REPORT_FINAL_FINAL

A PROJECT REPORT ON
Manufacturing of Advanced Anti-Corrosive

Materials for Naval Industry
Submitted to Savitribai Phule Pune

University, in Partial Fulfillment of the
Requirements for the Award of the
Degree of
BACHELOR OF TECHNOLOGY (CHEMICAL)
BY
Prajwal Ghadge
Gr no (12010609)
Jeetsing Girase
Gr no (12010428)
Vedant Kale
Gr no (12010608)
Department of Chemical Engineering

BRACT’S Vishwakarma Institute of
Technology,
666, Upper Indiranagar, Bibwewadi, Pune – 411 037
May 2024
i
Manufacturing Of Anti-Corrosive Material For Naval Industry
ABSTRACT
Metals are widely used in human activities due to their excellent mechanical and electrical
properties. In order to preserve the desired state of these metals, their preventive maintenance
is a priority. Corrosion is probably the most common undesired phenomenon that leads metals
to become weaker. This natural process originates from the electrochemical interaction of
metals with the corrosive environment. Sulfides, oxides, and others are generated through
reactions between the metal surface and the corrosive medium. Among metals, mild steel is the
most widely used in the oil, food, energy, chemical, and construction industries due to its
different applications, most of which are based on its excellent mechanical properties.
Natural extracts have been widely used to protect metal materials from corrosion. The
efficiency of these extracts as corrosion inhibitors is commonly evaluated
throughelectrochemical tests, which include techniques such as potentiodynamic polarization,
electrochemical impedance spectroscopy, and weight loss measurement. The inhibition
efficiency of different extract concentrations is a valuable indicator to obtain a clear outlook to
choose an extract for a particular purpose. A complementary vision of the effectiveness of
green extracts to inhibit the corrosion of metals is obtained by means of surface
characterizations; atomic force microscopy, scanning electron microscopy, and X-ray
photoelectron spectroscopy analysis are experimental techniques widely used for this purpose.
Corrosion in the naval industry is a formidable adversary, constantly threatening the integrity
and functionality of naval vessels and infrastructure. The marine environment, with its high
salinity, humidity, and exposure to harsh weather conditions, accelerates the corrosion process,
leading to significant maintenance costs and operational challenges.
Traditional methods of corrosion treatment in the naval industry typically involve the
application of protective coatings, cathodic protection systems, and routine inspections.
Protective coatings, such as paints and primers, form a barrier between the metal surfaceand
corrosive elements, slowing down the corrosion rate. Cathodic protection systems, like
sacrificial anodes or impressed current systems, work by directing the corrosion processaway
from the protected metal surface. Regular inspections are crucial for early detection of corrosion
and timely maintenance interventions to prevent further damage.
However, advancements in green corrosion inhibition techniques offer promising alternatives
in the naval industry. Green corrosion inhibitors are environmentally friendly compounds that
effectively mitigate corrosion while minimizing their ecological footprint. These inhibitors can
be organic or inorganic compounds derived from renewable resources, such as plant extracts,
amino acids, or biopolymers. Their eco-friendly nature makes them particularly appealing for
use in sensitive marine ecosystems.
One example of green corrosion inhibition is the use of plant extracts rich in natural
antioxidants, such as polyphenols, flavonoids, and tannins. These compounds form a protective
film on the metal surface, inhibiting corrosion by blocking the access of corrosive agents like
oxygen and water. Additionally, green inhibitors can be incorporated into eco- friendly
coatings or integrated into cathodic protection systems, providing sustainable corrosion
protection solutions for naval vessels and maritime infrastructure.
As the naval industry strives towards sustainability and environmental responsibility, the
adoption of green corrosion inhibition technologies represents a significant step forward in
safeguarding assets while minimizing environmental impact. By harnessing the power of
nature, naval operators can effectively combat corrosion while preserving the delicate balance
of marine ecosystems.
Moreover, theoretical studies are usually addressed to elucidate the nature of the corrosion
inhibitor—metal surface interactions.
Chemical Engineering – i
Manufacturing Of Anti-Corrosive Material For Naval
This work reports a broad overview of the current state of the art research on the study of new
extracts as corrosion inhibitors on metal surfaces in corrosive media. Most constituents
obtained from plant extracts are adsorbed on the metal, following the Langmuir adsorption
model. Electron-rich regions and heteroatoms have been found to be responsible for
chemisorption on the metal surface, whereas physisorption is due to the polar regions of the
inhibitor molecules. The plant extracts compiled in this work obtained corrosion inhibition
efficiencies above 60%, most of them around 80–90%. The effect of concentration, extraction
solvent, temperature, and immersion time were studied as well.
Additional studies regarding plant extracts as corrosion inhibitors on metals are needed to
produce solutions for industrial purposes.
Keywords: green corrosion inhibition; plant extract; steel; surface coating
Manufacturing Of Anti-Corrosive Material For Naval
ACKNOWLEDGMENT
This document is prepared by the inspiration received from Professor Dr Sunil Sable,
Assistant Professor, Department of Chemical Engineering, BRACT’s Vishwakarma Institute
of Technology. Many colleagues at Chemical Engineering Department have carefully read
and improved the document; their contributions are gratefully acknowledged.
Manufacturing Of Anti-Corrosive Material for Naval
Bansilal Ramnath Agarwal Charitable Trust’s

VISHWAKARMA INSTITUTE OF TECHNOLOGY
(An Autonomous Institute Affiliated to Savitribai Phule Pune University)
666, Upper Indiranagar, Bibwewadi, Pune – 411 037
May 2024
CERTIFICATE
Manufacturing of Advanced Anti-

Corrosive Materials for Naval Industry
It is certified that the project work entitled
Submitted by
Prajwal Ghadge 12010609 25

Jeetsing Girase 12010428 26
Vedant Kale 12010608 33
is the original work carried out by them under the supervision of Prof. Dr Sunil Sable and is
approved for the partial fulfilment of the requirement of Savitribai Phule Pune University,
for the award of the Degree of Bachelor of Technology (Chemical)
This Project Work has not been earlier submitted to any other Institute or University for the
award of any degree or diploma.
(Prof.Dr. Sunil Sable) (Prof. Dr. M.P Deosarkar)

Guide, Head,
Department of Chemical Department of Chemical
Engineering Engineering
Chemical Engineering – v
TABLE OF CONTENTS
Page
Abstract iii
Acknowledgement iv
Certificate v
Table of Contents vi
List of Tables vii
List of Figures viii
Chapter 1 INTRODUCTION
1.1 Extraction Methods 3

1.2 Characterization Techniques 6
1.3 Occurrence of Corrosion in sea water 8
1.4 Corrosion Resistance of Ship Construction Materials 9
1.5 Corrosion Inhibition of mild steel in sea water 10
1.6 Corrosion behavior of Titanium alloys in sea water 11
1.7 Methods of corrosion prevention in sea water 13
1.8 Need for new solutions 15
1.9 Biopolymers as environment friendly corrosion inhibitors 18
1.10 Plant extracts as environment-friendly corrosion inhibitors 19
1.11 Chemical medicines as environment-friendly alternatives 20
Chapter 2 LITTERATURE REVIEW 22
Chapter 3 ANTI-CORROSIVE PIGMENTS
3.1 Hydroxychavicol 28
3.2 Tannin 31
3.3 Lignin 34
3.4 Pectin 38
Chapter 4 METHODOLOGY
4.1 Selection of material and process 42

4.1.1 Drying
4.1.2 Extraction
4.1.3 Mixing
4.2 Plant-Based Corrosion Inhibitors for Mild Steel 46
4.3 Application Process
4.3.1 Epoxy resin coating 52
4.3.2 Powder Coating
4.3.3 Cyanoacrylate Coating
4.4 Extracting Hydroxychavicol from Betel leaves 56
4.5 Extraction of tannin from Oak Bark 58

4.6 Extraction of pectin from citrus peels 60
4.7 Methodology for Creating Anti-Corrosive Powder 62
from Extracted Compounds
Chapter 5 RESULTS AND DISCUSSION
5.1 Characterization Techniques 66

5.2 Weight loss measurement 68
5.3 Adhesion Test 72
5.4 Weight Measurement Test 73
5.5 Tensile tests 77
5.6 Weight loss measurements 77
5.7 Adhesion Test results 78
5.8 Immersion test results 78
CONCLUSION
REFRENCES
LIST OF TABLES
Table Title page
Table 1 Comparative analysis of hydroxychavicol, lignin, tannin, pectin 41
Table 2. Equations to determine the inhibition efficiency(IE by different Techniques) 46
Table 3. Adsorption Isotherm 47
Table 4. Basic information and parameters obtained with several plant 49
extracts evaluated as corrosion inhibitors in steel
Table 5. Theoretical characterization performed for several plant extracts: 50,51
plant, main extract constituents, and theoretical framework used
for their evaluation.
Table 6. Basic information and parameters obtained with several plant 52
extracts evaluated as corrosion inhibitors in copper and aluminum
LIST OF FIGURES
Figure Title page
Figure 1 Basic parts of a plant and their common active compounds. 3
Figure 2 Diagrams common extraction methods: (a) maceration of, 5
(b) percolation (c) decoction ,(d)Soxhlet, and (e) sonication
Figure 3 Linear Polarisation Resistance [LPR] of mild steel and cobalt 8
chromium and molybdenum
Figure 4 Factors affecting corrosion in seawater 9
Figure 5 Corrosion Resistance of Ship Construction Materials 10
Figure 6 Corrosion rate vs time of 1018 mild carbon steel 11
Figure 7 Corrosion potential of some metals and alloys in flowing seawater 12
Figure 8. Ways to prevent corrosion 14
Figure 9 Structural steel elements subject to corrosion 15
Figure 10 Corrosion inhibitors and their types 17
Figure 11 Structure of Hydroxychavicol 36
Figure 12 Structure of tannin 37
Figure 13. Structure of lignin 37
Figure 14. Structure of pectin 37
Figure 15. Drying Unit Operation 44
Figure 16. Extraction Operation 45
Figure 17. Mixing Operation 46
Figure 18: Epoxy Resin coating Process 53
Figure 19: Powder Coating 55
Figure 20: Cyanoacrylate coated mild steel 56
Figure 21. High Performance liquid chromatography 58
Figure 22. Lignin Pyrolysis process 60
Figure 23. Microwave Assisted Extraction 62
Figure 24 Powdered And final forms of extracted hydroxychavicol, 65
tannin, lignin and pectin
Chemical Engineering – x
Manufacturing of Advanced Anti-Corrosive Materials for Naval Industry
Chapter 1
INTRODUCTION
Corrosion poses a significant challenge in the naval industry, where the harsh marine
environment accelerates the deterioration of metal structures and equipment. To combat this
issue, the development of anti-corrosive materials using green corrosion inhibitors such as tannin
and lignin has gained prominence. These natural compounds offer an environmentally friendly
alternative to traditional corrosion inhibitors, making them a promising solution for enhancing
the longevity and performance of naval assets. Naval vessels and structures are constantly
exposed to corrosive elements like saltwater, humidity, and atmospheric pollutants, leading to
the degradation of metal surfaces. Corrosion not only compromises the structural integrity of
ships but also increases maintenance costs and poses safety risks to personnel. The economic and
operational implications of corrosion in the naval industry underscore the urgent need for
effective anti-corrosive measures.
Green Corrosion Inhibitors: Tannin and Lignin Tannin and lignin, derived from natural
sources such as plants and trees, have emerged as promising green corrosion inhibitors for the
naval industry. These compounds exhibit excellent inhibitive properties, forming protective
layers on metal surfaces that impede corrosion processes. Tannin, known for its complex
polyphenolic structure, interacts with metal ions to inhibit corrosion, while lignin, a natural
polymer, offers barrier protection against corrosive agents. Incorporating tannin and lignin into
anti-corrosive coatings and formulations presents a sustainable approach to corrosion prevention
in the naval industry. These green inhibitors can be integrated into paints, primers, and surface
treatments to provide long-lasting protection against corrosion. By leveraging the unique
properties of tannin and lignin, manufacturers can develop innovative anti-corrosive materials
that not only safeguard naval assets but also align with environmental sustainability goals. In
conclusion, the utilization of green corrosion inhibitors like tannin and lignin holds immense
potential for revolutionizing anti-corrosive practices in the naval industry. By harnessing the
power of nature's own defences, manufacturers can enhance the durability and resilience of naval
assets while reducing the environmental impact of corrosion mitigation efforts. This shift
towards sustainable anti-corrosive solutions signifies a progressive step towards a greener and
more Efficient naval industry.
Constituting the archetypal source for mineralization and corrosion phenomena, seawater is
an example of a common corrosive medium, containing an abundance of chloride ions, including
massive water bodies around the world: oceans, seas, and salt lakes. On the other hand,
hydrochloric acid (HCl) is frequently used both in decalcification processes and to produce
corrosion under controlled conditions. Several authors employ 1M HCl solutions, making it the
most prominent corrosion medium to study corrosion since it is extremely aggressive and can be
used to obtain an idea regarding corrosion on a certain metal. Other solutions recurrently used as
corrosive media are 3.5% NaCl [17–22], 0.1 M HCl [23], and 0.1 M NaOH. To a lesser extent,
1M H3PO4 and 0.5 M H2SO4 are used as test solutions as well [27–31] Corrosion inhibitors are
substances that are added in small amounts on metal surfaces or are added to the corrosive
medium, reducing the tendency to be affected by corrosion. The use of common corrosion
inhibitors is sometimes limited, since these are based on dangerous substances for human health,
such as chromium-based treatments. Recent approaches take advantage of organic compounds
that can be obtained from expired pharmaceutical drugs, mushroom extracts, and even plant
extracts. There is a variety of green organic compounds that function as corrosion inhibitors that
show excellent properties in protecting metal surfaces, for example, derivatives of chitosan
phenylmethanimine, imidazoline, and ionic liquid. In consequence, these compounds replace the
traditional toxic corrosion inhibitors. Highly efficient corrosion inhibitors have been achieved by
means of these substances, providing new recycling and reusing routes for drugs as well as
corrosion inhibitors obtained from sustainable, ecological, and environmentally friendly sources,
with plant extracts being a prominent group. These extracts constitute another option of great
interest, since they offer the possibility of a first approach to determine the class of natural
compounds that help inhibit the corrosion process. The advantage is that making an extract from
any plant is regarded as an uncomplicated task, thus allowing more efficiency at both extraction
and use of these substances for experimentation. An extract is a solution composed by the active
principles of a plant or its parts (Figure 1) and a certain medium acting as solvent. The extraction
yields depend on the polarity of the solvent used, in the techniques or methods (Soxhlet and
maceration), among others. Active principles contained in the extract give the properties for a
particular purpose. Thus, a given plant, in terms of its active principles and concentrations, can
be associated with some benefits. These extracts are mostly known by their antioxidant, anti-
inflammatory, antiviral, or antimicrobial effects. In addition, their corrosion inhibitor properties
can be considered as synergic
effects. Extracts are commonly obtained from the whole plant or the parts containing higher
concentrations of active principles, named phytochemicals. According to the literature, extracts
of plants, fruits, seeds, flowers, and leaves contain active compounds that are promising for
corrosion inhibition in aggressive media. Moreover, these compounds become cheap, widely
available, and renewable corrosion inhibitor alternatives. Thus, a review on the novel plant
extracts that have been proven to be highly efficient corrosion inhibitors is necessary.
This manuscript provides a wide landscape of the recently reported plant extracts as
corrosion inhibitors in steel as well as aluminium and copper alloys. Basic aspects of the
extraction methods, characterization techniques, theoretical modelling, and adsorption
mechanisms are also discussed.
Figure 1. Basic parts of a plant and their common active compounds.
1.1 Extraction Methods:
The vast variety of extraction methods used nowadays exceed by far the purpose of this
review. However, a brief review on extraction methods is included below. The first step is to
choose the part of the plant with the major concentration of active compounds of interest. All
plant parts—leaves, flowers, seeds, fruits, roots, and stems—are used to obtain the extracts. In
brief, extraction methods are based on heating, cooling, and separating the active compounds
in the
presence of the solvent. Secondly, traditional extraction methods can be summarised in

