Please wait a minute...
Journal of Chinese Society for Corrosion and protection  2025, Vol. 45 Issue (3): 643-652    DOI: 10.11902/1005.4537.2024.169
Current Issue | Archive | Adv Search |
Preparation and Anticorrosion Performance of a Coal-gangue Modified Epoxy Coating
CHEN Li1,2, FENG Jia3, MENG Fandi1(), WANG Fuhui1
1.Corrosion and Protection Center, Northeastern University, Shenyang 110819, China
2.High Performance Metal Materials and Protection Laboratory, Ningxia Institute of Science and Technology, Shizuishan 745260, China
3.China National Petroleum Corporation Changqing Oilfield Branch Ninth Oil Extraction Plant, Yinchuan 750000, China
Cite this article: 

CHEN Li, FENG Jia, MENG Fandi, WANG Fuhui. Preparation and Anticorrosion Performance of a Coal-gangue Modified Epoxy Coating. Journal of Chinese Society for Corrosion and protection, 2025, 45(3): 643-652.

Download:  HTML  PDF(11502KB) 
Export:  BibTeX | EndNote (RIS)      
Abstract  

Epoxy resin is a popular choice as the matrix of organic coatings in the metal protection sector. However, the single shielding effect of epoxy coatings is limited. One effective method to improve their protective properties is to add inorganic fillers to epoxy coatings. Coal gangue with a large number of micropores and a high specific surface area, is a rich source of alumina, silica, iron oxide, calcium oxide, magnesium oxide and other components. There are few relevant reports on the application of coal gangue in the field of anticorrosion at home and abroad. Therefore, expanding the application of coal gangue in the field of anticorrosion coating may be of significance in environmental benefits, technical application and innovation. Herein, the impact of coal gangue addition on the performance of epoxy coatings was studied with epoxy resin E44 as matrix and different proportions (1%, 5%, and 10% in mass fraction) of coal gangue as fillers to prepare coal gangue-modified epoxy resin coatings. These coatings were subsequently applied to silica gel plates and Q235 mild steel surfaces, yielding samples of free coating film and coated steel. The average coating thickness was approximately 150 μm. The morphology of coal gangue powders was revealed by means of JSM-7001F field emission scanning electron microscope as that the coal gangue presented multi lamellar structure with an average particle size of 3.18 ± 0.12 μm, which may be conductive to the improvement of the coating properties. Then, a series of tests were conducted to assess the performance of the coating, including a water absorption test, tensile test, adhesion test and electrochemical EIS test. The results showed that the addition of coal gangue to the epoxy resin in proper quantity can enhance the densification, strength, toughness, adhesion and anticorrosive properties of the coatings. However, the performance improvement showed non-linear dependence on the dosage of coal gangue; an excess addition of coal gangue can result in particle agglomeration, which may lead to an increase in defects, and reduction in the protective properties of the coating. For the coating with the addition of coal gangue 5%, the fracture strength reaches 35.30 MPa, the maximum strain reaches 6.13%, and the lower saturated water absorption rate of 2.24% can be obtained after immersing for 10 d. This is accompanied by a loss of adhesion of 58.65%, maintaining the maximum low-frequency impedance modulus value of 3.40 × 108 Ω·cm2 and the maximum coating resistance of 6.36 × 107 Ω·cm2. The multi lamellar structured coal gangue with large specific surface area and anisotropic multi-orientations of grains, which may be beneficial to the enhancement of the densification, further the mechanical properties, the adhesion, and the anticorrosive properties of the coating as well. The coal gangue serves as a filler, and its additive mass fraction of 5% represents the better performance of the coating. The utilization of gangue in anticorrosive coating represents a novel avenue for the effective deployment of coal gangue and the diversification of filler types in anticorrosive coating. The composition and distinctive microstructure of coal gangue permit the optimization of coating performance through the implementation of appropriate modifications.

