Dear readers, colleagues, and industry professionals,
I thank the editors of this journal for inviting me to share my professional perspective on a pressing technical topic at the intersection of science and industrial practice. Such dialogue between industry and academia is especially important today, when technological development is directly linked to the quality of engineering education and the applicability of scientific knowledge in real-world production settings.
In this article, I briefly examine corrosion as an engineering challenge that requires not only the selection of materials or coatings but also an understanding of the physical and chemical mechanisms underlying metal degradation processes. The observations presented are based on a combination of research and practical experience and are aimed at practical applications.
I hope that the considerations presented will be useful to industry specialists and will contribute to professional discussions on metal protection issues and the development of modern technological solutions.
Professor Zhumabay Bakenov General Director, Institute of New Materials and Energy Technologies
Academician of the National Academy of Sciences of the Republic of Kazakhstan under the President of the Republic of Kazakhstan, Honored Figure in Science and Technology of the Republic of Kazakhstan, Professor at the School of Engineering and Digital Sciences at Nazarbayev University
Corrosion remains one of the most underestimated, yet most costly, problems facing modern industry. International organizations estimate that direct and indirect losses from corrosion reach 3–4% of the GDP of developed countries. In the oil and gas, chemical, energy, and construction industries, corrosion not only reduces the service life of equipment but also directly impacts safety, environmental risks, and business sustainability. As a specialist in chemical engineering and electrochemistry, I would like to share my views on why corrosion protection should be considered today as a comprehensive engineering strategy rather than a secondary process step, and the role that modern paints and coatings play in this regard.
Corrosion Is Not “Rust,” But an Electrochemical Process.
In the public consciousness, corrosion is often associated exclusively with rust. Scientifically, however, corrosion is a spontaneous electrochemical process in which a metal seeks to return to a more stable thermodynamic state.
Simply put, most metals used in industry exist “in defiance of nature.” Iron, aluminum, and zinc were extracted from ores with the expenditure of energy, and corrosion is a way of “repaying” the environment. The conditions in the oil and gas industry are particularly aggressive:
◆ high mineralization of water,
◆ the presence of CO₂ and H₂S,
◆ temperature and pressure changes,
◆ microbiological activity,
◆ mechanical damage to surfaces. Under such conditions, corrosion accelerates and its mechanisms become more complex: localized corrosion, pitting, crevice corrosion, and stress corrosion cracking.
A Coating Is an Engineered System, Not Just a Layer of Paint.
Modern anticorrosion coatings are no longer just “paint.” They are multilayer, functional systems, each component performing a specific task:
◆ barrier protection,
◆ electrochemical protection,
◆ adhesion to the substrate,
◆ decorative function,
◆ protection from UV radiation, chemicals, and abrasive wear.
From an electrochemical point of view, a good coating:
1. Minimizes access of electrolyte to the metal surface;
2. Slows down the transfer of ions and electrons;
3. Stabilizes surface potential;
4. Prevents local defects where intense corrosion can begin.
It’s important to understand that a coating defect isn’t just a point of damage, but a potential anode or cathode, where corrosion can occur tens of times faster than on an exposed surface. Therefore, improper design or a compromised coating’s homogeneity and integrity can lead to accelerated electrochemical corrosion.
Why Materials Alone Are Not Enough
Engineers often ask, “Why not simply use a more corrosion-resistant metal?” The answer is simple: economics and technological limitations. Stainless steels, titanium alloys and nickel-based materials do have high resistance, but:
◆ they are much more expensive,
◆ more difficult to process and weld,
◆ not always available for large-sized structures. Therefore, in practice, carbon steel is almost always used, and the problem of corrosion protection is solved with the help of:
◆ coatings,
◆ inhibitors,
◆ electrochemical protection,
◆ competent engineering design.
And this is where coatings play a key role.
Features of Operation in Kazakhstan
The Central Asian region has its own specifics:
◆ sharp daily and seasonal temperature changes,
◆ high solar radiation,
◆ dust, sand, and salt aerosols,
◆ a continental climate. Under such conditions the coating must be:
◆ resistant to UV degradation,
◆ elastic under temperature-induced deformations,
◆ chemically resistant,
◆ technologically advanced in application and repair.
Companies operating in the region, such as Asiacolor, play a vital role in adapting global coating technologies to local operating conditions, which is often more important than blindly copying foreign solutions.
Common Mistakes in Corrosion Protection
Over the years of teaching the “Corrosion Protection in the Oil and Gas Industry” course and working on industrial projects, we regularly encounter the same mistakes:
1. Underestimating surface preparation Up to 70% of coating failures are not related to the composition of the material, but to poor cleaning and preparation of the metal surface. 2. Incorrect choice of coating system There are no universal solutions — what works on a tank may not work on a pipeline.
3. Lack of control during the application process Layer thickness, drying conditions, humidity — all of this is critical. 4. Ignoring the life cycle A coating is an investment and should be evaluated by its lifespan rather than its initial price.
The Future of Anti-Corrosion Coatings
Current trends in corrosion protection include:
◆ smart coatings capable of self-healing;
◆ systems with inhibitors released in case of damage;
◆ environmentally friendly compositions with reduced solvent content;
◆ digital monitoring of coating conditions. However, even the most advanced technologies cannot re-place an engineering approach and professional expertise.
Conclusion
Corrosion is not an enemy that can be defeated once and for all. It’s a natural process that must be managed properly. The key lies in a combination of science, practical experience, and high-quality materials. Companies working in the coatings and metal protection sector are becoming more than just product suppliers — they are partners in ensuring the reliability and safety of industrial infrastructure. This approach is precisely what drives the sustainable development of many industrie