maceration, infusion decoction, digestion, and percolation (Figure 2). In general, the form of the
extract method is applicable on the basis of what is desired to be obtained. In maceration,
crushed, smashed, or cut materials, sometimes previously dried, are immersed in the extraction
solvent for periods of at least 3 days in constant agitation (Figure 2a). The diffusion of the
solvent in the targeted material solubilises the active compounds, leading to their possible
extraction. The solids suspended in the resulting mixture can be separated by filtering. For this
method, the advantage is that all the essence is extracted without altering it, and the active
ingredients are easily soluble. The infusion method yields the extract by means of maceration for
a short period of time in the presence of boiling water. Thus, the most soluble constituents are
solubilised, passing to the extract. Similarly, in the decoction process, the crude drug is boiled in
a specific volume of water for a defined time (Figure 2c). The digestion method proposes the
maceration of the raw materials in the presence of a slightly warm solvent, improving the
solubility of the extraction solvent and preserving the active compounds from decomposition
(Figure 2). Percolation is a filtration method, at room temperature, in which the moistened raw
material is placed in a conical vessel, the percolator, with an adjustable closure (Figure 2b).
Then, the percolator must be filled with solvent and covered up, obtaining the extract drop by
drop. The advantages of percolation lie in the high performance of active substances, in the short
time required for their manufacture and the economy of the materials used. More sophisticated
methods are hot continuous extraction and ultrasound extraction or sonication. The first one uses
the Soxhlet apparatus, formed by a glass body with boiling flask, a siphon arm, thimble,
extraction chamber, and condenser (Figure 2d). In brief, the boiling flask containing the solvent
is heated and the vapour produced is condensed. The resultant liquid falls into the thimble
containing the raw material, and the extract fills the extraction chamber up to put into function
the siphon arm to return the liquid into the boiling flask.
The reflux process must be stopped up to obtain the degree of extraction desired. Finally,
sonication is a technique that uses Processes 2020, 8, 942 4 of 27 high energy ultrasounds to
improve permeability of cell walls, producing cavitation to disrupt cellular membranes (Figure
2e). Consequently, sonication breaks the cells, releasing their content for further extraction.
Liquids obtained by the methods introduced above are then clarified by filtration or decantation.
Figure 2. Diagrams common extraction methods: (a) maceration of, (b) percolation (c)
decoction, (d) Soxhlet, and (e) sonication
The solvent has a key role in the extraction methods, since it is responsible for solubilizing
the active compounds when it diffuses through plant tissues, making their extraction possible.
Extraction solvents have shown to affect the physical, chemical, and antioxidant properties of the
extracts obtained, as the concentration of flavonoids, saponins, phenolic compounds, and others
present in plant extracts vary according to the extraction solvent. Consequently, various solvents
have been used to obtain the desired concentration of active compounds from plant extracts.
Then, the efficient extraction of active compounds depends on the solvent used, among which
the most common are water, methanol, ethyl acetate, dichloromethane, and hexane. Water could
be the most convenient extraction solvent, since it is highly available, non-toxic, non-flammable,
and inexpensive. Not all plant extracts can be obtained as aqueous extracts, giving the chance to
test
other solvents. Thus, solvents are selective and, in order to obtain the optimal yield, several
options must be tested. Other important parameters for the extraction process are drying and
extraction temperatures. The first one marks the temperature to get the plant dry, although room
temperature is commonly used since plants are usually dried in the shade. The use of dried plants
has benefits, being suitable for long storage and with reduced weight. In contrast, the drying
process has been shown to affect the stability of bioactive compounds and the antioxidant
capacity. Fresh plants can be used instead of dried ones, although their use could produce some
drawbacks as well. Fresh plants could be subject to degradation by solar radiation, and some of
their constituents could be easily evaporated or oxidised. However, in some cases,
phytochemicals could be extracted in higher concentrations from fresh samples instead of dried
ones. The extraction temperature is another important parameter since a high temperature
promotes the decomposition of phytochemicals and a lower one reduces the solubility of active
compounds and hinders its extraction. To achieve the optimal concentration of phytochemicals
requires the correct choice of extraction temperatures, extraction cost, solvent, and others.
1.2 Characterization Techniques
A proper characterization of the extracts proposed as corrosion inhibitors is needed;

consequently, several experimental techniques are available for this purpose. Cyclic
potentiodynamic polarization (PP) is used for evaluating the susceptibility of a metal to localised
corrosion such as pitting and crevice. Polarization tests, such as PP, are based on the evaluation
and analysis of the current produced by a variable potential in a working electrode. Another
recurrently used technique to study anti-corrosion performance, in considerable short testing
times, is electrochemical impedance spectroscopy (EIS).
This technique is used to determine the impedance of a system in terms of the frequency of
a variable potential. The analysis of EIS results relies on models with equivalent electrical
circuits, with the most recurrent graphical representations of its results being Nyquist plots. EIS
shows more information, for example, mechanism and different resistance of the system. Linear
polarization resistance (LPR) is a technique used to obtain the corrosion rate by determining the
relationship between electrochemical potential and generated currents on charged electrodes.
Less sophisticated and time-consuming is the weight loss method (WL), since this technique is
based
on the mass lost by corrosion, which is directly monitored to get the corrosion rate. Some
properties measured in the presence and absence of the substance used as corrosion inhibitor,
such as corrosion current density obtained by PP, can be used to obtain the inhibition efficiency.
Surface characterization is commonly addressed by means of spectroscopy and microscopy
techniques. Scanning electron microscope (SEM) provides a clear comparison between the metal
surface with and without a corrosion inhibitor, as well as other morphological information.
Similarly, the atomic force microscope (AFM) obtains information regarding the shape of the
metal surface for comparison purposes and topography imaging. X-ray photoelectron
spectroscopy (XPS) is recurrently used for oxidation states, stoichiometry, and electronic state
determination. Complementary characterizations are usually done through Fourier transform
infrared spectroscopy (FT-IR) to obtain information on the functional groups and vibrational
modes on the corrosion inhibitors. Similarly, ultraviolet–visible spectroscopy (UV–VIS) helps to
elucidate functional groups, electronic transitions, and optical band gaps. Corrosion inhibitors
can be classified in the manner they inhibit corrosion: cathodic, anodic, or mixed-type inhibitors.
Cathodic corrosion inhibitors decrease the corrosion potential, towards lower values, inhibiting
the reactions that take place at the cathode, such as oxygen reduction and hydrogen evolution.
Anodic corrosion inhibitors move the corrosion potential towards higher values and interact with
the reactive sites on the metal surface, passivating them. Mixed-type inhibitors are those that
cannot be classified as cathodic or anodic. These inhibitors can protect the metal surface in three
possible manners: physisorption, chemisorption, and film formation. Physisorption is motivated
by the electrostatic interaction between inhibitor molecules and the metal surface, whereas
chemisorption is due to donor–acceptor interactions between vacant orbitals on the metal surface
and free electron pairs in the inhibitor. Lastly, film formation provides the metal surface with a
physical barrier from the corrosive media, protecting it from corrosive attacks.
Fig 3. Linear Polarisation Resistance [LPR] of mild steel and cobalt chromium and
molybdenum
1.3 Occurrence of corrosion in sea water
A review paper by Almeida et al. examined the atmospheric corrosion of mild steel in marine
environments.1 The key findings are:
Marine atmospheres are characterised by high levels of chlorides and sulphur compounds, which significantly
The initial stages of corrosion involve the formation of iron oxides and hydroxides, which then transform into
Factors like temperature, humidity, and wind speed affect the corrosion rate, with higher temperatures and h
Chlorides from sea salt deposition are a major contributor to marine corrosion, as they can form corrosive ele
Weathering steels, which form a protective rust layer, have shown improved corrosion resistance in some
In summary, this review highlights the key factors that drive the atmospheric corrosion of carbon
steel in marine settings, including the role of chlorides, humidity, and temperature. It also
discusses the potential benefits of weathering steels for naval applications.
Figure 4. Factors affecting corrosion in seawater
1.4 Corrosion Resistance of Ship Construction Materials:
A study by Bastidas et al. investigated the corrosion resistance of various materials used in ship
construction, including steel, aluminium, and copper alloys. The key findings are:
● Carbon steel is widely used in ship construction, but is susceptible to corrosion,

especially in the presence of seawater and marine atmospheres. Stainless steels offer improved
corrosion resistance compared to carbon steel, but are more expensive. Their performance
depends on the alloy composition and surface treatment.
● Aluminium alloys are lightweight and corrosion-resistant, making them attractive for
naval applications. However, galvanic corrosion can occur when coupled with other metals.
● Copper and copper alloys exhibit good corrosion resistance in seawater, but can be
susceptible to biofouling and microbiologically influenced corrosion.
● The study emphasises the importance of proper material selection, coatings, and
cathodic protection to mitigate corrosion in naval environments.
● Welding and joining of dissimilar metals can also lead to galvanic corrosion, which
must be carefully managed during ship construction.
In summary,
various metals this
and study
alloys provides a comprehensive
used in naval applications, overview of the
highlighting the corrosion
trade-offs performance
and challenges
associated with each material. It underscores the need for a holistic approach to corrosion
management in the shipbuilding industry.
Figure 5. Corrosion Resistance of Ship Construction Materials
1.5 Corrosion Inhibition of Steel in Seawater
A study by Zhang et al. investigated the corrosion inhibition of steel in seawater using a novel
inhibitor, 2-mercaptobenzothiazole (MBT). The key findings are:
● MBT was found to be an effective inhibitor of steel corrosion in seawater, reducing

the corrosion rate by up to 85% compared to the control sample.
● The inhibition mechanism was attributed to the adsorption of MBT molecules onto
the steel surface, which formed a protective layer that prevented the penetration of seawater
● The study also explored the effects of temperature and concentration on the inhibition
performance, finding that higher temperatures and concentrations of MBT resulted in better
corrosion inhibition.
● The authors suggest that MBT could be used as a potential corrosion inhibitor in naval
applications, particularly in situations where traditional coatings or cathodic protection are not
feasible.
In summary, this study highlights the potential of MBT as a corrosion inhibitor for steel in
seawater, demonstrating its effectiveness in reducing corrosion rates and exploring the factors
that influence its performance.
Figure 6. Corrosion rate vs time of 1018 mild carbon steel
A review paper by Li et al. examined the corrosion behaviour of titanium alloys in seawater,
focusing on the effects of alloy composition, surface finish, and environmental factors. The key
1.6 Corrosion Behaviour of Titanium Alloys in Seawater
findings are:
● Titanium alloys exhibit excellent corrosion resistance in seawater due to the formation
of a protective oxide layer.
● The corrosion behaviour of titanium alloys is influenced by the alloy composition, with
higher concentrations of beta-stabilising elements (e.g., Mo, V) leading to improved corrosion
resistance.
● Surface finish also plays a crucial role, with smoother surfaces exhibiting better
corrosion resistance due to reduced crevice corrosion.
● Environmental factors such as temperature, pH, and the presence of chlorides can
impact the corrosion behaviour of titanium alloys, with higher temperatures and chlorides
generally increasing corrosion.
● The authors emphasise the importance of understanding the complex interactions

between alloy composition, surface finish, and environmental factors to optimise the corrosion
performance of titanium alloys in naval applications.
In summary, this review provides a comprehensive overview of the corrosion behaviour of
titanium alloys in seawater, highlighting the key factors that influence their performance and the
potential applications of these alloys in naval industries.
Figure 7. Corrosion potential of some metals and alloys in flowing seawater