Key words:  coal gangue      multilayer lamellar structure      shielding effect      anticorrosive property     
Received:  29 May 2024      32134.14.1005.4537.2024.169
ZTFLH:  TG174  
Fund: National Natural Science Foundation of China(52271052);Scientific Research Project of Ningxia Universities(NGY2022145);Natural Science Foundation of Ningxia(2023AAC03363)
Corresponding Authors:  MENG Fandi, E-mail: fandimeng@mail.neu.edu.cn

URL: 

https://www.jcscp.org/EN/10.11902/1005.4537.2024.169     OR     https://www.jcscp.org/EN/Y2025/V45/I3/643

SampleE44 / gGangue / gSolvent / gCuring agent / g
1%CE5.000.053.004.00
5%CE0.25
10%CE0.50
Table 1  Composition of paint samples
Fig.1  Infrared spectra of coal gangue before and after etching
Fig.2  Morphological images of coal gangue before (a) and after (b) etching
Fig.3  Statistical chart of coal gangue dimensions
Fig.4  Water absorption kinetics curves of different coatings
Fig.5  Tensile property curves of different coatings
Fig.6  Adhesion strength of different coatings before and after 10 d of immersion
Fig.7  Nyquist (a1-a4) and Bode (b1-b4) plots of EP (a1, b1), 1%CE (a2, b2), 5%CE (a3, b3) and 10%CE (a4, b4)
Fig.8  Time-dependent Rc (a) and CPEdl (b) of different coatings under atmospheric pressure soaking conditions
Fig.9  Surface morphologies of metal substrate after the removing of different coatings: (a1, a2) 1%CE coating, (b1, b2) 5%CE coating, (c1, c2) 10%CE coating
Fig.10  EDS surface analysis results of metal surfaces after removal of different coatings: (a) 1%CE coating, (b) 10%CE coating
Fig.11  Schematic diagram of protection mechanisms of CE coating
[1] Hou B R. Corrosion costs and economic development [J]. Chin. Sci. Technol. Ind., 2020, (2): 21
侯保荣. 腐蚀成本与经济发展 [J]. 中国科技产业, 2020, (2): 21
[2] Lyon S B, Bingham R, Mills D J. Advances in corrosion protection by organic coatings: what we know and what we would like to know [J]. Prog. Org. Coat., 2017, 102: 2
[3] Olajire A A. Recent advances on organic coating system technologies for corrosion protection of offshore metallic structures [J]. J. Mol. Liq, 2018, 269: 572
[4] Huang J B, Yang M, Zhu W H, et al. Zinc-rich polyester powder coatings with iron Phosphide: lower zinc content and higher corrosion resistance [J]. J. Ind. Eng. Chem., 2024, 133: 577
[5] Liu D, Wu F, Zhao W J, et al. Advance in anticorrosion performance of epoxy resin [J]. Mater. China, 2015, 34: 852
刘 丹, 伍 方, 赵文杰 等. 环氧树脂防腐性能研究进展 [J]. 中国材料进展, 2015, 34: 852
[6] Salehinasab H, Majidi R, Danaee I, et al. Engineering a zinc-rich ethyl silicate coating based on nickel oxide nanoparticles for improving anticorrosion performance [J]. Hybrid Adv., 2024, 5: 100132
[7] Li Z Y, Ravenni G, Bi H C, et al. Effects of biochar nanoparticles on anticorrosive performance of zinc-rich epoxy coatings [J]. Prog. Org. Coat., 2021, 158: 106351
[8] George J S, Vijayan P P, Paduvilan J K, et al. Advances and future outlook in epoxy/graphene composites for anticorrosive applications [J]. Prog. Org. Coat., 2022, 162: 106571
[9] Mourya P, Goswami R N, Saini R, et al. Epoxy coating reinforced with graphene-PANI nanocomposites for enhancement of corrosion-resistance performance of mild steel in saline water [J]. Colloids Surf., 2024, 687A: 133500
