Painting & Coating Industry (PCI) logo Powder coating summit logo
  • Sign In
  • Create Account
  • Sign Out
  • My Account
  • NEWS
  • PRODUCTS
  • MATERIALS
  • TECHNOLOGIES
  • FINISHING
  • RESOURCES
  • EVENTS
  • DIRECTORIES
  • EMAGAZINE
  • CONTACT
cart
facebook twitter linkedin youtube
  • NEWS
  • Latest News
  • Market Trends & Reports
  • Price Alerts
  • Subscribe to eNewsletters
  • Global Top 10/ PCI 25
  • Weekly Featured Article
  • COATLE Word Game
  • PRODUCTS
  • Product News
  • Must See Products and Services
  • MATERIALS
  • Additives
  • Resins/Polymers
  • Pigments
  • Equipment
  • Distributors
  • TECHNOLOGIES
  • Adhesives
  • Architectural Coatings
  • Industrial Coatings
  • Nanotechnology
  • Powder Coatings
  • Solventborne
  • Special Purpose Coatings
  • Sustainability
  • UV Coatings
  • Waterborne
  • Waterborne
  • FINISHING
  • Finishing News
  • Finishing Technologies
  • Finishing Equipment
  • RESOURCES
  • Columns
  • Blogs
  • Coatings Supplier Handbook
  • Podcasts and Videos
  • PCI Store
  • Classifieds
  • eBooks
  • Sponsor Insights
  • White Papers
  • COATLE Word Game
  • Columns
  • Ask Joe Powder
  • Did you know?
  • Distribution Dive
  • Focus on Canada
  • Formulating With Mike
  • Innovation Insights
  • Moody's Coatings Conundrums
  • Powder Coating Perspectives
  • Target the Market
  • TiO2 Insider
  • Blogs
  • Editor's Viewpoint
  • Industry Insights
  • Podcasts and Videos
  • COAT-IT! Podcast
  • Videos/PCI TV
  • EVENTS
  • Coatings Trends & Technologies Summit
  • Paint and Coatings Academy
  • Webinars
  • Calendar of Events
  • Lifetime Achievement Award
  • DIRECTORIES
  • Buyer's Guide
  • Equipment Directory
  • Materials Directory
  • EMAGAZINE
  • Current Issue
  • eMagazine Archive
  • China Issue Archive
  • Editorial Advisory Board
  • CONTACT
  • Contact Us
  • Advertise
  • Subscribe to eMagazine
  • Subscribe to eNewsletters
Painting & Coating Industry (PCI) logo Powder coating summit logo
search
cart
facebook twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
Painting & Coating Industry (PCI) logo Powder coating summit logo
  • NEWS
    • Latest News
    • Market Trends & Reports
    • Price Alerts
    • Subscribe to eNewsletters
    • Global Top 10/ PCI 25
    • Weekly Featured Article
    • COATLE Word Game
  • PRODUCTS
    • Product News
    • Must See Products and Services
  • MATERIALS
    • Additives
    • Resins/Polymers
    • Pigments
    • Equipment
    • Distributors
  • TECHNOLOGIES
    • Adhesives
    • Architectural Coatings
    • Industrial Coatings
    • Nanotechnology
    • Powder Coatings
    • Solventborne
    • Special Purpose Coatings
    • Sustainability
    • UV Coatings
    • Waterborne
    • FINISHING
      • Finishing News
      • Finishing Technologies
      • Finishing Equipment
    • RESOURCES
      • Columns
        • Ask Joe Powder
        • Did you know?
        • Distribution Dive
        • Focus on Canada
        • Formulating With Mike
        • Innovation Insights
        • Moody's Coatings Conundrums
        • Powder Coating Perspectives
        • Target the Market
        • TiO2 Insider
      • Blogs
        • Editor's Viewpoint
        • Industry Insights
      • Coatings Supplier Handbook
      • Podcasts and Videos
        • COAT-IT! Podcast
        • Videos/PCI TV
      • PCI Store
      • Classifieds
      • eBooks
      • Sponsor Insights
      • White Papers
      • COATLE Word Game
    • EVENTS
      • Coatings Trends & Technologies Summit
      • Paint and Coatings Academy
      • Webinars
      • Calendar of Events
      • Lifetime Achievement Award
    • DIRECTORIES
      • Buyer's Guide
      • Equipment Directory
      • Materials Directory
    • EMAGAZINE
      • Current Issue
      • eMagazine Archive
      • China Issue Archive
      • Editorial Advisory Board
    • CONTACT
      • Contact Us
      • Advertise
      • Subscribe to eMagazine
      • Subscribe to eNewsletters
    Industrial Coatings

    Protecting Tank Farms from Corrosion: The Three Most Important Considerations

    eoncoat
    May 13, 2019

    With asset utilization critical, and community and regulatory pressure always looming, it is essential that tank farm owners proactively prevent any loss of containment with reliable, cost-effective corrosion protection. This is crucial since atmospheric corrosion is one of the main culprits of tank leaks, containment loss and early replacement.

