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TR2025001661A2 - COMPOSITION AND PRODUCTION METHOD OF SOLVENT-FREE EPOXY-BASED COATING WITH INCREASED CORROSION RESISTANCE - Google Patents

COMPOSITION AND PRODUCTION METHOD OF SOLVENT-FREE EPOXY-BASED COATING WITH INCREASED CORROSION RESISTANCE Download PDF

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TR2025001661A2
TR2025001661A2 TR2025/001661 TR2025001661A2 TR 2025001661 A2 TR2025001661 A2 TR 2025001661A2 TR 2025/001661 TR2025/001661 TR 2025/001661 TR 2025001661 A2 TR2025001661 A2 TR 2025001661A2
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solvent
epoxy
coating
mixing
corrosion resistance
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TR2025/001661
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Turkish (tr)
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Dayet Sario Ullari H
Dem Rkurt Akbal Merve
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Kanat Boyacilik Ti̇caret Ve Sanayi̇ Anoni̇m Şi̇rketi̇
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Publication of TR2025001661A2 publication Critical patent/TR2025001661A2/en

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Abstract

Buluş, çelik yüzeylerde korozyon önleyici olarak ve akış verimliliği kaplaması olarak kullanılacak yeni solventsiz epoksi bazlı kaplama ve bunun üretim yöntemi ile ilgilidir. Buluş özellikle çelik gaz iletim boru hatlarında dış yüzey ve iç yüzeylerde kullanılmak üzere geliştirilmiş çevresel etkisi azaltılırken korozyon dayanımı arttırılmış solventsiz epoksi bazlı kaplama ile ilgilidir.The invention relates to a new solvent-free epoxy-based coating to be used as a corrosion inhibitor and flow efficiency coating on steel surfaces and its production method. The invention relates to a solvent-free epoxy-based coating that has been developed to be used on external and internal surfaces of steel gas transmission pipelines, with reduced environmental impact and increased corrosion resistance.

Description

TARIFNAME KOROZYON DAYANIMI ARTTIRILMIS SOLVENTSIZ EPOKSI BAZLI KAPLAMA Teknik Alan Bulus, çelik yüzeylerde korozyon önleyici olarak ve akis verimliligi kaplamasi olarak kullanilacak yeni solventsiz epoksi bazli kaplama ve bunun üretim yöntemi ile ilgilidir. Bulus özellikle çelik gaz iletim boru hatlarinda dis yüzey ve iç yüzeylerde kullanilmak üzere gelistirilmis çevresel etkisi azaltilirken korozyon dayanimi arttirilmis solventsiz epoksi bazli kaplama ile ilgilidir. Teknigin Bilinen Durumu Mevcut teknikte gaz ve petrol iletim hatlarinin korunmasinda, dis yüzeylerde genellikle solvent bazli epoksi kaplamalar tercih edilmektedir. Bu kaplamalar, korozyon dayanimi saglamak amaciyla boru hatlarinin dis yüzeyine uygulanarak çevresel faktörlerden kaynaklanan hasarlari en aza indirmeyi hedefler. Solvent bazli kaplamalar, kürlenme esnasinda solventin buharlasmasi ve ardindan kimyasal bilesenlerin çapraz baglanmasi yoluyla sertlesmektedir. Bu yapi, özellikle ince film kaplamalar için uygundur ve akis verimliligini artirmak amaciyla iç yüzey kaplamalarinda da siklikla kullanilmaktadir. Ancak mevcut solvent bazli epoksi kaplamalar, solvent buharlasmasi sirasinda çevreye zararli uçucu organik bilesiklerin (VOC) salinimina neden olmaktadir. Bu durum, hem isçi sagligini tehdit etmekte hem de çevresel düzenlemelere