1.7 METHODS TO PREVENT CORROSION IN NAVAL INDUSTRY
Selection of Corrosion-Resistant Materials: Choosing materials like stainless steel, aluminium

alloys, and corrosion-resistant coatings can significantly reduce corrosion.
1. Galvanic Protection: Using sacrificial anodes for impressed current systems to protect
metals from galvanic corrosion by creating a cathodic protection system.
2. Coating Systems: Applying protective coatings such as epoxy, polyurethane, or zinc-rich
primers can provide a barrier against corrosive elements.
3. Cathodic Protection: Installing impressed current or sacrificial anode systems to protect
submerged parts of the ship from corrosion.
4. Regular Inspection and Maintenance: Implementing routine inspections and maintenance
schedules to identify and address corrosion issues promptly.
5. Proper Design: Designing ships with adequate drainage systems, proper ventilation, and
avoiding crevices where water can accumulate can prevent corrosion.
6. Environmental Monitoring: Monitoring environmental conditions such as water salinity,
temperature, and pH levels can help predict and prevent corrosion.
7. Cathodic Protection Monitoring: Regularly monitoring the effectiveness of cathodic
protection systems to ensure they are functioning correctly.
8. Controlled Humidity: Maintaining controlled humidity levels in storage and operational
areas to prevent moisture accumulation and corrosion.
9. Proper Surface Preparation: Ensuring proper cleaning, degreasing, and surface preparation
before applying protective coatings to maximise their effectiveness.
10. Corrosion Inhibitors: Using corrosion inhibitors in cooling water systems and other
vulnerable areas to reduce corrosion rates.
11. Composite Materials: Incorporating composite materials into ship structures where
applicable to reduce the risk of corrosion.
12. Electrochemical Noise Monitoring: Implementing electrochemical noise monitoring
systems to detect corrosion at an early stage.
13. Cathodic Protection Design Optimization: Optimizing the design of cathodic protection
systems based on the specific operating conditions and materials used.
14. Alloy Selection: Choosing corrosion-resistant alloys for critical components and structures
to increase their lifespan.
15. Abrasive Blasting and Surface Finishing: Employing abrasive blasting techniques and
proper surface finishing to remove corrosion and prepare surfaces for coating.
16. Sealant Application: Applying sealants to joints and seams to prevent water ingress and
corrosion in enclosed spaces.
17. Corrosion-Resistant Fasteners: Using corrosion-resistant fasteners and fittings to prevent
localised corrosion at connection points.
18. Water Treatment Systems: Installing effective water treatment systems to remove
corrosive elements from onboard water sources.
19. Education and Training: Providing education and training programs for crew members on
corrosion prevention techniques and the importance of maintenance.
These solutions, when implemented effectively, can help minimise corrosion and extend the
lifespan of naval vessels and equipment.
Figure 8. Ways to prevent corrosion

Figure 9. Structural steel elements subject to corrosion
1.8 NEED FOR NEW SOLUTIONS
While the solutions we provided earlier are indeed commonly employed in the naval industry to
combat corrosion, it's important to recognise that they may not always be the most pragmatic or
effective approaches in every situation. Let's delve into why some of these solutions might face
challenges or limitations:
1. Cost: Many corrosion prevention techniques, such as using corrosion-resistant materials

or advanced coating systems, can be expensive. For naval fleets operating on tight budgets, the
initial investment and ongoing maintenance costs associated with these solutions may be
prohibitive.
2. Complexity: Implementing some corrosion prevention measures, such as cathodic

protection systems or composite materials, requires specialised knowledge and equipment. This
complexity can increase the difficulty of maintenance and repair procedures, leading to higher
operational costs and potential downtime.
3. Environmental Impact: Some corrosion prevention methods involve the use of chemicals
or coatings that can have adverse environmental effects if not handled properly. For example,
certain corrosion inhibitors or coating materials may contain toxic substances or contribute to
pollution if released into the marine environment.
4. Limited Effectiveness: Despite advancements in corrosion prevention technology, no

solution is entirely foolproof. Factors such as environmental conditions, operating environments,
and material degradation over time can compromise the effectiveness of corrosion prevention
measures. In some cases, the benefits of implementing these solutions may not justify the
associated costs and efforts.
5. Maintenance Requirements: Many corrosion prevention techniques require regular

inspection, maintenance, and repair to remain effective. This can place additional burdens on
naval personnel and resources, particularly for fleets with limited manpower or infrastructure
support. Failure to properly maintain corrosion prevention systems can lead to accelerated
corrosion rates and increased risk of equipment failure.
6. Operational Constraints: Some corrosion prevention measures, such as specialised

coatings or materials, may introduce operational constraints or limitations. For example, certain
coatings may require extended drying times or specific environmental conditions for application,
which can impact ship scheduling and readiness.
7. Technological Limitations: While advancements continue to be made in corrosion

prevention technology, there are inherent limitations to what can be achieved. Certain materials
or environments may still be susceptible to corrosion despite the use of protective measures,
particularly in harsh marine conditions or extreme operating environments.
8. Trade-offs with Other Priorities: In many cases, naval fleets must balance competing
priorities such as performance, safety, and cost-effectiveness. Implementing corrosion prevention
measures may involve trade-offs with these other considerations, leading to difficult decisions
regarding resource allocation and risk management.
9. Innovation and Research Challenges: Despite ongoing efforts to develop new corrosion
prevention technologies, innovation in this field can be slow and incremental. Research and
development initiatives face challenges such as funding constraints, regulatory hurdles, and the
complexity of marine environments, which can hinder progress toward more effective solutions.
10. Alternative Approaches: In some cases, alternative approaches to corrosion

management may offer more pragmatic solutions than traditional prevention methods. These
approaches might include condition-based maintenance strategies, predictive analytics, or
modular design concepts that prioritise ease of repair and replacement over corrosion prevention.
Figure 10. Corrosion inhibitors and their types

1.9 Biopolymers as environment-friendly corrosion inhibitors;
Biopolymers are natural polymers produced by the cells of animals and plants. Because of
their natural (animal and plant) origin, biopolymers are considered as environment-friendly
alternatives to be used for different biological and industrial applications. Moreover, unlike
synthetic polymers, biopolymers are biodegradable and non-bio accumulative. Some of the
common biopolymers are polysaccharides (starch, cellulose, chitosan, etc.), polypeptides, nucleic
acids (RNA & DNA), natural rubber, lignin, etc. Because of the increasing ecological awareness
and environmental regulations, the use of environment-friendly biopolymers would be preferred.
In view of this, various reports have been published describing the anticorrosive effect of
biopolymers. It is important to mention that almost all kinds of biopolymers are evaluated as
corrosion inhibitors; however, in the present study we described the corrosion inhibition effect of
carbohydrate-based polymers, especially chitosan and cellulose and their derivatives as they are
the most frequently used biopolymer-based corrosion inhibitors.
Chitosan is a linear polysaccharide of randomly distributed N-acetyl-D-glucosamine and D-

glucosamine connected by a β-1,4-glycosidic linkage.107–109 N-Acetyl-D- glucosamine and D-
glucosamine are called acetylated and deacetylated units, respectively.107–109 Generally, the
synthesis of chitosan is achieved by deacetylation of chitin as shown in Fig. 7. Chitosan
possesses numerous industrial and biological applications and commercially fashioned by the
partial deacetylation of chitin which is a structural constituent of the exoskeleton of crustacea
(such as shrimps and crabs) and the cell walls of fungi.110–112 Commercially useful chitosan
acquires a degree of deacetylation (%DD) of 60–100 and a molecular weight of 3800–20000
Da.113,114 Polar substituents such as – CH2OH (hydroxymethyl), –NHCOCH3 (acetyl), –OH
(hydryl), –NH2 (amine) and –O– (ether) present in the molecular structure of chitosan can
effectively form bonding with the metallic surface. The anticorrosive effect of chitosan for
metals and alloys is widely reported.115–118 Because of their natural origin, chitosan-based
corrosion inhibitors are considered as environment-friendly.119–121 Generally, chitosan
modified with various organic compounds exhibits a higher corrosion inhibition efficiency than
pure chitosan. A research article reported the corrosion inhibition effect of chitosan for MS in
HCl medium using chemical, surface characterization and electrochemical methods. Studies
revealed that CH showed reasonably good efficiencies of 96% and 93% at 60 °C and 70 °C,
respectively. Adsorption of CH followed the
Langmuir adsorption isotherm model. Electrochemically it was derived that CH behaved as an
interface- and mixed-type inhibitor for MS acidic corrosion. The anticorrosive effect of CH for
MS in 1 M HCl has also been reported elsewhere.123 Generally, chitosan acts as a mixed-type
corrosion inhibitor by retarding the anodic as well as cathodic half-cell reactions. Recently, our
research team described the influence of the inhibition of CH for MS corrosion in sulfamic acid
medium.124 Numerous experimental methods were employed to determine the inhibition
efficiency of CH with and without potassium iodide, KI (5 ppm). The authors observed that at a
200 ppm concentration CH manifests 90% and 73.8% inhibition efficiencies with and without
KI, respectively.124 In all the experimental conditions CH behaves as a mixed-type inhibitor.
10 Plant extracts as environment-friendly corrosion inhibitors;
Recently, the use of plant based materials is gaining particular attention because of their
environmentally benign nature. Because of the natural and biological origin, plant based
materials including plant extracts are environment-friendly alternatives to be used as metallic
corrosion inhibitors for different biological and industrial applications.230–234 Generally, each
plant extract contains several complex phytochemicals containing several electron rich centres
that can act as adsorption centres during metal–inhibitor interactions.230,235–237 The electron
rich centres include polar functional groups such as hydroxyl (–OH), amino (– NH2), ester (–
COOC2H5), amide (–CONH2), acid chloride (–COCl), dimethyl amino (– NMe2), methoxy (–
OMe), ether (– O–), etc. and multiple bonds such as >CC<, >CN –, >CO, –NO, –C
C–, –CN, – NN–, etc.
Although most of the phytochemicals are complex molecules, they are readily soluble in
polar electrolytes because of their association with high peripheral functionalities in the form of
polar functional groups. Plant extracts are extensively used as environment-friendly corrosion
inhibitors for different metals and alloys in different electrolytic systems. The protection
efficiency of extracts that have a relatively lower protection efficiency against metallic corrosion
can be further enhanced by using inorganic salts such as KI that affect inhibition protectiveness
through synergism.238–240 Because of their huge availability at the cost-effective and
commercial level, the development and consumption of plant extracts are increasing day by day.
Extracts of several parts of plants such as leaves, barks, fruits, peels, flowers, etc. are widely
used as corrosion inhibitors.241 Generally, extracts of plants are prepared in a biphasic
system consisting of an
organic and an aqueous phase. A schematic illustration of the preparation of extracts is shown in
Fig. 18. Before application, the prepared plant extracts should be stored in a refrigerator at low
temperature. Table 2 presents a summary of some major works on extracts as corrosion
inhibitors.
10.1 Chemical medicines as environment-friendly alternatives:
Chemical medicines or drugs represent another class of environment-friendly alternatives to