    As oil depots and terminals are often comprised of ample pipeline through which to draw product, it is also vital to address corrosion under insulation (CUI), which can cause serious problems including forced shutdowns, lost production, etc. CUI, which involves the corrosion of vessels or pipe beneath insulation due to water penetration, is insidious because it can remain undetected until leaks occur or the insulation is removed for inspection. Consequently, dealing with CUI and inspecting for it are very costly.

    Fortunately, by addressing a few important considerations regarding corrosion, tank farm owners can stop corrosion and CUI for years to dramatically extend tank and pipe service life. In doing so, they can also improve safety, reduce downtime and expedite maintenance turnaround.

     

    Go Beyond Barrier Coatings

    Tank farm corrosion protection typically involves applying polymer paints and rubber type coatings. Such methods create a physical barrier to keep corrosion promoters such as water and oxygen away from steel substrates. However, this only works until the paint is scratched, chipped, or breached and corrosion promoters enter the gap between the substrate and coating. When this occurs the coating can act like a greenhouse – trapping water, oxygen and other corrosion promoters – which allows the corrosion to spread.

    Instead, as a better alternative, a growing number of the world’s largest petrochemical companies with tank farms are finding success with an innovative approach toward stopping corrosion.

    To extend the service life of tank farm assets, including those already experiencing atmospheric corrosion, owners and facility managers are turning to a new category of tough, Chemically Bonded Phosphate Ceramics (CBPCs) that can stop the corrosion, ease application and reduce production downtime even in very wet, humid conditions.

    One example of this is EonCoat, a spray-applied inorganic coating from the Raleigh, North Carolina-based company of the same name.

    In contrast to traditional polymer coatings that sit on top of the substrate, the EonCoat corrosion resistant CBPC coating bonds through a chemical reaction with the substrate. The surface of steel is passivated as an alloy layer is formed. This makes it impossible for corrosion promoters like oxygen and humidity to get behind the coating the way they can with ordinary paints.

    Although traditional polymer coatings mechanically bond to substrates that have been extensively prepared, if gouged, moisture and oxygen will migrate under the coating’s film from all sides of the gouge.

    By contrast, the same damage to the ceramic-coated substrate will not spread corrosion because the carbon steel’s surface has been chemically transformed into an alloy of stable oxides. Once the steel’s surface is stable (the way noble metals like gold and silver are stable) it will no longer react with the environment and therefore cannot corrode.

    Visible in scanning electron microscope photography, EonCoat does not leave a gap between the steel and the coating because the bond is chemical rather than mechanical. Since there is no gap, even if moisture was to get through to the steel due to a gouge, there is nowhere for the moisture to travel. This effectively stops atmospheric corrosion on carbon steel assets.

     

    Address the “Silent Killer” CUI

    CUI is the root cause of many of the global petrochemical industry’s most serious problems including forced shutdowns, lost production, early repair and replacement, as well as safety and environmental consequences that can cost millions of dollars per incident.

    “CUI is the silent killer,” explains Merrick Alpert, President of EonCoat. “The insulation creates a terrarium on the steel in which corrosion is guaranteed to occur if traditional coatings are used. And the insulation then hides the corrosion from being detected until it’s too late.”

    Pipe is particularly susceptible to mechanical damage from shipping, installation or facility operation that may breach traditional coatings and accelerate CUI.

    Because of the risk of CUI, a dedicated team is often required to inspect vessels or extensive piping on a virtually continuous basis. However, removing pipe insulation and spot-checking that portion of pipe does not eliminate the risk of CUI along the entire pipe network at the tank farm.

    As an alternative that helps to curtail this costly inspection and maintenance cycle, a CBPC coating like EonCoat provides a corrosion barrier that is covered by a ceramic layer that further resists corrosion, water, impact, abrasion, chemicals, fire and high temperatures.

    In this way, the ceramic layer provides a tough outer coating that dramatically reduces mechanical damage and any potential breach of the coating.

    The CBPC coating’s chemical bond further ensures that even if moisture were to get through to the steel due to a gouge, it would travel no farther than the boundaries of the gouge. This quality effectively prevents the hidden spread of corrosion, which is arguably the most insidious aspect of CUI.

     

    Faster Turnaround Time

    One of the greatest benefits of the CBPC coating, however, is the rapid return to service that minimizes facility downtime. The time saved on an anti-corrosion coating project with the ceramic coating comes from less surface preparation, the elimination of the intermediate coat and expedited curing time.