uyum açisindan zorluk yaratmaktadir. Ayrica, solvent bazli kaplamalar, kalin film uygulamalarinda daha fazla kürlenme süresi gerektirdiginden genellikle yüksek sicaklik gibi sert çevresel kosullara karsi daha dayaniksizdir. Bu, uzun vadede koruyucu kaplamanin performansini düsürerek kaplamanin dayanikliligini azaltir. Bu nedenle teknik bilinen durumunda bu problemleri önleyecek yüksek korozyon direnci ve dayaniklilik saglayan ve çevreci bir ürüne ihtiyaç duyulmaktadir. Literatürde yapilan arastirmada teknigin bilinen durumuna bir örnek olarak TR2017/15987 numarali doküman gösterilebilir. Söz konusu basvuru bir çelik boru kaplamasi ile ilgilidir. Söz konusu dokümanda sehir içi sebekelerinde ve isale hatlarinda gaz ve sivi iletiminde kullanilmak üzere gelistirilen silindirik ana gövdenin dis yüzeyinde termal püskürtülmüs, en az 200 gr/m2 çinko metali içeren en az bir birinci kaplama, bahsedilen birinci kaplama üzerine, birinci kaplamayi saracak sekilde kaplanmis olan, yapistirici özellikte malzeme içeren en az bir ikinci kaplama, bahsedilen ikinci kaplama üzerine, ikinci kaplamayi saracak sekilde kaplanmis olan, polietilen, polipropilen, poliüretan, epoksi, vernik arasindan seçilen birey veya kombinasyonlari içeren en az bir üçüncü kaplama uygulandigi belirtilmektedir. Ancak basvuruda dis yüzeyler için korozyon önleyici olarak ve iç yüzeylerde akis verimliliginde kaplamasi olarak kullanilabilecek iki bilesenli solventsiz epoksi kaplama kompozisyondan bahsedilmemektedir. Sonuç olarak, yukarida anlatilan olumsuzluklardan dolayi ve mevcut çözümlerin konu hakkindaki yetersizligi nedeniyle ilgili teknik alanda bir gelistirme yapilmasi gerekli kilinmistir. Bulusun Amaci Bulus, mevcut durumlardan esinlenerek olusturulup yukarida belirtilen olumsuzluklari çözmeyi amaçlamaktadir. Bulusun ana amaci, yüksek korozyon direnci ve dayaniklilik saglayan solventsiz epoksi bazli kaplama ve bu kaplamanin üretim yöntemini ortaya koymaktir. Bulusun amaci, çelik gaz iletim boru hatlari için dis yüzeylerde korozyon önleyici olarak ve iç yüzeylerde akis verimliliginde kaplamasi olarak kullanilabilecek çevresel etkisi azaltilmis solventsiz (%98) epoksi bazli kaplama saglamaktir. Bulusun diger amaci, 300°C`lere kadar olan sicakliklara dayanim gösteren bir kaplama saglamaktadir. Bulusun diger amaci hizli kuruma özelligi saglayan bir ürün gelistirmektir. Bulus içerdigi epoksi karisimi ile isi dayanimini, sertlestirici karisim kisim ise elastikiyeti saglamayi amaçlamaktadir. Bulusun diger amaci, solvent bazli ürünlere göre VOC içerigi oldukça az olan bir ürün saglamaktir. Yukarida anlatilan amaçlarin yerine getirilmesi için bulus, çelik yüzeylerin kaplamasinda kullanilmak üzere akis verimliligi, yüksek korozyon direnci ve dayaniklilik saglayan solventsiz epoksi bazli kaplama olup, o Likit epoksi reçine, yari kati novolak epoksi reçine, çözgen 1, çözgen 2, kirmizi pigment, dolgu malzemesi 1, dolgu malzemesi 2, dolgu malzemesi 3, yüzey ajani, köpük kesici, reoloji ajani 1 ve reoloji ajani 2 içeren A komponenti ve o Epoksi kürleme ajani 1, kürleme ajani 2 ve Aktivatör 1 ve Aktivatör 2 içeren B komponenti ihtiva etmektedir. Yukarida anlatilan amaçlarin yerine getirilmesi için bulus, çelik yüzeylerin kaplamasinda kullanilmak üzere akis verimliligi, yüksek korozyon direnci ve dayaniklilik saglayan solventsiz