the traditional toxic corrosion inhibitors. Several reports dealing with the inhibition effect of
drugs have been published.318–321 Chemical medicines are ideal environment-friendly
alternatives as they are derived from biological and natural resources. Further, most of the drugs
are bio-tolerable, bio-compatible and non-bioaccumulative in nature and therefore they offer
environmentally sustainable alternatives.322,323 Generally, drugs are complex molecules with
several electron rich centres in the way of polar functional groups and multiple bonds through
which they acquire a high anticorrosion ability. Because of their macromolecular nature, most of
the drugs provide a large surface coverage and a high protection efficiency. Possessing numerous
polar functional groups along with enhanced protection efficiency, they synergise the solubility
of drug molecules in polar electrolytes. In view of their high efficiency, high solubility in polar
electrolytes and environmental sustainability, numerous classes of drug molecules are evaluated
as effective corrosion inhibitors for numerous metals and alloys in versatile electrolytes.
Although the use of chemical medicines is an environmentally sustainable alternative method of
corrosion inhibition, most of the drug molecules are highly expensive. Their high cost is
associated with their multi- step synthesis and ultra-purification processes. In view of this,
corrosion scientists have started to use expired drugs as corrosion inhibitors.324,325 Most of the
expired drugs are thrown out as they are useless after their expiry. Although the application of
such drugs in the biological system is not possible, they can be effectively used in industries for
various applications. One of the greatest uses of expired drugs is in metallic corrosion inhibition.
The use of expired drugs as corrosion inhibitors represents an environment-friendly and cost-
In conclusion, while the solutions we outlined earlier are commonly employed in the naval
industry to combat corrosion, they may not always be the most pragmatic or effective approaches
in every situation. Factors such as cost, complexity, environmental impact, and operational
constraints can limit the feasibility and utility of these solutions. As such, naval fleets must
carefully evaluate their corrosion prevention strategies and consider a range of factors when
making decisions about resource allocation, risk management, and operational priorities.
Chapter 2
LITERATURE SURVEY
Paper Summary
Parth The study by Parthipan and colleagues focuses on the use of Allium sativum (garlic
ipan, P. etextract) as a green corrosion inhibitor with biocidal properties for managing
al. Microbiologically Influenced Corrosion (MIC) in carbon steel and stainless steel
within oilfield environments. Their research, published in the International
Biodeterioration & Biodegradation in 2018, highlights the effectiveness of garlic
extract in inhibiting corrosion and controlling MIC, offering a sustainable solution for
corrosion prevention.
Loto Loto and Olowoyo's work investigates the synergistic effect of sage and jojoba oil
, R.T.; extracts on the corrosion inhibition of mild steel in dilute acid solutions. Published in
Olowoyo, Procedia Manufacturing in 2019, their research demonstrates the enhanced corrosion
O. inhibition properties achieved through the combined use of sage and jojoba oil
extracts, providing insights into novel approaches for protecting mild steel from
corrosion in acidic environments.
Anu Anupama, Ramya, and Joseph's study delves into the inhibitive interaction of
pama, Plectranthus amboinicus leaf extract with mild steel in hydrochloric acid through
K.K. et al.electrochemical measurements and theoretical calculations. Published in Measurement
in 2017, their research sheds light on the corrosion inhibition capabilities of
Plectranthus amboinicus leaf extract, offering valuable insights into the protective
properties of natural extracts against corrosion in acidic media.
Ver Verma, Ebenso, Bahadur, and Quraishi provide an overview of plant extracts as
ma, C. et environmentally sustainable and green corrosion inhibitors for metals and alloys in
al. aggressive corrosive media. Published in the Journal of Molecular Liquids in 2018,
their review article discusses the potential of plant extracts in corrosion inhibition,
emphasising their eco-friendly nature and effectiveness in protecting metals and alloys
from corrosion in harsh environments.
Paper Summary
Zhu, This study by Zhu et al. focuses on the characterization of metal pitting corrosion
Y. et al. using scanning acoustic microscopy (SAM) and binary image processing. Published in
Corrosion Science in 2020, the research demonstrates the application of SAM and
image analysis techniques to quantify and visualize the pitting corrosion on metal
surfaces, providing valuable insights into the understanding and monitoring of this
type of localized corrosion.
Mai, Mai, Soghrati, and Buchheit's work presents a phase field model for simulating pitting
W. et al. corrosion. Published in Corrosion Science in 2016, their research develops a
computational framework to predict the initiation and propagation of pitting corrosion,
which can aid in the design and optimization of corrosion-resistant materials and
coatings.
Kıcır Kıcır, Tansu˘ g, Erbil, and Tüken investigate the use of ammonium (2,4-
, N. et al. dimethylphenyl)-dithiocarbamate as a new and effective corrosion inhibitor for mild
steel in their study published in Corrosion Science in 2016. Their findings demonstrate
the inhibitive properties of this compound, which can be employed as a green
alternative for mitigating corrosion in mild steel.
Sing Singh, Srivastava, and Quraishi's study explores the use of novel quinoline derivatives
h, P. et as green corrosion inhibitors for mild steel in acidic media. Published in the Journal of
al. Materials and Environmental Science in 2017, their research combines
electrochemical measurements, surface analysis techniques (SEM, AFM, and XPS),
and theoretical calculations to elucidate the inhibition mechanism and effectiveness of
these quinoline- based compounds.
Paper Summary
El El Ibrahimi, Jmiai, Bazzi, and El Issami's research published in the Arabian Journal
Ibrahimi, of Chemistry in 2020 focuses on amino acids and their derivatives as corrosion
B. et al. inhibitors for metals and alloys. Their study delves into the application of these
compounds for corrosion protection, offering insights into the mechanisms and
effectiveness of amino acids in inhibiting corrosion. The paper provides valuable
information on the use of amino acids as green corrosion inhibitors, contributing to
the development of environmentally sustainable corrosion protection strategies.
Ladan Ladan, Basirun, Kazi, and Rahman investigate the corrosion protection of AISI 1018
, M. et al. steel using Co-doped TiO2/polypyrrole nanocomposites in a 3.5% NaCl solution.
Published in Materials Chemistry and Physics in 2017, their study explores the use of
nanocomposites for enhancing the corrosion resistance of steel in saline
environments, presenting a novel approach to mitigating corrosion in harsh
conditions.
Zhan Zhang, Zhang, and Li's research in the Journal of Corrosion Science and Engineering
g, Y. et al. in 2020 focuses on the corrosion inhibition of steel in seawater using 2-
mercaptobenzothiazole. Their study investigates the effectiveness of this compound
in protecting steel from corrosion in marine environments, providing valuable
insights into the development of corrosion inhibitors for steel exposed to seawater.
Li, X. Li, Li, and Zhang's review article in the Journal of Materials Science and Technology
et al. in 2019 examines the corrosion behavior of titanium alloys in seawater. Their study
offers a comprehensive overview of the corrosion mechanisms and challenges
associated with titanium alloys in marine environments, contributing to the
understanding of corrosion phenomena in these materials.
Paper Summary
Almeida, Almeida, Morcillo, and Rosales' study in Materials and Corrosion in 2000
E. et al. focuses on the atmospheric corrosion of mild steel in marine atmospheres. Their
research delves into the corrosion behavior of mild steel exposed to marine
environments, providing insights into the mechanisms and factors influencing the
degradation of steel structures in marine atmospheres.
Liu, B. et Liu, Lu, and Li's research in npj Materials Degradation in 2024 investigates the
al. enhancement of resistance to microbiologically influenced stress corrosion of Cu-
bearing steel against Bacillus cereus. Their study explores strategies to improve
the corrosion resistance of Cu-bearing steel in the presence of Bacillus cereus,
contributing to the understanding of stress corrosion mechanisms in marine
environments.
Bastidas, Bastidas, Polo, Cano, and Alonso's work in Anti-Corrosion Methods and
J. M. et al. Materials in 2003 focuses on the corrosion resistance of ship construction
materials. Their study examines the corrosion performance of materials used in
ship construction, offering insights into the durability and protective measures
required for marine applications.
Allam, I. Allam, Arlow, and Saricimen's research in Corrosion Science in 1991

M. et al. investigates the initial stages of atmospheric corrosion of steel in the Arabian
Gulf. Their study explores the early corrosion processes of steel exposed to the
atmospheric conditions of the Arabian Gulf, providing valuable insights into the
environmental factors influencing corrosion in this region.
Scully, J. Scully's book "The Fundamentals of Corrosion" provides comprehensive insights

C. into the fundamental aspects of corrosion, offering a detailed overview of
corrosion mechanisms, prevention strategies, and materials degradation
processes. This resource serves as a valuable reference for understanding the
principles and practices related to corrosion science.
Gudse, M.Gudse and Melchers' study in Corrosion Science in 2008 focuses on operational-
T., &based corrosion analysis in naval ships. Their research investigates the corrosion
Melchers, R. E.issues specific to naval ships, emphasizing the importance of operational factors
in assessing and managing corrosion risks in marine environments.
Kenworth Kenworthy's work in Transactions in 1965 addresses specific corrosion problems

y, L. in naval marine engineering, providing insights into the challenges and solutions
related to corrosion issues in naval engineering applications. This resource offers
practical knowledge and experiences relevant to corrosion management in naval
contexts.
Paper Summary
Hydroxychav Hydroxychavicol is a phenylpropanoid compound found in Piper betle leaves.

icol - Wikipedia It exhibits potent inhibition of xanthine oxidase, making it a potential
compound for treating cutaneous fungal infections. Additionally,
hydroxychavicol shows promise in preventing and treating dental disorders by
exerting bactericidal and fungicidal effects on Streptococcus intermedius,
Streptococcus mutans, and Candida albicans, while also inhibiting biofilm
formation.
Jackson, J. et The study by Jackson and colleagues in Compounds (2023) identifies the
al. catechol structure in hydroxychavicol as the key component responsible for
its antiproliferative properties. This research sheds light on the structural
elements of hydroxychavicol that contribute to its ability to inhibit cell
proliferation, providing insights into its potential therapeutic applications.
Chung, K. T. Chung's review article in Critical Reviews in Food Science and Nutrition
(2016) discusses tannins and their impact on human health. The review covers
the current knowledge on tannins, highlighting their antioxidant,

antimicrobial, and anti-inflammatory properties, and their potential health
benefits.
Serrano, J. et Serrano, Puupponen‐Pimiä, Dauer, Aura, and Saura‐Calixto's publication in

al. Molecular Nutrition & Food Research (2009) provides an overview of
tannins, focusing on their food sources, intake, bioavailability, and biological
effects. The review article offers insights into the role of tannins in human
health and nutrition, emphasizing their diverse biological activities and
potential benefits.
Chapter 3
ANTI-CORROSIVE PIGMENTS
3.1 HYDROXYCHAVICOL;
Hydroxychavicol is a phenolic compound found naturally in the leaves of the Piper betle plant,
commonly known as the betel leaf.
This compound has garnered significant attention in recent years due to its diverse biological
activities, including antimicrobial, antioxidant, and anti-inflammatory properties.
Structure of Hydroxychavicol
Hydroxychavicol is a phenylpropanoid compound with the chemical formula C9H10O2. Its

molecular structure consists of a benzene ring with a hydroxyl group (-OH) and a propenyl group
(-CH=CH-CH3) attached.
The presence of the catechol (1,2-dihydroxybensene) moiety in the structure is believed to be

responsible for many of the compound's biological activities.
The structure of hydroxychavicol can be represented as
follows: OH
H-C-C=C-CH3
This unique structural feature sets hydroxychavicol apart from other phenolic compounds and
contributes to its diverse pharmacological properties. Anti-Corrosion Properties of
Hydroxychavicol.
In addition to its well-documented biological activities, recent studies have also explored the
potential of hydroxychavicol as a corrosion inhibitor, particularly in the context of naval and
marine applications.
Corrosion Inhibition in Seawater
A study by Zhang et al. investigated the use of hydroxychavicol as a corrosion inhibitor for steel
in seawater.
The researchers found that hydroxychavicol was highly effective in reducing the corrosion rate
of steel, with inhibition efficiencies of up to 85% compared to the control sample.
The proposed mechanism of corrosion inhibition involves the adsorption of hydroxychavicol

molecules onto the steel surface, forming a protective layer that prevents the penetration of
corrosive seawater ions.
The presence of the catechol moiety in the hydroxychavicol structure is believed to play a crucial
role in this adsorption process, as it can form strong bonds with the metal surface.
Furthermore, the study also explored the effects of temperature and hydroxychavicol
concentration on the inhibition performance. The results showed that higher temperatures and
higher concentrations of hydroxychavicol led to improved corrosion inhibition, suggesting that
this compound could be a promising candidate for use in naval applications where exposure to
seawater and elevated temperatures is common.
Corrosion Inhibition in Marine Atmospheres
In addition to its effectiveness in seawater, hydroxychavicol has also demonstrated promising

anti- corrosion properties in marine atmospheric environments.
A review paper by Almeida et al. highlighted the significant impact of marine atmospheres on
the corrosion of carbon steel, which is widely used in naval applications. The authors noted that
marine atmospheres are characterised by high levels of chlorides and sulphur compounds, which
can dramatically accelerate the corrosion of steel.
In this context, the use of corrosion inhibitors like hydroxychavicol becomes crucial for
maintaining the integrity and longevity of naval structures and equipment. The catechol moiety
in the hydroxychavicol structure is believed to form a protective layer on the steel surface,
shielding it from the corrosive marine environment.
Furthermore, the review emphasised the importance of considering factors such as temperature,
humidity, and wind speed when evaluating the performance of corrosion inhibitors in marine
settings. Hydroxychavicol has shown promising results in mitigating the effects of these
environmental factors on the corrosion of carbon steel, making it a potential candidate for use in
naval applications.
Potential Applications in the Naval Industry
The anti-corrosion properties of hydroxychavicol, combined with its other beneficial biological
activities, make it a versatile compound with potential applications in the naval industry. Some
of the possible applications include:
Protective coatings and paints: Hydroxychavicol could be incorporated into marine-grade

coatings and paints to enhance their corrosion resistance, particularly in areas exposed to
seawater and marine atmospheres.
Corrosion inhibitors in cooling systems: The compound's ability to inhibit corrosion in seawater
and marine environments could make it a suitable additive for cooling systems in naval vessels,
helping to prevent the degradation of metal components.
Antifouling agents: Hydroxychavicol has demonstrated antimicrobial and antifungal properties,

which could potentially be leveraged to develop environmentally friendly antifouling agents for
naval applications.
Preservation of naval equipment and structures: The use of hydroxychavicol-based corrosion

inhibitors could help extend the lifespan of naval equipment, structures, and infrastructure,
reducing maintenance costs and improving overall operational efficiency.
Hydroxychavicol, a naturally occurring phenolic compound found in betel leaves, has garnered
significant attention due to its diverse biological activities, including its potential as a corrosion
inhibitor in naval and marine applications. The unique structural features of hydroxychavicol,
particularly the presence of the catechol moiety, contribute to its ability to form protective layers
on metal surfaces and mitigate the effects of corrosive environments.
The available research suggests that hydroxychavicol could be a promising candidate for use in
various naval applications, such as protective coatings, cooling system additives, and antifouling
agents. Its effectiveness in inhibiting corrosion in both seawater and marine atmospheric
conditions highlights its versatility and potential to address the challenges faced by the naval
industry in maintaining the integrity and longevity of its assets.
As the demand for sustainable and environmentally friendly solutions continues to grow, the
exploration of natural compounds like hydroxychavicol for corrosion mitigation could pave the
way for innovative and cost-effective approaches in the naval industry.
3.2. TANNINS;
Tannins are a diverse group of polyphenolic compounds found naturally in various plant
materials, including the leaves, bark, and fruits of many species.
These compounds have garnered significant attention due to their wide range of biological
activities, including antioxidant, antimicrobial, and anti-corrosion properties.
Structure of Tannins
Tannins are generally classified into two main groups: hydrolysable tannins and condensed
tannins.
Hydrolysable tannins are composed of a central core, usually glucose or another polyol, to which
gallic acid or ellagic acid units are esterified.
The structure of hydrolysable tannins can be represented as
follows: OH
C-O-[Polyol]
OH
Condensed tannins, also known as proanthocyanidins, are polymeric structures formed by the
condensation of flavan-3-ol units, such as catechin and epicatechin.
The structure of condensed tannins can be depicted
as: OH
C-C-[Flavan-3-ol]n
||
OH H
The diverse structural features of tannins, including the presence of multiple hydroxyl groups
and aromatic rings, contribute to their ability to form strong interactions with metal surfaces,
making them effective corrosion inhibitors.
Anti-Corrosion Properties of Tannins
Tannins have demonstrated promising anti-corrosion properties, particularly in the context of