[10] Hao Y S, Liu F C, Han E H. Mechanical and barrier properties of epoxy/ultra-short glass fibers composite coatings [J]. J. Mater. Sci. Technol., 2012, 28: 1077
[11] Meng F D, Gao H D, Liu L, et al. Preparation and anticorrosive performance of a basalt organic coating for deep sea coupled pressure-fluid environment [J]. J. Chin. Soc. Corros. Prot., 2023, 43: 704
孟凡帝, 高浩东, 刘 莉 等. 适用于深海压力-流体耦合环境的玄武岩有机防腐涂层的制备及性能研究 [J]. 中国腐蚀与防护学报, 2023, 43: 704
doi: 10.11902/1005.4537.2023.142
[12] Liu L S, Zhao M Y, Pei X Y, et al. Improving corrosion resistance of epoxy coating by optimizing the stress distribution and dispersion of SiO2 filler [J]. Prog. Org. Coat., 2023, 179: 107522
[13] Ratnam D, Bhaumik S K. Functionalized borosilicate-silica-epoxy nanocomposite superhydrophobic coating for corrosion inhibition under harsh environment [J]. Prog. Org. Coat., 2024, 188: 108264
[14] Cheng X, An Y K, He Y M, et al. Effect of Nano-Al2O3/h-BN composite modification on the electrothermal properties of epoxy resin composites [J]. Polym. Mater. Sci. Eng., 2023, 39(7): 131
程 显, 安永科, 贺永明 等. 纳米Al2O3/h-BN复配改性对环氧树脂复合材料电热性能的影响 [J]. 高分子材料科学与工程, 2023, 39(7): 131
[15] Yao H R, Bi W Y, Jiang Y, et al. Research progress on protective properties of epoxy coatings reinforced by nanometer oxides [J]. Fine Chem., 2021, 38: 662
姚红蕊, 毕文雅, 姜 岩 等. 纳米氧化物颗粒增强环氧涂层防护性能的研究进展 [J]. 精细化工, 2021, 38: 662
[16] Randis R, Darmadi D B, Gapsari F, et al. The potential of nanocomposite-based coatings for corrosion protection of metals: a review [J]. J. Mol. Liq., 2023, 390: 123067
[17] Chen R Q, Zhang H R, Ma X L, et al. Two-dimensional reduced graphene oxide/polypyrrloe-based coating enable superior corrosion protection and photothermal-induced in-situ internal environmental regulation [J]. Chem. Eng. J., 2023, 458: 141481
[18] Shen P H, Wen J, Dong B Q, et al. Anticorrosion mechanism of ethylene-chlorotrifluoroeethylene coatings reinforced with hydroxylated carbon nanotubes: An experimental and molecular dynamics simulation study [J]. Prog. Org. Coat., 2024, 186: 107991
[19] Wan S, Chen H K, Cai G Y, et al. Functionalization of h-BN by the exfoliation and modification of carbon dots for enhancing corrosion resistance of waterborne epoxy coating [J]. Prog. Org. Coat., 2022, 165: 106757
[20] Rangel-Olivares F R, Arce-Estrada E M, Cabrera-Sierra R. Development of polyaniline/chitosan (PANI/CTS) and TiO2-PANI/CTS nanocomposites as anti-corrosion coatings: Synthesis and characterization [J]. Surf. Coat. Technol, 2024, 476: 130163
[21] Kong W Q, Serdechnova M, Kasneryk V, et al. ZIF-8 based bifunctional coatings with anticorrosive and antibacterial properties: a new design strategy for more efficiency [J]. Surf. Coat. Technol., 2024, 483: 130812
[22] Ji X H, Ji W H, Pourhashem S, et al. Novel superhydrophobic core-shell fibers/epoxy coatings with self-healing anti-corrosion properties in both acidic and alkaline environments [J]. React. Funct. Polym., 2023, 187: 105574