epoksi bazli kaplamanin üretim yöntemi olup; A komponentinin; i. Likit epoksi reçine, yari kati novolak epoksi reçinenin kazana ilave edilerek karistirilmasi ii. Çözgen 1 kazana ilave edilerek karistirilmasi, iii. Kirmizi pigmentin kazana ilave edilerek karistirilmasi, iv. Karisima sirasiyla Dolgu malzemelerinin karistirma altinda eklenmesi v. Karisima sirasiyla Yüzey ajani, reoloji ajani 1, köpük kesici ve reoloji ajani 2 karistirma altinda ilave edilerek karistirilmasi vi. Karisimin ezme makinesiyle ezilmesi, vii. Ezilen karisima çözgen 2 ilave edilerek vakum altinda karistirilmasi islem adimlariyla; B komponentinin; a) Epoksi kürleme ajani 1 kazana ilave edilerek karistirilmasi, b) Sirasiyla Aktivatör 1 ve aktivatör 2 kazana ilave edilerek karistirilmasi, c) Karisima Epoksi kürleme ajani 2 ilave edilerek karistirilmasi islem adimlariyla elde edilmesini ihtiva etmektedir. Bulusun yapisal ve karakteristik özellikleri ve tüm avantajlari asagida verilen detayli açiklama sayesinde daha net olarak anlasilacaktir ve bu nedenle degerlendirmenin de bu detayli açiklama göz önüne alinarak yapilmasi gerekmektedir. Bulusun Detayli Açiklamasi Bu detayli açiklamada, bulusa konu olan yüksek korozyon direnci ve dayaniklilik saglayan solventsiz epoksi bazli kaplama kompozisyonu ve tercih edilen yapilanmalari, sadece konunun daha iyi anlasilmasina yönelik olarak açiklanmaktadir. Mevcut bulus, çelik yüzeylerin kaplamasinda kullanilmak üzere akis verimliligi, yüksek korozyon direnci ve dayaniklilik saglayan solventsiz epoksi bazli kaplama kompozisyonu ve bunun üretim yöntemi ile ilgilidir. Bulus konusu ürün A komponenti ve B komponenti içermektedir. Bahsedilen A komponenti (boya) Likitepoksi reçine, yari kati novolak epoksi reçine, çözgen 1, çözgen 2, kirmizi pigment, dolgu malzemesi 1, dolgu malzemesi 2, dolgu malzemesi 3, yüzey ajani, köpük kesici, reoloji ajani 1 ve reoloji ajani 2 içermekte ve bahsedilen B komponenti (Sertlestirici) ise Epoksi kürleme ajani 1, kürleme ajani 2 ve Aktivatör 1 ve Aktivatör 2 içermektedir. Tablo 1 ve tablo 2 de bu komponentlerin bilesenlerinin agirlikça tercih edilen ve kullanilabilir miktarlari verilmektedir. Tablo 1 A komponenti reçetesi Agirlikça Tercih edilen Agirlikça Kullanilabilir miktar (%) miktar (%) Likit Epoksi Reçine 30 20-35 Yari Kati Novolak Epoksi 3 1-10 Çözgen 1 3 0.001- 5 Kirmizi Pigment 20 5-25 Dolgu malzemesi 1 3 0.5-5 Dolgu malzemesi 2 10 1-15 Dolgu malzemesi 3 10 5-25 Yüzey Ajani 2 1-5 Reoloji Ajani 1 0.5 0.001-1 Köpük Kesici 0.5 0.001-1 Reoloji Ajani 2 3 1-5 Çözgen 2 15 5-25 Tablo 2 B komponenti reçetesi Agirlikça Tercih Agirlikça edilen Kullanilabilir miktar (%) miktar (%) Epoksi Kürleme Ajani 1 70 50-93 Aktivatör 1 7 1_10 Aktivatör 2 3 1_5 Epoksi Kürleme Ajani 2 20 5-15 Bulus konusu kaplama kompozisyonun bir uygulamasinda; bahsedilen A komponenti agirlikça %20-35 araliginda Likit epoksi reçine, % 1-10 araliginda yari kati novolak araliginda kirmizi pigment, %0.5-5 araliginda dolgu malzemesi 1, %1-15 araliginda dolgu malzemesi 2, %5-25 araliginda dolgu malzemesi 3, % 1-5 araliginda yüzey ajani, reoloji ajani 2 içermektedir. Burada çözgen 1 tercihen reaktif çözgen ve çözgen 2 tercihen Monoepoksi reaktif çözgendir. Bulus konusu kaplama kompozisyonun bir uygulamasinda; bahsedilen B komponenti agirlikça % 50-93 araliginda Epoksi kürleme ajani 