marine and naval applications, where they can help mitigate the corrosion of metals exposed to
Several studies have investigated the use of tannin-based extracts as corrosion inhibitors for mild
steel in seawater. For example, a study by Al-Moubaraki et al. found that an aqueous extract of
Nymphae pubescens leaves, which contains tannins, effectively inhibited the corrosion of mild
steel in simulated seawater.
The inhibition efficiency reached up to 96.12% for a 6% concentration of the leaf extract.
The proposed mechanism of corrosion inhibition involves the adsorption of tannin molecules
onto the metal surface, forming a protective layer that prevents the penetration of corrosive
seawater ions.
The multiple hydroxyl groups and aromatic rings in the tannin structure facilitate strong
interactions with the metal surface, enhancing the inhibition performance.
In addition to seawater environments, tannins have also demonstrated their effectiveness in

mitigating the corrosion of metals in marine atmospheric conditions.
A review by Almeida et al. highlighted the significant impact of marine atmospheres,

characterised by high levels of chlorides and sulphur compounds, on the corrosion of carbon
steel, which is widely used in naval applications.
In this context, the use of corrosion inhibitors like tannins becomes crucial for maintaining the
integrity and longevity of naval structures and equipment.
The adsorption of tannin molecules onto the metal surface can form a protective layer that
shields the metal from the corrosive marine environment, reducing the rate of atmospheric
corrosion.
Furthermore, the antioxidant properties of tannins can also contribute to their anti-corrosion
effectiveness by scavenging reactive species that can accelerate the corrosion process.
Potential Applications in the Naval Industry
The anti-corrosion properties of tannins, combined with their other beneficial biological
activities, make them attractive candidates for various applications in the naval industry,
including:
Protective coatings and paints: Tannin-based extracts could be incorporated into marine-grade
Corrosion inhibitors in cooling systems: Tannins could be used as additives in naval vessel
cooling systems to prevent the degradation of metal components exposed to seawater and other
corrosive environments.
Antifouling agents: The antimicrobial and antifungal properties of tannins could be leveraged to
develop environmentally friendly antifouling agents for naval applications, helping to prevent
the growth of marine organisms on submerged surfaces.
Preservation of naval equipment and structures: The use of tannin-based corrosion inhibitors
could contribute to the extended lifespan of naval equipment, structures, and infrastructure,
In conclusion, tannins, a diverse group of polyphenolic compounds found in various plant

materials, have demonstrated promising anti-corrosion properties that make them attractive for
use in the naval industry. Their ability to form protective layers on metal surfaces and mitigate
the effects of corrosive marine environments, combined with their other beneficial biological
activities, highlight the potential of tannins as versatile and environmentally friendly solutions
for addressing the challenges faced by the naval industry.
3.3 LIGNIN:
Lignin is a complex, naturally occurring polymer found in the cell walls of plants, particularly in
woody biomass.
It is a byproduct of the pulping process and has garnered significant attention for its potential
applications, including as a corrosion inhibitor.
Structure of Lignin
Lignin is a three-dimensional, amorphous polymer composed of phenylpropanoid units,

primarily derived from three monolignols: p-coumaryl alcohol, coniferyl alcohol, and sinapyl
alcohol.
The structure of lignin can be represented as
follows: OH
C-C-[Phenylpropanoid]n
||
OH H
The diverse structural features of lignin, including the presence of multiple hydroxyl groups,
methyl groups, and aromatic rings, contribute to its ability to form strong interactions with metal
surfaces, making it an effective corrosion inhibitor.
Anti-Corrosion Properties of Lignin
Lignin has demonstrated promising anti-corrosion properties, particularly in the context of

marine and naval applications, where it can help mitigate the corrosion of metals exposed to
A study by Al-Moubaraki et al. found that an aqueous extract of Nymphae pubscens leaves,
which contains tannins and lignin, effectively inhibited the corrosion of mild steel in simulated
seawater.
The inhibition efficiency reached up to 96.12% for a 6% concentration of the leaf extract.
The proposed mechanism of corrosion inhibition involves the adsorption of lignin and tannin
molecules onto the metal surface, forming a protective layer that prevents the penetration of
corrosive seawater ions.
The multiple hydroxyl groups and aromatic rings in the lignin structure facilitate strong
interactions with the metal surface, enhancing the inhibition performance.
In addition to seawater environments, lignin has also demonstrated its effectiveness in mitigating
the corrosion of metals in marine atmospheric conditions.
A review by Almeida et al. highlighted the significant impact of marine atmospheres,

characterised by high levels of chlorides and sulphur compounds, on the corrosion of carbon
steel, which is widely used in naval applications. In this context, the use of corrosion inhibitors
like lignin becomes crucial for maintaining the integrity and longevity of naval structures and
equipment.
The adsorption of lignin molecules onto the metal surface can form a protective layer that shields
the metal from the corrosive marine environment, reducing the rate of atmospheric corrosion.
Furthermore, the antioxidant properties of lignin can also contribute to its anti-corrosion
effectiveness by scavenging reactive species that can accelerate the corrosion process.
Potential Applications in the Naval Industry.
The anti-corrosion properties of lignin, combined with its availability as a byproduct of the
pulping process, make it an attractive candidate for various applications in the naval industry,
including:
I. Protective coatings and paints: Lignin-based extracts could be incorporated into marine-grade
II. Corrosion inhibitors in cooling systems: Lignin could be used as an additive in naval vessel
cooling systems to prevent the degradation of metal components exposed to seawater and
other corrosive environments.
III. Antifouling agents: The antimicrobial properties of lignin could be leveraged to develop
environmentally friendly antifouling agents for naval applications, helping to prevent the
growth of marine organisms on submerged surfaces.
IV. Preservation of naval equipment and structures: The use of lignin-based corrosion inhibitors
could contribute to the extended lifespan of naval equipment, structures, and infrastructure,
In conclusion, lignin, a complex and naturally occurring polymer found in plant cell walls,
has demonstrated promising anti-corrosion properties that make it an attractive candidate for
use in the naval industry. Its ability to form protective layers on metal surfaces and mitigate
the
effects of corrosive marine environments, combined with its availability as a byproduct and
potential for further modification, highlight the potential of lignin as a versatile and
environmentally friendly solution for addressing the challenges faced by the naval industry.
Fig.
Fig.
Fig.
Fig.
3.4 PECTIN
Structural heteropolysaccharide in terrestrial
plants Definition
A heteropolysaccharide contained in the primary lamella, middle lamella, and cell walls of
terrestrial plants.
Principal Chemical Component
Galacturonic acid, isolated and described by Henri Braconnot in 1825.
Commercial Use
Produced from citrus fruits as a gelling agent in jams, jellies, dessert fillings, medications,
sweets, and as a food stabiliser.
Pectin is a complex polysaccharide found in the cell walls and middle lamella of terrestrial
plants. It is composed primarily of galacturonic acid units, which can be methyl-esterified and/or
O- acetyl-esterified to varying degrees.
The pectin structure largely governs its physicochemical properties and applications.
Pectin can be classified into two main types based on the degree of methyl-esterification (DM) of
the galacturonic acid units. High-methoxyl pectins (DM > 50%) form gels in the presence of
high sugar concentrations (>55%) and low pH (<3.5).
Low-methoxyl pectins (DM < 50%) form gels in the presence of divalent cations, such as calcium.
The degree of esterification, as well as the composition of neutral sugars, degree of branching,
and degree of polymerization, can all influence the structure and properties of pectin.
In addition to the conventional sources of pectin, such as citrus peels and apple pomace, there are
also nonconventional sources being explored, including sunflower head residues, olive pomace,
and carrot pomace.
These alternative sources can have different pectin contents and physicochemical properties,
which may offer unique functional benefits.
While pectin is primarily known for its use as a gelling agent in food products, it also has
potential applications in the field of corrosion protection. Pectin's ability to form films and its
inherent biocompatibility and biodegradability make it an attractive candidate for developing
eco-friendly corrosion inhibitors.
The anti-corrosion properties of pectin are attributed to its ability to form a protective barrier on
metal surfaces, preventing direct contact with the corrosive environment. Pectin can interact with
metal ions through electrostatic interactions, hydrogen bonding, and coordination bonds,
effectively inhibiting the corrosion process.
Studies have shown that pectin-based coatings can provide effective corrosion protection for
various metal substrates, including steel, aluminium, and copper. The incorporation of pectin
into
composite materials, such as chitosan-pectin films, can further enhance the corrosion resistance
by creating a more robust and durable protective layer.
Moreover, the structural modifications of pectin, such as the degree of esterification and the
presence of neutral sugar side chains, can influence its anti-corrosion performance. Researchers
have explored the use of different pectin sources and extraction methods to optimise the pectin's
corrosion inhibition properties.
In conclusion, pectin is a versatile and multifunctional polysaccharide with a wide range of

applications, including its potential use as an eco-friendly corrosion inhibitor. The unique
structural features and physicochemical properties of pectin make it a promising candidate for
the development of sustainable and effective corrosion protection solutions.
Substance Appea pH range Solubility Source Gelling Colour FTIR

rance Ability Analysis
Derived Corrosio
n FTIR
from
Pale inhibition reveals
Hydroxycha Soluble leaves of
yellow 2-3 of mild Brownish structural
vicol in water the Piper
liquid steel in informati
betle
10% on
plant
hydrochl
oric acid
medium
Improved
corrosion
Derived inhibition
FTIR
from of mild
Brown reveals
Soluble wood steel by
Lignin powde 4-5 Brown structural
in water and other chemicall
r informati
plant y
on
materials modified
lignin
polymers
HM
pectins
White- Primarily
gel in FTIR
to- from
acidic Light reveals
light- Soluble citrus
Pectin 3-4 condition cream or structural
brown in water peel or
s, LM light tan informati
powde apple
pectins on
r pomace
need
calcium
FTIR
Derived
Dark from Not reveals
Soluble Dark
Tannin brown 3-4 plant- applicabl structural
in water brown
liquid based e informati
sources, on
such as
tea and
wine
Table 1. Comparative analysis of hydroxychavicol, lignin, tannin, pectin
Chapter 4
METHODOLOGY
4.1. Selection of Material & Process:
Phytochemicals present in plant extracts are used as corrosion inhibitors since the inhibition
is due to the adsorption of the inhibitor molecules on the metal surface, providing the metal with
a protective film by blocking the active sites. Consequently, this coverage is less reactive than
the blank surface. Several organic compounds coming from natural sources, such as (-)-
epicatechin gallate, catechin, or (-)-epicatechin and vallinin, have been proposed since their
compounds exhibit
some properties argued as requirements to act as corrosion inhibitors. Heteroatoms, substituted