    With a typical corrosion coating, near white metal blast cleaning (NACE 2/SSPC-SP 10) is required to prepare the surface. But with the ceramic coating, only a NACE 3/SSPC-SP 6 commercial blast is typically necessary.

    Furthermore, with traditional coatings, extensive surface preparation is required and done a little at a time to avoid surface oxidation, commonly known as ‘flash rust’, which then requires re-blasting.

    However, with the CBPC coating, the flash rust is no issue. There is no need to ‘hold the blast’. The reason for this unique CBPC characteristic is due to the presence of iron in the rust, which helps to create the magnesium iron phosphate alloy layer. It is this alloy layer that allows CBPCs to so effectively protect carbon steel from corrosion.

    For traditional ‘three part system’ coatings utilizing polyurethanes or epoxies, the cure time may also be days or weeks before the next coat can be applied, depending on the product.

    In contrast, a corrosion-resistant coating for carbon steel utilizing the ceramic coating in a single coat requires almost no curing time. Return to service for tank farms can be achieved in as little as one hour, which can potentially save hundreds of thousands of dollars per day in reduced facility downtime.

     

    Boosting the Bottom Line

    For petrochemical tank farms with massive carbon steel structures, corrosion and CUI have been a costly, perennial problem.

    Now, however, by proactively using best-in-class anti-corrosion products like CBPC coatings, facility managers will be able to deter corrosion and CUI for decades, reduce downtime, and postpone tank and pipe replacement. This will significantly help the bottom line.

    For more information, visit www.eoncoat.com.

    By EonCoat

    KEYWORDS: Corrosion Control Corrosion Under Insulation Coatings

    Share This Story

    Looking for a reprint of this article?
    From high-res PDFs to custom plaques, order your copy today!

    Recommended Content

    JOIN TODAY
    to unlock your recommendations.

    Already have an account? Sign In

    • PCI-0724-Global10-Feature-1440.png

      2024 Global Top 10: Top Paint and Coatings Companies

      Who ranks on top? PCI’s annual ranking of the top 10...
      Global Top 10 and PCI 25
      By: Courtney Bassett
    • PCI-0724-PCI25-Feature-1440.png

      2024 PCI 25: Top Paint and Coatings Companies

      PCI's annual ranking of the top 25 North American paint...
      Paint and Coating Market Reports
      By: Courtney Bassett
    • pci1022-Kinaltek-Lead-1170.jpg

      A Novel Pigment Production Technology

      Following an extensive R&D program that demonstrated...
      Paint and Coating Pigments
      By: Jawad Haidar and Nitin Soni
    You must login or register in order to post a comment.

    Report Abusive Comment

    Manage My Account
    • eMagazine
    • eNewsletter
    • Online Registration
    • Subscription Customer Service

    The Coatings Minute: Print Returns with PCI’s New Showcase Issue

    The Coatings Minute: Print Returns with PCI’s New Showcase Issue

    The Coatings Minute: Your Inside Look at PCInnovations

    The Coatings Minute: Your Inside Look at PCInnovations

    CTT Registration Now Open

    CTT Registration Now Open

    The Coatings Minute: Why Industry News Matters More Than Ever

    The Coatings Minute: Why Industry News Matters More Than Ever

    More Videos

    Sponsored Content

    Sponsored Content is a special paid section where industry companies provide high quality, objective, non-commercial content around topics of interest to the PCI audience. All Sponsored Content is supplied by the advertising company and any opinions expressed in this article are those of the author and not necessarily reflect the views of PCI or its parent company, BNP Media. Interested in participating in our Sponsored Content section? Contact your local rep!

    close
    • Modern arapartment complex painted in bright colors.
      Sponsored byEPS - Engineered Polymer Solutions

      Architectural Polymers Leading the Way in Coatings Innovation

    • paint sprayer in a workshop
      Sponsored byallnex

      Enabling Performance and Compliance: allnex Introduces a New Line of VOC Exempt Solvent-Borne Resins

    Popular Stories

    No. 3 AkzoNobel

    AkzoNobel to Close Two Manufacturing Sites

    BASF SE Logo

    BASF Reportedly Eyes Exit from Coatings

    Modern living room interior with green plants, sofa and green wall

    Reimagining Architectural Paints with Plant-Based Acrylic Binders



    PCI Buyers Guide

    Submit a Request for Proposal (RFP) to suppliers of your choice with details on what you need with a click of a button

    Start your RFP

    Browse our Buyers Guide for manufacturers and distributors of all types of coatings products and much more!

    Find Suppliers

    Events

    September 3, 2025

    Coatings Trends & Technologies Summit

    The Coatings Trends & Technologies (CTT) Summit is an annual conference for both liquid and powder coatings formulators and manufacturers to discuss innovations in coatings technology. This event combines high-quality technical presentations, a resource-rich exhibit hall, and dedicated networking opportunities to connect scientific minds, foster innovation, and cultivate game-changing new ideas!

