response the present to the work public, aims government, to give an and overall consumers’ picture commitment on how the coatingto sus- tainability.market is evolvingSpecial attention as a response is paid to to the new public, trends government, in the anticorrosive and consumers’ coating commitmentfield, as the to sustainability. Special attention is paid to new trends in the anticorrosive coating scientific community is addressing the high demand for environmentally friendly coat- field, as the scientific community is addressing the high demand for environmentally ings with innovative solutions. Moreover, a selection of applications is made to highlight friendly coatings with innovative solutions. Moreover, a selection of applications is made the urgency of a proper balance between cost, technical performance, and environmental to highlight the urgency of a proper balance between cost, technical performance, and issues in the coating sector. environmental issues in the coating sector. 2.2. Anticorrosive Anticorrosive Coating Coating Market Market and and Its Its Challenges Challenges CorrosionCorrosion affects affects countless countless industries. industries. One One of ofthe the most most significant significant success success stories stories in corrosionin corrosion control control is the is thechange change in corrosion in corrosion management management strategy strategy and andapplication application of in- of novativeinnovative technology technology in the in the automotive automotive industry, industry, as ashighlighted highlighted by by NACE’s NACE’s report report [11]. [11]. BeforeBefore 1975, 1975, car car manufacturers manufacturers used minimal protectiveprotective solutionssolutions and and corrosion corrosion was was costing cost- ingthe the industry industry billions billions of US$ of US$ annually. annually. Since Since 1975, 1975, corrosion corrosion management management solutions solutions started startedto be implemented to be implemented by car manufacturers,by car manufacturer leadings, toleading an annual to an savings annual in savings 1999 compared in 1999 comparedto 1975 of to 9.6 1975 billion of 9.6 US$ billion or 52% US$ in or corrosion-related