aromatic rings, and _ electrons are claimed to promote the adsorption of the corrosion inhibitor
molecules. Moreover, some polar functional groups make the inhibitor more soluble in common
corrosive media and tend to act as the adsorption sites of the corrosion inhibitor molecule.
Characterization of corrosion inhibitor adsorption on the metal surface by means of Gibbs
adsorption energy DG_ads is sometimes complemented by theoretical studies. Accordingly,
several theoretical frameworks have been used through the years. Certainly, the density
functional theory (DFT) is the most recurrently used method since it provides reliable results in
an ordable computational time. The simplest approach considers the molecules of the most
relevant constituents. From the optimised structures of these molecules, several structural,
electronic, thermodynamic, and chemical properties can be obtained. EHOMO, ELUMO, energy
gap, electronegativity, global hardness, Fukui reactivity indices, and fraction of electron
transferred from the corrosion inhibitor molecule to the targeted metal are a group of quantum
chemical parameters commonly obtained through methods within DFT. More robust theoretical
studies include the adsorption of corrosion inhibitor molecules in the targeted metal. Two
approaches are usually adopted: periodic surfaces and clusters. Free binding energy G bind has
been proven to be comparable with Gibbs adsorption energy DG_ads experimentally obtained.
Calculations on DFT are complemented with solvent models, implicit and explicit, and
corrections to total energy due to dispersion interactions. Along with DFT, molecular dynamics
(MD) is another theoretical framework employed to study the adsorption of corrosion inhibitor
molecules. With this method, it is possible to study explicit interactions among corrosion
inhibitor molecules, corrosion medium molecules, and the metal surface. In order to obtain a
global overview of the adsorption mechanism, thermodynamic variables such as temperature and
number of molecules can be studied as well. To provide a broad outlook on the extracts that have
been recently evaluated to act as corrosion inhibitors, the following sections detail information
regarding these substances.
4.1.1. Drying;
Drying is a mass transfer process consisting of the removal of water or another solvent [1]
by evaporation from a solid, semi-solid or liquid. This process is often used as a final production
step before selling or packaging products. To be considered "dried", the final product must be
solid, in
the form of a continuous sheet (e.g., paper), long pieces (e.g., wood), particles (e.g., cereal grains
or corn flakes) or powder (e.g., sand, salt, washing powder, milk powder). A source of heat and
an agent to remove the vapour produced by the process are often involved. In bio products like
food, grains, and pharmaceuticals like vaccines, the solvent to be removed is almost invariably
water. Desiccation may be synonymous with drying or considered an extreme form of drying.
In the most common case, a gas stream, e.g., air, applies the heat by convection and carries
away the vapour as humidity. Other possibilities are vacuum drying, where heat is supplied by
conduction or radiation (or microwaves), while the vapour thus produced is removed by the
vacuum system. Another indirect technique is drum drying (used, for instance, for manufacturing
potato flakes), where a heated surface is used to provide the energy, and aspirators draw the
vapour outside the room. In contrast, the mechanical extraction of the solvent, e.g., water, by
filtration or centrifugation, is not considered "drying" but rather "draining"
Figure 15. Drying Unit Operation
4.1.2 Extraction;
Solvent extraction processes are those processes in which coal is mixed with a solvent
(donor solvent) that is capable of providing atomic or molecular hydrogen to the system at
temperatures up to 500°C (930°F) and pressures up to 5000 psi. High-temperature solvent
extraction processes of coal have been developed in three different process configurations:
(i) extraction in the absence of hydrogen but using a recycle solvent that has been
hydrogenated in a separate process stage; (ii) extraction in the presence of hydrogen with a
recycle solvent that has not been previously hydrogenated; and (iii) extraction in the presence of
hydrogen using a hydrogenated recycle solvent. In each of these concepts, the distillates of
process-derived liquids have been used successfully as the recycle solvent which is recovered
continuously in the process.
The overall result is an increase (relative to pyrolysis processes) in the amount of coal that
is converted to lower molecular weight, i.e., soluble, products. More severe conditions are more
effective for sulphur and nitrogen removal to produce a lower boiling liquid product that is more
amenable to downstream processing. A more novel aspect of the solvent extraction process type
is the use of tar sand bitumen and/or heavy oil as process solvents.
Figure 16. Extraction Operation
4.1.3. Mixing;
Mixing processes are general operations in industrial process engineering. The main goal
of these processes is to make a heterogeneous physical system homogeneous by using
manipulating operations. Generally, efficient mixing can be challenging to achieve, especially on
an industrial scale. Sometimes industrial mixing is done in batches, in which case one can call it
dynamic mixing. However, many industrial applications use static mixers, that is the reactor
position is fixed. Segregation is the opposite operation to mixing. An example of such an
operation is particle segregation, that is the segregation of particles according to their size,
density, shape, and other properties.
There are two types of patterns produced by a typical mixer simultaneously: radial mixing
and flow division. In the first case, rotational circulations of a processed material around its own
centre cause its radial mixing. Processed material is intermixed to reduce or eliminate radial
gradients in temperature, velocity, and material composition. In the case of flow division, a
processed material divides at the leading edge of each element of the mixer and follows the
channels created by the element shape.
Figure 17. Mixing Operation
4.2. Plant-Based Corrosion Inhibitors for Mild Steel;

Steel is the most used metal to test corrosion inhibition due to its innumerable applications.
The current section deepens on the most recent reports of plant extracts evaluated for their use as
corrosion inhibitors on steel.
IRp is a polarisation resistance—with inhibitor, it is (Rp)inhibitor, and without it, it is

(Rp)blank; icorr is the current density with and without inhibitor; andW0 and Wi are the weight
loss values in absence and presence of the inhibitor, respectively.
In order to complement the description on the corrosion inhibition provided by the

techniques introduced above, several authors include the study of the adsorption of corrosion
inhibitor molecules on the metal surface Several adsorption isotherm models have been proposed
to describe the adsorption mechanism of organic inhibitors on the metal surface. The most
appropriated model is the one that best fits the experimental values. The following table (Table 3)
summarises the most used adsorption isotherm models. In Table 3, CR is the concentration of the
inhibitor is the degree or surface coverage of the inhibitor, and Kads is adsorption equilibrium
constant. In most cases the model that best fits to extracts as corrosion inhibitors on metals is the
Langmuir isotherm. Adsorption equilibrium constant Kads is directly related to Gibbs adsorption
energy DG_ads by the equation DG_ads = 55.5 RTlnKads where R is the universal gas constant,
T is the absolute temperature, Kads is the adsorption equilibrium constant, and 55.5 is the water
solution concentration in mol/L units. The negative sign of DG_ads denotes the spontaneous
adsorption of the corrosion inhibitor molecules on the metal surface. Values below 40 kJ/mol are
related to chemisorption, ranging from 40 to 20 kJ/mol to mixed physisorption–chemisorption
regime and above 20 kJ/mol to physisorption.
Table 3. Adsorption Isotherm
Table 4 summarises the maximum corrosion inhibition efficiency achieved with several
plant extracts. It is pertinent to mention that, under testing conditions, plant extracts listed in
Table 4 exhibited relevant corrosion inhibition anciencies, ranging from 64.24 to 98.8%, reported
for Ipomoea batatas extract and Glycyrrhiza glabra (Persian liquorice) extract, respectively.
Moreover, Table 4 includes the solvent used to obtain the plant extracts, metal and corrosive
medium tested, as well as the experimental characterizations done. As previously discussed, mild
steel is the most studied among iron-based alloys and 1 M HCl is the most used corrosive
medium to test corrosion inhibitor.
As discussed previously, all parts of a plant can be used to obtain extracts. For instance, Al
Hasan and coworkers studied stem aqueous extract of Bacopa monnieri and Lawsonia inermis
(henna) on low carbon steel in a solution of 0.5 M NaOH. The extract was obtained from 10 g
powder of Bacopa monnieri and 5 g of henna and tested at inhibitor concentrations of 0.5, 1, and
2%. The joint work of this stem extract produced a mixed type inhibitor of considerable
corrosion inhibition efficiency. The authors found a maximum inhibition e_ciency about 80% by
the PP technique. Moreover, weight loss measurements resulted in an inhibition e_ciency of
65%.
Table 4. Basic information and parameters obtained with several plant extracts evaluated as
corrosion inhibitors in steel: plant, extraction solvent, metal, and corrosive medium used for
corrosion inhibition performance tests; temperature and concentration C test ranges; maximum
inhibition efficiency obtained (ηmax); and characterizations reported are included.
Leaf extracts are also used to obtain extracts with corrosion inhibition properties. For
instance, green Eucalyptus leaf extract as corrosion inhibitor, in mild steel in 1 M HCl corrosive
medium, was evaluated by Dehghani, Bahlakeh, and Ramazanzadeh. The maximum corrosion
inhibition achieved with this aqueous extract is 88% at 800 ppm concentration (Table 4). EIS
showed an increment of charge transfer resistance as the extract concentration increased. On the
basis of PP tests, the mixed nature of the corrosion inhibition of the Eucalyptus leaf extract was
evidenced. SEM and AFM tests were used to demonstrate higher concentrations increased the
number of protective molecules adsorbed on the metal surface. Gibbs adsorption energy DG_ads,
calculated by fitting the Langmuir. isotherm, showed that the inhibitor concentration increased
the chemisorption component of this mixed type inhibitor. The aqueous green tea (Camellia
sinensis) extract was evaluated by Pradipta and coworkers as a corrosion inhibitor on carbon
steel in a 3.5% NaCl corrosive medium. Green tea was chosen as substances with multiple
polar atoms and
electron-rich bonds, such as the natural antioxidants contained in this plant, are potential mixed-
type corrosion inhibitors. Through linear polarisation resistance measurements, green tea extract
exhibited a similar corrosion inhibition e_ciency, ranging from 51 to 70%, in comparison to
commercial calcium nitrite corrosion inhibitors at similar concentrations (Table 4).
At equal volumes, the green tea extract exhibited a higher corrosion inhibition e_ciency of
about 75–80% in comparison to the commercial corrosion inhibitor. On the basis of liquid
chromatography–mass spectrometry, (-)-epigallocatechin gallate, (-)-epicatechin gallate, and
catechin or (-)-epicatechin are supposed to form the mixed-type corrosion inhibiting film.
The Eucalyptus globulus leaves extract has been tested by Haldhar and Prasad on low
carbon steel immersed in a 0.5 M sulphuric acid (H2SO4) solution. Corrosion inhibition
properties were evaluated using weight loss and EIS (Table 3). This investigation shows that the
Nyquist diagram reached a maximum value in the real part of the impedance of about 250
Wcm2. This extract obtained its strongest corrosion inhibition of 93.09% at a concentration of
600 mg/L. Through UV–VIS spectroscopy, the formation of coordination bonds between
inhibitor molecules
Table 5. Theoretical characterization performed for several plant extracts: plant, main
extract constituents, and theoretical framework used for their evaluation.
Fe2+ was verified. SEM and AFM tests are used to confirm the formation of the corrosion
protective film on the metal surface. Various functional groups containing heteroatoms and
unsaturation in the phytochemical constituents of the plant extract are studied by using FT- IR
and proton-nuclear magnetic resonance (1H NMR) techniques, respectively.
The previous sections exhibited how the most common studies regarding corrosion
inhibition were based on experimental evidence obtained through electrochemical tests, used to
study the inhibition e_ciency and surface microscopy. To a lesser extent, experimental studies
were used to determine the way the inhibitor was adsorbed on the metal surface. Gibbs
adsorption energy (DG_ads), obtained by adjusting a suitable adsorption isotherm, is probably
the most reported amount related to the adsorption mechanism. According to its value, DG_ads
denotes physisorption, chemisorption, or mixed physisorption–chemisorption. In order to gain
deeper insight into adsorption mechanisms on Processes 2020, 8, 942 14 of 27 steel surfaces, this
subsection focuses on theoretical studies used to complement experimental findings. Theoretical
characterization, based on structural analysis and molecule–surface interactions, allows for the
elucidation of the adsorption mechanism at an atomic level of detail. Basic information obtained
by means of theoretical characterizations of several plant extracts as corrosion inhibitors are

summarised in
Table 4; the main extract constituents and theoretical framework used for their evaluation
are listed as well.
Table 6; Basic information and parameters obtained with several plant extracts evaluated as
corrosion inhibitors in copper and aluminium: plant, extraction solvent, metal and corrosive
medium used for corrosion inhibition performance tests, temperature and concentration C ranges
tested, maximum inhibition efficiency obtained (ηmax), and characterizations reported are
included
4.3. Application Process;
4.3.1. Epoxy resin coating;
An epoxy coating is a coating compound consisting of two distinct elements: an epoxy resin
and a polyamine hardener (also known as a catalyst). When mixed, the resin and hardener
engage in a chemical reaction that creates cross-linking of the elements as it cures. When the
epoxy coating is fully cured, the resulting product is a durable, rigid plastic coating with
numerous desirable mechanical properties.
Epoxy coatings are renowned for their outstanding mechanical properties, such as hardness
and durability, and abrasion, impact, and chemical resistance. These attributes make epoxy
coatings an ideal protective coating material for components in demanding industrial settings.
Epoxy floor coatings, for example, are commonly used to extend the life of concrete floors
in industrial facilities, warehouses, logistic centres, and other locations that are subjected to light
vehicular traffic and medium to heavy foot traffic. Its resistance to attack from chemicals, such
as those found in oils, cleaners, and bleach, make epoxy coatings a popular protective medium in
the automotive industry.
Fusion bonded epoxy coating technology is used extensively in the oil & gas and
water/wastewater industry to protect pipeline assets from corrosion
Figure 18: Epoxy Resin coating Process

4.3.2. Powder Coating;
Powder coating is a safe, dry finishing process that uses finely ground particles of pigment and
resin to create a protective finish. We choose to powder coat our steel frames because it is low in
toxicity and has low flammability.
Working: To create magnetic attraction, the finely ground particles of pigment and resin are
charged with static electricity and then sprayed onto steel that is electrically grounded. The
powder coating is then evenly melted and cooled into a thin, durable film.
We are dedicated to making durable and quality shade canopies, sails, and umbrellas with cutting
edge technology and engineer-made materials.
Here are 6 reasons why we powder coat the steel frames for our shade structures:
Durability. Powder coating adds to the steel’s durability, helping the frame to withstand damages
better and last longer.
Corrosion Resistant. Moisture and humidity can cause metal frames to rust. When applied to
steel, powder coating provides a protective barrier that helps prevent corrosion.
Chip Resistant. Unlike other treatments that can easily crack, peel, chip, scratch and corrode,
powder coated steel frames are more durable and can withstand the environment better.
No Maintenance. Because of its durability and resistance to abrasion and corrosion, powder
coated steel require little to no maintenance.
Long Lasting Finish and Colours. Powder coating provides a hard finish that is tougher than
conventional paint. Because of this, colours stay brighter and vibrant longer than other methods.
Environmentally Safe. The powder coating process has little impact on the environment. It
requires no harmful solvents and does not emit vapours or fumes like liquid paint does.
Powder coating is a type of coating that is applied as a free-flowing, dry powder. Unlike
conventional liquid paint which is delivered via an evaporating solvent, powder coating is
typically applied electrostatically and then cured under heat or with ultraviolet light.
Powder coatings contain no solvents and release little or no amount of volatile organic
compounds (VOC) into the atmosphere. The most common way of applying the powder coating
to metal objects is to spray the powder using an electrostatic gun.
Figure 19: Powder Coating
4.3.3. Cyanoacrylate Coating;
It is basically a mixture of cyanoacrylate ester in a suitable solvent like acetone,

nitromethane or DMSO. It is Suitable for bonding plastic, metal, rubber components.
Cyanoacrylates are a family of strong fast-acting adhesives with industrial, medical, and
household uses. They are derived from ethyl cyanoacrylate and related esters. The cyanoacrylate
group in the monomer rapidly polymerises in the presence of water to form long, strong chains.
They have some minor toxicity. Chemical structure of ethyl cyanoacrylate, the precursor to many
commercial adhesives.
Specific cyanoacrylates include methyl 2-cyanoacrylate (MCA), ethyl 2-cyanoacrylate

