MoS2 decorated with ZrO2 nanoparticles through mussel-inspired chemistry of dopamine for reinforcing anticorrosion of epoxy coatings

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Abstract

Faced with severe corrosion of casing in oil wells, the epoxy coating was applied to prevent corrosion. Based on the mechanism that the filler eliminated the internal stress during the curing process of the coating and prevented the penetration of corrosive medium into the coating, a new filler was successfully prepared by the hydrothermal method. When the molar ratio of the precursor of ZrO2 to MoS2 was 1.2:1, MoS2 was uniformly modified with ZrO2 through mussel inspired chemistry of dopamine. Introducing fillers into epoxy coatings, specifically, a proper content of 0.8 wt.% filler can greatly improve the mechanical properties and corrosion resistance of the coatings. The coating maintained the excellent corrosion resistance for 16 h under high temperature (108  °C) and high pressure (pressurized with CO2 gas of 35 MPa), which would provide us a reliable anticorrosive coating for oil wells metal casing.

Introduction

With the acceleration of the petroleum industry process, the drilling conditions of ultra-deep wells and corrosive gas wells are becoming more and more complex, and serious corrosion problems under high temperature, high pressure and salinity are of great concern. Epoxy coatings are widely used in the field of corrosion protection due to their excellent chemical stability and strong combination with metals [[1], [2], [3], [4]]. However, the plentiful tiny pores were always formed during the production process of the coating, especially curing the solvent-borne coating to evaporate the solvent at high temperature, which resulted in deteriorating corrosion resistance of coating. This problem can be effectively solved by adding nanomaterials to form composite coatings, as nanomaterials can eliminate the internal stresses in epoxy resin curing [[5], [6], [7]]. Also, nanomaterials can create effective barriers of corrosion medium by micropores into coatings [8,9], which is one of the most attractive features of this method. So, clay, carbon nanotubes, titanium dioxide (TiO2), silicon dioxide (SiO2), graphite carbon nitride (g-C3N4) and graphene (Gr) for instance have been introduced into epoxy coating to investigate the anticorrosion performance [[10], [11], [12], [13], [14], [15]]. In this strategy, the crucial step is to improve the compatibility and dispersion of nanomaterials in the coating [16]. Therefore, it is usually necessary to modify the surface of nanomaterials [[16], [17], [18], [19]], for example, functionalizing organic groups by silane coupling agent [20,21], and roughing the surface by loading other nanomaterials, such as PANI/zinc oxide/glass fiber, Ti3C2/graphene hybrid, Cu-8-HQ@HNTs [[22], [23], [24]].

The two-dimensional (2D) material has a large plane structure, so it has more advantages in preventing the corrosion medium in the anticorrosive coating. At present, the 2D materials as fillers are mainly Gr [14], graphene oxide (Go) [25], g-C3N4 [15], and boron nitride (BN) [26]. Compared with them, molybdenum disulfide (MoS2) from molybdenite is more economical as a filler for 2D materials. Zirconium dioxide (ZrO2) can form good compatibility with epoxy resin [27], and its surface is easily modified by silane coupling agent [28,29]. ZrO2 and MoS2 are typical materials with thermal and chemical stability, and they can be easily prepared by conventional solvothermal methods. Therefore, we envisioned loading zero-dimensional ZrO2 [30] onto the surface of 2D MoS2 [31], to achieve a rough surface, To enhance and uniformize the load of ZrO2, the surface of MoS2 was modified by mussel-inspired dopamine chemistry, because the phenolic hydroxyl group of phthalates in polydopamine can chelate metal ions, which provided a favorable condition of the successful load of ZrO2. Finally, to further enhance the compatibility with the resin, a silane coupling agent (KH560) was used to functionalize the epoxy group in the hybrid material. The application of the hybrid material to enhance the corrosion resistance of epoxy coatings has been extremely successful, especially in environment with high temperature and high pressure, thus providing us with a reliable anti-corrosion coating for metal casing in oil wells.

Section snippets

Materials

Dopamine hydrochloride and tris(hydroxymethyl aminomethane) (Tris-buffer) were procured from Aladdin. Hexaammonium heptamolybdate tetrahydrate (HHT), thiourea, gamma-(2,3-epoxypropoxy) propyl-trimethoxy silane (KH560), Hexadecyl trimethyl ammonium Bromide (CTAB), ammonium hydroxide (NH3·H2O), silver nitrate (AgNO3), Zirconium Oxychloride Octahydrate (ZrOCl2·8H2O), acetone, sodium chloride (NaCl), ethanol were purchased from Kelong Chemical Reagent Factory (Chengdu, China). These reagents were

Characterization of KZPM hybrid materials

In order to make the surface of MoS2 (Fig. 2(a)) more easily modified, the surface of MoS2 was firstly covered by mussel inspired chemistry of dopamine to prepare PDA-MoS2. As shown in Fig. 2(b), it can be clearly observed that the thickness of MoS2 become thicker, which is because its surface was coated with the strong adhesive ability of polydopamine [33]. As shown in Fig. 3, the microstructure of KZPM was characterized by SEM and TEM. Compared with the prepared MoS2 and PDA-MoS2, the surface

Conclusion

A novel KZPM hybrid material was successfully prepared through the hydrothermal method, ZrO2 was modified on the surface of PDA-MoS2, and functionalized by KH560. In addition, when the molar ratio of ZrOCl2·8H2O to MoS2 was 1.2:1, the prepared KZPM possessed good quality with uniformly dispersed ZrO2 nanoparticles. KZPM was introduced into the epoxy coating, especially a proper content of 0.8 wt.%, which can greatly improve the mechanical properties and corrosion resistance of the coating. The

CRediT authorship contribution statement

Yujuan Jing: Methodology, Conceptualization, Writing - original draft, Writing - review & editing. Pingquan Wang: Methodology, Investigation, Conceptualization. Qiangbin Yang: Methodology, Conceptualization, Writing - review & editing, Investigation. Qiurun Wang: Writing - review & editing. Yang Bai: Writing - review & editing.

Declaration of Competing Interest

The authors declare that they have no known competing for financial interests or personal relationships that could have appeared to influence the work reported in this paper.

Acknowledgments

This work was financially supported by the National Natural Science Foundation of China (No. 51974270), Open Fund of State Key Laboratory of Oil and Gas Reservoir Geology and Exploitation (Southwest Petroleum University) (PLN2020-9), Scientific Research Fund of Chongqing Municipal Education Commission (NO. KJQN202001317).

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