    January 1, 2030

    Webinar Sponsorship Information

    For webinar sponsorship information, visit www.bnpevents.com/webinars or email webinars@bnpmedia.com.

    View All Submit An Event

    Poll

    Longest-running laboratory experiment

    What is the longest-running laboratory experiment?
    View Results Poll Archive

    Products

    CTT Summit Short Courses (Live 9/3/25)

    Coatings Trends & Technologies Summit is expanding its offerings with four short courses. These short courses will offer an extensive day of interactive learning.

    See More Products
    pci  webinar april 2025

    PCI CASE EBOOK

    Related Articles

    • Protecting Metals from Corrosion During Transport

      Protecting Metals from Corrosion During Transport

      See More
    • Protecting Industrial Facilities from Harsh Environmental Corrosion

      Protecting Industrial Facilities from Harsh Environmental Corrosion

      See More
    • EonCoat

      Protecting Industrial Facilities from Harsh Environmental Corrosion

      See More

    Related Products

    See More Products
    • corrosion of linings.jpg

      Corrosion of Linings & Coatings: Cathodic and Inhibitor Protection and Corrosion Monitoring

    • intelligent.jpg

      Intelligent Coatings for Corrosion Control 1st Edition

    • corrosion.jpg

      Corrosion Control Through Organic Coatings 2nd Edition

    See More Products
    ×

    Keep the info flowing with our eNewsletters!

    Get the latest industry updates tailored your way.

    JOIN TODAY!
    • RESOURCES
      • Advertise
      • Contact Us
      • Directories
      • Store
      • Want More
    • SIGN UP TODAY
      • Create Account
      • eMagazine
      • eNewsletters
      • Customer Service
      • Manage Preferences
    • SERVICES
      • Marketing Services
      • Reprints
      • Market Research
      • List Rental
      • Survey & Sample
    • STAY CONNECTED
      • LinkedIn
      • Facebook
      • Youtube
      • X (Twitter)
    • PRIVACY
      • PRIVACY POLICY
      • TERMS & CONDITIONS
      • DO NOT SELL MY PERSONAL INFORMATION
      • PRIVACY REQUEST
      • ACCESSIBILITY

    Copyright ©2025. All Rights Reserved BNP Media.

    Design, CMS, Hosting & Web Development :: ePublishing

    Painting & Coating Industry (PCI) logo Powder coating summit logo
    search
    cart
    facebook twitter linkedin youtube
    • Sign In
    • Create Account
    • Sign Out
    • My Account
    Painting & Coating Industry (PCI) logo Powder coating summit logo
    • NEWS
      • Latest News
      • Market Trends & Reports
      • Price Alerts
      • Subscribe to eNewsletters
      • Global Top 10/ PCI 25
      • Weekly Featured Article
      • COATLE Word Game
    • PRODUCTS
      • Product News
      • Must See Products and Services
    • MATERIALS
      • Additives
      • Resins/Polymers
      • Pigments
      • Equipment
      • Distributors
    • TECHNOLOGIES
      • Adhesives
      • Architectural Coatings
      • Industrial Coatings
      • Nanotechnology
      • Powder Coatings
      • Solventborne
      • Special Purpose Coatings
      • Sustainability
      • UV Coatings
      • Waterborne
      • FINISHING
        • Finishing News
        • Finishing Technologies
        • Finishing Equipment
      • RESOURCES
        • Columns
          • Ask Joe Powder
          • Did you know?
          • Distribution Dive
          • Focus on Canada
          • Formulating With Mike
          • Innovation Insights
          • Moody's Coatings Conundrums
          • Powder Coating Perspectives
          • Target the Market
          • TiO2 Insider
        • Blogs
          • Editor's Viewpoint
          • Industry Insights
        • Coatings Supplier Handbook
        • Podcasts and Videos
          • COAT-IT! Podcast
          • Videos/PCI TV
        • PCI Store
        • Classifieds
        • eBooks
        • Sponsor Insights
        • White Papers
        • COATLE Word Game
      • EVENTS
        • Coatings Trends & Technologies Summit
        • Paint and Coatings Academy
        • Webinars
        • Calendar of Events
        • Lifetime Achievement Award
      • DIRECTORIES
        • Buyer's Guide
        • Equipment Directory
        • Materials Directory
      • EMAGAZINE
        • Current Issue
        • eMagazine Archive
        • China Issue Archive
        • Editorial Advisory Board
      • CONTACT
        • Contact Us
        • Advertise
        • Subscribe to eMagazine
        • Subscribe to eNewsletters