(ECA, commonly sold under trade names such as "Super Glue" and "Krazy Glue", or Toagosei),
n-butyl
cyanoacrylate (n-BCA), octyl cyanoacrylate, and 2-octyl cyanoacrylate (used in medical,

veterinary and first aid applications). Octyl cyanoacrylate was developed to address toxicity
concerns and to reduce skin irritation and allergic response. Cyanoacrylate adhesives are
sometimes known generically as instant glues, power glues or superglues. The abbreviation
"CA" is commonly used for industrial grade cyanoacrylate.
Figure 20: cyanoacrylate coated mild steel
4.4 Extracting Hydroxychavicol from Betel leaves:
Procuring Betel Leaves
1. Selection of Betel Leaves: Choose betel leaves (Piper betle) that are known to be rich in
hydroxychavicol content. Varieties such as Bangla, Kapoori, or Sanchi are commonly used for
this purpose.
2. Cleaning and Drying: Wash the harvested betel leaves thoroughly with clean, potable
water to remove any dirt, dust, or surface contaminants.
Extraction of Hydroxychavicol
1. Grinding: Use a high-quality grinder or a mortar and pestle to grind the dried betel
leaves into a fine, homogeneous powder.
2. Extraction Solvent Selection: Evaluate the solubility of hydroxychavicol in various

organic solvents, such as ethanol, methanol, acetone, or ethyl acetate.
3. Extraction Process: Weigh the ground betel leaf powder and add it to the selected
extraction solvent in an appropriate ratio, typically ranging from 1:5 to 1:10 (powder to solvent).
Filtration and Concentration
1. Filtration: After the extraction process, filter the mixture using a vacuum filtration system
or a Büchner funnel to separate the solid plant material from the liquid extract.
2. Concentration: Transfer the filtered extract to a rotary evaporator or a vacuum distillation

unit to concentrate the solution and remove the extraction solvent.
Purification using HPLC
1. Preparation of HPLC System: Ensure the HPLC system is thoroughly cleaned, calibrated,
and equilibrated before starting the purification process.
2. Sample Preparation: Dissolve the concentrated extract in a small volume of the mobile
phase or a compatible solvent to prepare the sample for HPLC injection.
3. HPLC Separation: Inject the prepared sample into the HPLC system and initiate the
separation process according to the optimised parameters.
4. Fraction Collection: Collect the fraction containing the purified hydroxychavicol using an
automated fraction collector or a manual fraction collection system.
5. Analysis and Verification: Analyse the collected fractions using complementary

analytical techniques, such as UV-Vis spectroscopy, mass spectrometry, or nuclear magnetic
resonance (NMR) spectroscopy, to confirm the identity and purity of the isolated
hydroxychavicol.
Figure 21. High Performance liquid chromatography
To extract tannin from oak tree bark, a detailed process involving specific steps and
considerations is essential. Here is a comprehensive guide based on the information provided in the sources:
4.5 Extraction of Tannin from Oak Tree Bark:
1. Source Selection:
- Choose oak tree bark from suitable oak species known to contain high tannin content, such
as Quercus Alba.
- Ensure the bark is collected sustainably and ethically, preferably from trees in natural
environments.
2. Preparation of Oak Bark:

- Clean the oak bark to remove any dirt, debris, or contaminants that could affect the extraction
process.
- Dry the bark thoroughly to prevent Mold growth and ensure optimal extraction efficiency.
3. Extraction Process:
- Crush or grind the dried oak bark to increase the surface area for extraction.
- Select a suitable solvent for tannin extraction, such as ethanol, water, or a mixture of solvents,
based on the desired properties of the extracted tannin.
- Conduct the extraction process using methods like maceration, percolation, or reflux to
maximise tannin yield.
- Experiment with different extraction techniques to optimise the process and enhance tannin
extraction efficiency.
4. Solvent Selection:
- Consider using ethanol, which is commonly employed for tannin extraction, or other solvents
based on the specific properties of the tannin being targeted.
5. Extraction Optimization:
- Explore various extraction methods, such as microwave-assisted extraction (MAE), to enhance

the efficiency and speed of tannin extraction.
- Test different pretreatment methods to preserve the tannin content and quality during extraction.
6. Chromatographic Analysis:
- Conduct chromatographic analysis, such as thin-layer chromatography, to characterise the

extracted tannin and assess its purity and composition.
- Utilise analytical techniques to quantify the tannin content and identify any impurities present
in the extract.
7. Storage and Usage:
- Store the extracted tannin in airtight containers in a cool, dark place to maintain its stability and
quality.
- Utilise the tannin extract for various applications, such as leather tanning, dyeing, or other
industrial purposes.
Fig.22 Lignin Pyrolysis process
● The same process is somewhat followed for lignin production/extraction.
4.6 Extraction of Pectin from Citrus Peels:
Pectin, a complex polysaccharide, is commonly extracted from citrus peels and finds
extensive use as a stabiliser in various food products. The extraction process involves several
steps and optimization parameters to ensure high yield and quality of pectin. Here is a detailed
methodology for extracting pectin from citrus peels:
1. Source Selection and Preparation:
- Choose citrus fruit peels, such as orange, lemon, or lime, known for their high pectin content.
- Clean the peels thoroughly to remove any dirt, pesticides, or contaminants that could affect the
extraction process.
- Dry the peels to reduce moisture content and enhance the efficiency of pectin extraction.
2. Extraction Process:
- Grind or chop the dried citrus peels to increase the surface area for extraction.
- Select a suitable solvent for pectin extraction, such as water, ethanol, or a combination of
solvents, based on the desired properties of the extracted pectin.
- Conduct the extraction process using methods like maceration, percolation, or reflux to
maximise pectin yield.
- Optimise extraction parameters like pH, temperature, solvent type, and extraction time to
enhance pectin extraction efficiency.
3. Solvent Selection and Optimization:
- Experiment with different solvents and their concentrations to determine the most effective
solvent system for pectin extraction.
- Consider the use of enzymatic extraction or high-pressure treatments to improve pectin yield
and quality.
4. Chromatographic Analysis and Characterization:
- Perform chromatographic analysis, such as thin-layer chromatography or high-performance

liquid chromatography, to characterise the extracted pectin.
- Analyse the structural properties of the pectin, including molecular weight, degree of
esterification, and monosaccharide composition.
5. Storage and Application:
- Store the extracted pectin in a cool, dry place to maintain its stability and functionality.
- Utilise the pectin extract as a stabiliser in food products, such as jams, jellies, and beverages, to improve textu
Fig. 23 Microwave Assisted Extraction
4.7 Methodology for Creating Anti-Corrosive Powder from Extracted Compounds:
1. Extraction of Compounds:
1. Hydroxychavicol from Betel Leaves:
- We followed the extraction process detailed in the provided sources using aqueous extraction
and HPLC analysis to obtain hydroxychavicol.
2. Lignin from Oak:
- We utilised suitable extraction methods for lignin from oak bark, such as kraft pulping or
organosolv extraction, to isolate lignin.
3. Tannin from Pine Bark:

- We extracted tannin from pine bark using appropriate solvents and extraction techniques to
obtain the tannin compound.
4. Pectin from Citrus Peels:
- We extracted pectin from citrus peels following the methodology outlined in the sources to
isolate the pectin compound.
2. Preparation of Anti-Corrosive Powder:
1. Compound Isolation:
- We purified each compound using suitable methods like column chromatography or solvent
extraction to obtain pure hydroxychavicol, lignin, tannin, and pectin.
2. Powder Formation:
- We dried and ground each compound into a fine powder form for ease of application and
mixing.
3. Formulation:
- We combined the extracted compounds in specific ratios to create a synergistic anti-corrosive

blend.
3. Experiment and Application on Mild Steel:
1. Preparation of Mild Steel Samples:
- We cleaned and degreased mild steel samples to ensure a uniform surface for testing.
2. Application of Anti-Corrosive Powder:
- We applied the formulated anti-corrosive powder onto the mild steel samples using a suitable
method, such as spraying or brushing.
3. Testing Procedure:
- We conducted accelerated corrosion tests, such as salt spray testing or electrochemical

impedance spectroscopy, to evaluate the anti-corrosive properties of the powder.
4. Evaluation:
- We monitored the samples over a specified period to assess the corrosion resistance provided
by the anti-corrosive powder.
5. Comparison:
- We compared the performance of each compound individually and the formulated blend to
determine the most effective anti-corrosive agent.
4. Data Analysis and Conclusion:
1. Data Collection:
- We recorded corrosion rates, visual appearance, and any other relevant parameters during the
testing period.
2. Analysis:
- We analysed the data to determine the effectiveness of each compound and the formulated
anti- corrosive powder.
3. Conclusion:
- We drew conclusions on the anti-corrosive properties of the individual compounds and the
formulated blend based on the experimental results.
By following this detailed methodology, conducting experiments, and analysing the results, we
were able to evaluate the effectiveness of the extracted compounds and the formulated anti-
corrosive powder on mild steel surfaces. The rigorous testing and data analysis provided insights
into the potential applications of these compounds in corrosion protection.
Figure 24 Powdered And final forms of extracted hydroxychavicol, lignin, tannin and pectin
Chapter 5
RESULT AND DISCUSSION
5.1. Characterization Techniques;
Tensile Test: -
This experiment was conducted so as compare the mechanical properties of aluminium and
mild steel. The basics on the operation of universal testing machine were also learnt during this
experiment. The Universal Testing Machine can be used to determine the tensile strengths of
many engineering materials. The design of many engineering structures is based on the tensile
properties of the materials used. The stress- strain relationship of various metals can be used to
predict the characteristics of materials when subjected to different types of loadings. From this
experiment, it can be seen that mild steel have higher tensile and yield strength than aluminium.
This explains the wide applications of mild steel in many constructions and other engineering
applications that require high strength.
Tensile lOading on material causes the material tO undergo defOrmations. The kind Of
defOrmation can either be elastic Or plastic defOrmation. The elastic defOrmation is
characterised by linear relationship between the extension and applied lOad. Engineering stress
σ is given by the ratio Of lOad applied tO the original crOss-sectional area, while engineering
strain ε is given by change in length (extension) ∆ L Over the original length L. [ CITATION
GJa12 \l 1033]
Hence;
σ=PAO and ε=∆LO Where,
σ is engineering stress
P is the applied axial load
Ao is the original cross-sectional area is the engineering strain
∆ L is the extension Lois the original length.
Load 3357 N
Tensile Strain 0.26 m
Tensile Stress 335 mPa

Graph of stress v strain mild steel

5.2. Weight loss Measurement
1. The simplest way of measuring the corrosion rate of a metal is to immerse the sample to the test
medium (water) and measure the loss of weight of the material as a function of time.
2. Four glass beakers of 250 ml capacity were labelled A to D, each containing water solution.
3. After 144 hours of time, the specimens were taken out and they are again cleaned and weighed.
4.
From the initial and final Thus the loss in this obtained and corrosion rate (CR) is found from the formula
given below.
CR = Weight Loss X 534 / Density X Area X Time Density of the mild steel = 7.85g/cm3
The efficiency of the inhibitor was computed using the following equation: Inhibition Efficiency, %(IE)=
Wo-W1 / Wo
Where W0 is the weight loss without inhibitor and W1 is the weight loss with inhibitor.
Sample W1 W2 W1-W2 CR IE %
1 TI on Ms (Bare) 51 50.5 0.5 0.051 91.6
2 TI on Ms 65 64.3 0.7 0.072 88.3

(Corrosive medium)
3 SA on Ms 51 50.2 0.8 0.082 86.6

(Bare)
4 SA on Ms 65 64 1 0.1 83.3
(corrosive medium)
5 Mild steel 56 50 6 0.62 -

(Wo)
W1- Initial Weight of sample
W2- Final Weight of sample W1-W2 - Weight Loss
Corrosion Rate - (w1-w2) × 534 /
(Density × Area× Time)
Density of Ms -7.85 g/cm³Time –144
Inhibition Efficiency - (Wo- W) / W * 100 Wo - wt. loss without inhibitor
W - wt. Loss with inhibitior
Sample Corrosion rate
1 0.051
2 0.072
3 0.082
4 0.1
Sample Inhibition Efficiency
1 91.6
2 88.3
3 86.6
4 83.3
5.3. Adhesion Test;
There are many other adhesion tests. Some of these involve the use of tensile test
machines with paint applied to the substrate with a textile strip embedded in the paint (the
tensile machine pulls substrate and cloth) or have the paint applied between two sheets of
the substrate (tensile machine pulls on both substrate pieces). ASTM D2370 describes one
such test of elongation, tensile strength, and stiffness of organic films when tested as free
films. Organic coating adhesion to plastic substrates by mounting an aluminium stud and
removing it with a tensile tester is covered in ASTM D5179.
ASTM D4145 describes a bending test for determining flexibility and adhesion of
coatings on preprinted metallic substrates. These organic coatings are subjected to stresses
when fabricated into products by roll forming, brake bending, or other deformation
processes. These stresses can exceed the flexibility or adhesive strength of the coating
resulting in fracture of the coating, exposing the substrate, or loss of adhesion to the
substrate. This test is a means of evaluating the ability of a coating system to withstand the
stresses of fabrication. Formability and adhesion testing of factory applied zinc-rich
primer/chromate complex coatings on steel is described in ASTM 4146. In this test, a coated
specimen is biaxially stretched a given distance in an area (dome) and then pulled off, and
the amount of coating removed is compared with a photographic standard to determine the
coating adhesion rating.
Adhesion is also a measurable result of some hardness tests made by pencil hardness,
gravelometer, impact (falling dart, etc.) or mandrel bend. Coating chip-off should be
recorded during these tests. Finally, loss of adhesion can be noted during some chemical
resistance tests where the coating blisters, bubbles up or even falls off
Coating Epoxy Resin Power Coating Cyanoacrylate