[23] Zhang S H, Shen Y, Lu J L, et al. Tannic acid-modified g-C3N4 nanosheets/polydimethylsiloxane as a photothermal-responsive self-healing composite coating for smart corrosion protection [J]. Chem. Eng. J., 2024, 483: 149232
[24] Yang C F, Smyrl W H, Cussler E L. Flake alignment in composite coatings [J]. J. Membr. Sci., 2004, 231(1-2): 1
[25] Duan D Y, Wang C Q, Bai D S, et al. Representative coal gangue in China: physical and chemical properties, heavy metal coupling mechanism and risk assessment [J]. Sustain. Chem. Pharm., 2024, 37: 101402
[26] Shen L L, Lai W A, Zhang J X, et al. Mechanical properties and micro characterization of coal slime water-based cementitious material-gangue filling: a novel method for co-treatment of mining waste [J]. Constr. Build. Mater., 2023, 408: 133747
[27] Qiu J S, Cheng K, Zhang R Y, et al. Study on the influence mechanism of activated coal gangue powder on the properties of filling body [J]. Constr. Build. Mater., 2022, 345: 128071
[28] Zheng Q W, Zhou Y, Liu X, et al. Environmental hazards and comprehensive utilization of solid waste coal gangue [J]. Prog. Nat. Sci. Mater. Int., 2024, 34: 223
[29] Li J R, Cao Y S, Sha A M, et al. Prospective application of coal gangue as filler in fracture-healing behavior of asphalt mixture [J]. J. Clean Prod., 2022, 373: 133738
[30] Chen Y F, Meng F D, Qu Y Y, et al. One-step synthesis of superhydrophobic polyaniline capsules and its effect on corrosion resistance of organic coatings [J]. J. Chin. Soc. Corros. Prot., 2023, 43: 345
陈异凡, 孟凡帝, 曲优异 等. 超疏水聚苯胺胶囊的一步可控合成及其对有机涂层防腐性能的影响 [J]. 中国腐蚀与防护学报, 2023, 43: 345
doi: 10.11902/1005.4537.2022.089
[31] Cao J Y, Li J, Yin W C, et al. Histamine-modified epoxy resin and its effect on properties of organic coatings [J]. J. Chin. Soc. Corros. Prot., 2024, 44: 151
曹京宜, 李 敬, 殷文昌 等. 组胺改性环氧树脂及其对有机涂层性能的影响 [J]. 中国腐蚀与防护学报, 2024, 44: 151
[32] Shao Y W, Gu S F, Zhang T, et al. Effect of size of mica filler on diffusion of water in epoxy coatings [J]. Paint Coat. Ind., 2007, 37(10): 11
邵亚薇, 顾胜飞, 张 涛 等. 云母填料尺寸效应对水在环氧涂层中扩散行为的影响 [J]. 涂料工业, 2007, 37(10): 11
[33] Meng F D, Zhang T, Liu L, et al. Failure behaviour of an epoxy coating with polyaniline modified graphene oxide under marine alternating hydrostatic pressure [J]. Surf. Coat. Technol., 2019, 361: 188
[34] Liu T, Liu Y, Ye Y W, et al. Corrosion protective properties of epoxy coating containing tetraaniline modified nano-α-Fe2O3 [J]. Prog. Org. Coat., 2019, 132: 455
[35] Li B W, Njuko D, Meng M J, et al. Designing smart microcapsules with natural polyelectrolytes to improve self-healing performance for water-based polyurethane coatings [J]. ACS Appl. Mater. Inter., 2022, 14: 53370
[36] Aghili M, Yazdi M K, Ranjbar Z, et al. Anticorrosion performance of electro-deposited epoxy/amine functionalized graphene oxide nanocomposite coatings [J]. Corros. Sci., 2021, 179: 109143
[1] MAO Chunkui, ZHU Zhiping, LI Tao, ZHOU Shangming, YANG Huo. Optimization and Applicability of Chemical Agents for Reclaimed Water, as Circulating Cooling Water of Thermal Power Plant[J]. 中国腐蚀与防护学报, 2025, 45(3): 675-686.
[2] XIAO Qikun, MA Jun, GUO Kai, XIONG Xin, YUAN Haoran. Numerical Simulation of Erosion Wear in Slurry Pipeline Based on DDPM-RSM[J]. 中国腐蚀与防护学报, 2025, 45(3): 709-719.