1, % 5-15 araliginda kürleme ajani 2 ve % 1-10 araliginda Aktivatör 1 ve % 1-5 araliginda Aktivatör 2 içermektedir. Bulus, A komponenti, B komponentinin dogrudan karistirilmasiyla uygulanmaktadir. Karisim agirlikça 2.5/1- 5. oranlariyla karistirilarak uygulanmaktadir. Bulus A ve B komponenti dogrudan karistirilarak airless tabanca iIe kullanilmaktadir. Bulus konusu kaplama kompozisyonun A komponenti bilesenlerinin özellikleri asagida verilmektedir' Likit Epoksi Reçinesi: oda sicakliginda sivi halde bulunan, bisfenol A ve epiklorohidrin kullanilarak üretilen orta viskoziteli bir epoksi reçinedir. Seyreltici içermez. Bu reçine, iyi pigment islanmasi saglar ve dolgu maddelerinin çökmesine karsi direnç gösterir. Kürlendikten sonra ise yüksek mekanik ve kimyasal direnç özellikleri sunar. Yari Kati Novolak Epoksi Reçinesi: çok fonksiyonlu bir novolak epoksi reçinesidir ve genellikle kati novolak epoksi reçineleri ile iliskilidir. Iyi bir yapisma kuvveti gösteren fonksiyonel epoksi gruplari içerir, bu da tamamen çapraz bagli yapilar olusturarak mükemmel isi ve kimyasal dayaniklilik saglar. Çözgen 1: reaktif bir çözgen olup, viskoziteyi düsürmek, korozyon, nem ve kimyasal dayanimini artirmak amaciyla formülasyona eklenir. Kirmizi Pigment: Pigment olup, yüksek örtücülük özelligi saglar. Bulus dolgu malzemesi olarak 3 farkli malzeme içermektedir Dolgu malzemesi 1: Dolgu maddesidir ve korozyon ile nem dayanimini artirir. Dolgu malzemesi 2: Dolgu maddesidir ve korozyon ile nem dayanimini iyilestirir. Dolgu malzemesi 3: Dolgu maddesidir ve korozyon, nem dayaniminin yani sira esneklik Yüzey Ajani: Katkidir ve özel epoksi-silan özellikleri sayesinde yapisma gücünü artirir. Bulus Reoloji Ajani olarak 2 farkli malzeme içermektedir Reoloji Ajani 1: Katkidir ve sarkma direncini iyilestirir. Köpük Kesici: Katkidir ve köpük olusumunu engeller. Reoloji Ajani 2: Reolojik katkidir ve sarkma direncini iyilestirir. Çözgen 2: Monoepoksi reaktif çözgendir; esneklik ve mekanik özelliklerin iyilestirilmesine katki saglar. Bulus konusu kaplama kompozisyonun B komponenti bilesenlerinin özellikleri asagida verilmektedir' Epoksi Kürleme Ajani 1: Biyo-bazli fenalkamin yapisiyla, hizli kürlenme, düsük viskozite, çevre dostu içerik ve yüksek mekanik ile kimyasal dayanim saglayan bir epoksi sertlestiricisidir. Aktivatör 1: Tris-2,4,6-dimetilaminometil fenol yapisina sahip olup, kürleme sürecinde etkili bir aktivatördür. Aktivatör 2: Kürleme islemini hizlandiran ve/veya yardimci sertlestirici olarak islev görür. Epoksi Kürleme Ajani 2: Iki bilesenli epoksi formülasyonlarinda kullanilmak üzere tasarlanmis, yüksek islevsellige sahip alifatik bir amindir. Özellikle çok islevli epoksi novolak reçinelerle kullanim için uygundur. Epoksi kürleme ajani 2, mükemmel kimyasal direnç saglayan formülasyonlar sunar. Bulus konusu çelik yüzeylerin kaplamasinda kullanilmak üzere akis verimliligi, yüksek korozyon direnci ve dayaniklilik saglayan solventsiz epoksi bazli kaplamanin üretim yöntemi asagidaki islem adimlarini içermektedir; A komponentinin; i. Likit epoksi reçine, yari kati novolak epoksi reçinenin kazana ilave edilerek karistirilmasi ii. Çözgen 1 kazana ilave edilerek karistirilmasi, iii. Kirmizi pigmentin kazana ilave edilerek karistirilmasi, iv. Sirasiyla Dolgu malzemelerinin karistirma altinda karisima eklenmesi