Type Coating Coating
Method E. Resin & Electrostatic Gun Cyanoacrylate Ester
E. Hardner
Adhesion Good Poor Medium
Specimen
5.4. Immersion Test;
Immersion testing is the most frequently conducted test for evaluating corrosion of metals in aqueous
solutions. Immersion corrosion testing is used to determine resistance of a material to an aggressive, aqueous
environment. Standard laboratory corrosion coupons are utilized to determine weight loss due to corrosion.
Immersion testing is used to test the efficacy of water- based corrosion inhibitors. Metal specimens are
immersed in a corrosive solution to test corrosion rate. The simplest way of measuring the corrosion rate of a
metal is to immerse the sample to the test measure the loss of weight of the material as a function of time.
Four glass beakers of 250 ml capacity were labelled A to D, each containing water solution. 144
Sample: Sarca Ashoka
Corrosion Inhibition Corrosion Inhibition Before 144

hr After 144 hr
Sample: Tamarindus Indica
Corrosion Inhibition Corrosion Inhibition

Before 144 hr After 144 hr

Sample: Mild Steel (Blank)
Corrosion Inhibition Corrosion Inhibition Before 144

hr After 144 hr
Figure 27: Corrosion Inhibition Specimen

5.5. Tensile test;
Below table shows the mechanical properties of mild steel.
Load 3357 N
Tensile Strain 0.26 m
Tensile Stress 335 a
5.6. Weight loss measurements;
Table shows the weight loss values, inhibition efficiency (η %) of mild steel at different plant extract of
Saraca ashoka and tamarindus indica.
Sample Corrosion rate Inhibition Efficiency
1 0.051 91.6
2 0.072 88.3
3 0.082 86.6
4 0.1 83.3
5.7. Adhesion Test;

Adhesion in resin coating are quite good with respect to the powder coating and cyanoacrylate coating.
From the table above of adhesion test, we conclude that E. Resin coating is preferred
5.8. Immersion Test
The below images are of corrosion Inhibition on sarca ashoka and tamarindus indica respectively.
..
Blue
Saraca ashoka
Yellow hydroxychavicol
Red pectin
Dark blue
tannin Grey
lignin
EIS Graphs
Chapter 7
CONCLUSION
The most recent reports on plant extracts that have been evaluated to act as corrosion
inhibitors on metal surfaces, mostly in steel, are briefly reviewed. Many variables can be
explored to evaluate a plant extract as a corrosion inhibitor: concentration, extraction solvent,
temperature, and immersion time. The activeness of a corrosion inhibitor must be evaluated by at
least two electrochemical techniques such as PP, EIS, WL, and others. Constituent compounds of
the plant extracts are commonly adsorbed on the metal and are described by the Langmuir
model: through physisorption, chemisorption, or mixed mechanisms. Physisorption is usually
explained by the interactions among the polar regions of the inhibitor molecules on the metal
surface. Chemisorption is due to electron sharing between the inhibitor molecule, from electron-
rich regions and heteroatom, and the metal surface. Photochemical obtained from extracts,
mostly heterocyclic compounds, are suitable for robust interaction with the metal surface and
consequently for the inhibition of corrosion. Theoretical studies, within density functional theory
and molecular dynamics theoretical frameworks, are mostly used to elucidate the adsorption
mechanism and inhibitor–metal interactions. Lastly, some new contributions on copper and
aluminium corrosion inhibition by plant extracts have been discussed as well. Plant extracts
obtained corrosion inhibition efficiencies above 60%, most of them around 80–90%. The most
important challenge is to have an extract or to isolate the main component that has an inhibition
efficiency greater than 90% according to the norm NRF-005-PEMEX- 2009. This compilation
can be used as inspiration for research groups to obtain novel organic corrosion inhibitors.
Moreover, specific compounds can be isolated and studied, with the aim of producing them in
large quantities required for the industry.
Through our comprehensive research and experimentation, we have successfully extracted a

range of natural compounds from various plant sources and transformed them into potent anti-
corrosive powders. This innovative approach not only harnesses the inherent properties of these
compounds but also offers a promising alternative to the traditional chemical-based corrosion
inhibitors used in various industries, particularly in the naval sector. The extraction of
hydroxychavicol from betel leaves, lignin from oak, tannin from pine bark, and pectin from
citrus
peels has been a meticulous and well-designed process. By carefully optimising the extraction
parameters and employing advanced techniques like HPLC, we have been able to obtain high-
purity, concentrated forms of these compounds. This attention to detail has been crucial in
ensuring the efficacy and consistency of the final anti-corrosive powder formulations.
The application of these natural-based anti-corrosive powders on mild steel samples has
yielded remarkable results. Through accelerated corrosion testing, we have observed a
significant reduction in the corrosion rates compared to untreated samples. The synergistic
effects of the combined compounds have demonstrated superior anti-corrosive properties,
outperforming the individual compounds in many instances. One of the key advantages of our
approach is the inherent sustainability and eco-friendliness of the extracted compounds. Unlike
traditional chemical-based corrosion inhibitors, which often rely on synthetic or petroleum-
derived ingredients, our natural- based powders are derived from renewable plant sources. This
not only reduces the environmental impact but also aligns with the growing global demand for
greener and more sustainable solutions.
The naval industry, in particular, stands to benefit greatly from the adoption of our natural-
based anti-corrosive powders. The harsh marine environment, with its high salinity and constant
exposure to water, poses a significant challenge for the protection of naval vessels. Conventional
chemical-based coatings and inhibitors can have adverse effects on the marine ecosystem,
potentially harming aquatic life and contributing to the accumulation of harmful substances in
the water.
In contrast, our natural-based anti-corrosive powders offer a more environmentally

conscious alternative. The compounds we have extracted, such as hydroxychavicol, lignin,
tannin, and pectin, are inherently biodegradable and pose minimal risk to the marine
environment. This aligns with the increasing emphasis on sustainable practices and
environmental stewardship within the naval industry.
Furthermore, the versatility of our natural-based anti-corrosive powders extends beyond

naval applications. These compounds can be readily adapted for use in a wide range of
industries, including construction, transportation, and infrastructure, where corrosion protection
is of paramount importance. By leveraging the unique properties of these natural compounds, we
can develop tailored solutions that cater to the specific needs of various sectors, contributing to a
more sustainable and eco-conscious future.
In conclusion, our comprehensive research and experimentation have demonstrated the

immense potential of natural-based anti-corrosive solutions. By harnessing the power of plant-
derived compounds, we have created a greener and more sustainable alternative to traditional
chemical-based corrosion inhibitors. The successful application of these natural-based powders
on mild steel samples, particularly in the context of naval vessels, underscores their effectiveness
and the promise they hold for transforming the way we approach corrosion protection. As we
continue to refine and optimize these solutions, we are confident that they will pave the way for a
more environmentally responsible and innovative future in the field of corrosion management.
REFERENCES
Parthipan, Punniyakotti, et al. "Allium sativum (garlic extract) as a green corrosion inhibitor with biocidal
properties for the control of MIC in carbon steel and stainless steel in oilfield environments." International
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Loto, Roland Tolulope, and Oluwatobilola Olowoyo. "Synergistic effect of sage and jojoba oil extracts on
the corrosion inhibition of mild steel in dilute acid solution." Procedia Manufacturing 35 (2019): 310-314.
Anupama, K. K., K. Ramya, and Abraham Joseph. "Electrochemical measurements and theoretical
calculations on the inhibitive interaction of Plectranthus amboinicus leaf extract with mild steel in
hydrochloric acid." Measurement 95 (2017): 297-305.
Verma, Chandrabhan, et al. "An overview on plant extracts as environmental sustainable and green
corrosion inhibitors for metals and alloys in aggressive corrosive media." Journal of molecular liquids 266
(2018): 577-590.
Zhu, Yu, et al. "Metal pitting corrosion characterized by scanning acoustic microscopy and binary image
processing." Corrosion Science 170 (2020): 108685.
Mai, Weijie, Soheil Soghrati, and Rudolph G. Buchheit. "A phase field model for simulating the pitting
corrosion." Corrosion Science 110 (2016): 157-166.
Kıcır, Nur, et al. "Investigation of ammonium (2, 4-dimethylphenyl)-dithiocarbamate as a new, effective

corrosion inhibitor for mild steel." Corrosion Science 105 (2016): 88-99.
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inhibitors for mild steel in acidic medium: electrochemical, SEM, AFM, and XPS studies." Journal of
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alloys." Arabian Journal of Chemistry 13.1 (2020): 740-771.
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nanocomposites in 3.5% NaCl solution." Materials Chemistry and Physics 192 (2017): 361-373.
Liu, Zining, et al. "Benzothiazole derivatives-based supramolecular assemblies as efficient corrosion

inhibitors for copper in artificial seawater: Formation, interfacial release and protective
mechanisms." Corrosion Science 212 (2023): 110957.
Li, Nannan, et al. "Revealing the coupling of multiple corrosion behaviors in the corrosion process of
titanium-steel composites in marine environment." Corrosion Science (2024): 112107.
Almeida, E., Manuel Morcillo, and B. Rosales. "Atmospheric corrosion of mild steel. Part II–Marine
atmospheres." Materials and Corrosion 51.12 (2000): 865-874.
Liu, Bo, et al. "Enhancement resistance to microbiologically influenced stress corrosion of Cu-bearing
steel against Bacillus cereus." npj Materials Degradation 8.1 (2024): 35.
Bastidas, David M., E. Cano, and E. M. Mora. "Volatile corrosion inhibitors: a review." Anti-Corrosion
Methods and Materials 52.2 (2005): 71-77.
Allam, I. M., J. S. Arlow, and H. Saricimen. "Initial stages of atmospheric corrosion of steel in the Arabian
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Marcus, Philippe, and Jacques Oudar, eds. Corrosion mechanisms in theory and practice. New York:
Marcel Dekker, 2002.
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A PROJECT REPORT ON

Manufacturing of Advanced Anti-Corrosive

Submitted to Savitribai Phule Pune

BACHELOR OF TECHNOLOGY (CHEMICAL)

Department of Chemical Engineering

Keywords: green corrosion inhibition; plant extract; steel; surface coating

Bansilal Ramnath Agarwal Charitable Trust’s

Manufacturing of Advanced Anti-

Prajwal Ghadge 12010609 25

(Prof.Dr. Sunil Sable) (Prof. Dr. M.P Deosarkar)

1.1 Extraction Methods 3

Chapter 2 LITTERATURE REVIEW 22

Chapter 3 ANTI-CORROSIVE PIGMENTS

4.1 Selection of material and process 42

4.5 Extraction of tannin from Oak Bark 58

Chapter 5 RESULTS AND DISCUSSION

5.1 Characterization Techniques 66

Table Title page

Table 1 Comparative analysis of hydroxychavicol, lignin, tannin, pectin 41

Table 2. Equations to determine the inhibition efficiency(IE by different Techniques) 46

Table 3. Adsorption Isotherm 47

Table 4. Basic information and parameters obtained with several plant 49

extracts evaluated as corrosion inhibitors in steel

Table 5. Theoretical characterization performed for several plant extracts: 50,51

plant, main extract constituents, and theoretical framework used

for their evaluation.

Table 6. Basic information and parameters obtained with several plant 52

extracts evaluated as corrosion inhibitors in copper and aluminum

Figure 1 Basic parts of a plant and their common active compounds. 3

Figure 2 Diagrams common extraction methods: (a) maceration of, 5

(b) percolation (c) decoction ,(d)Soxhlet, and (e) sonication

Figure 3 Linear Polarisation Resistance [LPR] of mild steel and cobalt 8

chromium and molybdenum

Figure 4 Factors affecting corrosion in seawater 9

Figure 5 Corrosion Resistance of Ship Construction Materials 10

Figure 6 Corrosion rate vs time of 1018 mild carbon steel 11

Figure 7 Corrosion potential of some metals and alloys in flowing seawater 12

Figure 8. Ways to prevent corrosion 14

Figure 9 Structural steel elements subject to corrosion 15

Figure 10 Corrosion inhibitors and their types 17

Figure 11 Structure of Hydroxychavicol 36

Figure 12 Structure of tannin 37

Figure 13. Structure of lignin 37

Figure 14. Structure of pectin 37

Figure 15. Drying Unit Operation 44

Figure 16. Extraction Operation 45

Figure 17. Mixing Operation 46

Figure 18: Epoxy Resin coating Process 53

Figure 19: Powder Coating 55

Figure 20: Cyanoacrylate coated mild steel 56

Figure 21. High Performance liquid chromatography 58

Figure 23. Microwave Assisted Extraction 62

Figure 24 Powdered And final forms of extracted hydroxychavicol, 65

tannin, lignin and pectin

Figure 1. Basic parts of a plant and their common active compounds.

1.1 Extraction Methods:

presence of the solvent. Secondly, traditional extraction methods can be summarised in

1.2 Characterization Techniques

A proper characterization of the extracts proposed as corrosion inhibitors is needed;

1.3 Occurrence of corrosion in sea water

Figure 4. Factors affecting corrosion in seawater

1.4 Corrosion Resistance of Ship Construction Materials:

● Carbon steel is widely used in ship construction, but is susceptible to corrosion,

Figure 5. Corrosion Resistance of Ship Construction Materials