[3] ZHAO Fei, WANG Dongwei, GUO Quanzhong, WANG Chuan. Performance of RGO-CNTs Hybrid Material Modified RuO2-IrO2-SnO2/Ti Anode[J]. 中国腐蚀与防护学报, 2025, 45(3): 787-794.
[4] PENG Liyuan, XIE Jingli, CAO Shengfei, TAN Jibo, WU Xinqiang, ZHANG Ziyu. Review on Corrosion Thickness Design of Canister for High-level Radioactive Waste in Japan[J]. 中国腐蚀与防护学报, 2025, 45(3): 563-576.
[5] WEI Ran, JIANG Quantong, SUN Chen, WANG Weiwei, DUAN Jizhou, HOU Baorong. A Review on Corrosion and Protection of Mg-alloy in Marine Environment[J]. 中国腐蚀与防护学报, 2025, 45(3): 533-547.
[6] TIAN Qiumei, NI Chunhua, LUO Yunpeng, WANG Yanjian, XU Hao, LI Xia, YU Liangmin, YAN Xuefeng. Preparation and Antifouling Properties of N-Methylol Acrylamide (NMA)-Modified Acrylic Resins[J]. 中国腐蚀与防护学报, 2025, 45(3): 747-756.
[7] WANG Deling, LIU Yijun, GUO Zhangwei, LIU Tao. Research Progress on Failure Analysis and Protective Measures of Ship Hull Materials[J]. 中国腐蚀与防护学报, 2025, 45(3): 611-619.
[8] CHEN Lijuan, CHAO Liuwei, ZHAO Jingmao. Preparation of CeO2@Zr-MOF Composites and Their Effect on Corrosion Protectiveness of Epoxy Coatings on Galvanized Steel Plate[J]. 中国腐蚀与防护学报, 2025, 45(3): 664-674.
[9] WANG Yuhan, LI Jun, LIU Hengwei, XU Nan, LIU Jie, CHEN Xu. Research Progress of Microbial Corrosion of Metallic Materials in Marine Environment[J]. 中国腐蚀与防护学报, 2025, 45(3): 577-588.
[10] WANG Kang, JIANG Jianjun, YANG Lijing, SONG Zhenlun. Copper Electroplating Process and Performance of HEDP-potassium Pyrophosphate System on Sintered NdFeB Surface[J]. 中国腐蚀与防护学报, 2025, 45(3): 687-697.
[11] ZHANG Dingwen, ZHANG Jilan, YU Yijun, REN Ke, DING Qiang, SHI Huimei, YANG Xinhui, WANG Yuanwei, ZHANG Xuefeng, WU Duodong, LIU Feng, FENG Xingyu, LIU Pengshuai, KUANG Wenjun. Chemical Decontamination Process for Main Pump of Hualong One PWR[J]. 中国腐蚀与防护学报, 2025, 45(3): 739-746.
[12] ZHENG Wei, QU Dongyang, SUN Zhonghui, NIU Li. Research Progress of Zinc Ion Batteries in Zinc Metal Electrodes and Electrolytes[J]. 中国腐蚀与防护学报, 2025, 45(3): 548-562.
[13] 婕 李. Lifetime Prediction of Organic Coatings Based on Multi-Scale Image Feature Fusion[J]. 中国腐蚀与防护学报, 0, (): 0-0.
[14] . Effect of NaCl on the Corrosion Behavior of 347H Stainless Steel and Ni-Based GH3539 Alloy in Molten Nitrate Salts[J]. 中国腐蚀与防护学报, 0, (): 0-0.
[15] BAI Zhengqing, NONG Jing, WEI Shichen, XU Jian. Effect of Pre-charging Hydrogen on Corrosion Behavior of Ni-Cr Alloy in High Temperature and High Pressure Water[J]. 中国腐蚀与防护学报, 2025, 45(2): 338-346.
No Suggested Reading articles found!