v. Karisima sirasiyla Yüzey ajani, reoloji ajani 1, köpük kesici ve reoloji ajani 2 karistirma altinda ilave edilerek karistirilmasi vi. Karisimin ezme makinesiyle ezilmesi, vii. Ezilen karisima çözgen 2 ilave edilerek vakum altinda karistirilmasi islem adimlariyla; B komponentinin; a) Epoksi kürleme ajani 1 kazana ilave edilerek karistirilmasi, b) Sirasiyla Aktivatör 1 ve aktivatör 2 kazana ilave edilerek karistirilmasi, c) Karisima Epoksi kürleme ajani 2 ilave edilerek karistirilmasi islem adimlariyla elde edilmesini içermesidir. Bulus konusu yöntemin i) adimi Likit epoksi reçine, yari kati novolak epoksi reçinenin vakumlu dissolver kazana ilave edilerek tercihen 1000 devirde 15 dakika süresince karistirilmasini içermektedir. Bulus konusu yöntemin iii) adimi karisima kirmizi pigment ilave edilerek tercihen 1200 devirde minimum 10 dakika süresince karistirilmasini içermektedir. Bulus konusu yöntemin bir uygulamasinda iv) adim dolgu malzemesi 1 karistirma altinda ilave edilerek minimum 30 dakika süresince karistirilmasi, ardindan dolgu malzemesi 2 tercihen 1200 devirde karistirma altinda ilave edilerek 30 dakika karistirilmasi ve dolgu malzemesi 3 tercihen 1200 devirde karistirma altinda ilave edilerek 30 dakika karistirilmasini içermektedir. Burada karistirma sicakligi 65- 70 °C araligindadir. Bulus konusu yöntemin vi) adiminda Karisim ezme makinesiyle tercihen max 30 um boyutuna ezilmektedir. Bulus konusu yöntemin vii) adiminda ezilen karisima çözgen 2 ilave edilerek tercihen 600 mmHg vakum altinda 30 dakika karistirilmasini içermektedir. Bulus konusu yöntemin A komponentinin hazirlanmasinda karistirma islemleri 20-70 °C araliginda sicaklikta gerçeklestirilmektedir. A komponent bir örneginin hazirlanmasi için dikkat edilmesi qerekenler su seki/dedin' 1.adim: Likit epoksi ve yari kati novolak epoksi reçineleri vakumlu dissolver (sogutmali) Kazanina alinarak 1000 devirde karistirmaya baslanmaktadir. 2.adim: Çözgen 1 karistirma altinda kazana eklenmekte ve karistirilmaktadir. 3.adim: Kirmizi pigment karistirma altinda eklenerek 1200 devirde 10 dakika karistirilmaktadir. 4.adim: Ardindan dolgu malzemeleri eklenmektedir, ilk olarak dolgu malzemesi 1 karistirma altinda eklenerek 1200 devirde 30 dakika karistirilmaktadir. Ardindan dolgu malzemesi 2 karisim altinda eklenerek 1200 devirde 30 dakika karistirilmakta ve dolgu malzemesi 3 karistirma altinda eklenerek 1200 devirde 30 dakika karistirilmaktadir. Bu adimda sicaklik kontrolü (Min.65C-Max.70C) yapilmaktadir. .adim: Karisima sirasiyla yüzey ajani karistirma altinda eklenmekte, ardindan reoloji ajani 1 karistirma altinda eklenmekte, köpük kesici karistirma altinda eklenmekte ve reoloji ajani 2 karistirma altinda eklenmekte ve 1200 Devirde 10 Dakika Karistirilmaktadir. Bu adimda sicaklik kontrolü (Min.65C-Max.70C) yapilmaktadir. 6.adim:Karisimin ezme prosesine alinmasi ve en az 1 pas ezme islemi yapilmasi ve grindometre ile tanecik boyutu kontrol edilmesi. Istenilen tanecik boyutu 30 pm altidir. Bu degere ulasilana kadar ezme islemi yapilmaktadir. altinda karistirilmaktadir. Vakum altinda karistirma ile olusan köpügün giderilmesi saglanmaktadir. B komponent bir örneginin hazirlanmasi için dikkat edilmesi qerekenler su seki/dedin' Sertlestirici hazirlanmasi setüp is merkezi prosesinde gerçeklestirilmektedir. Öncelikle epoksi kürleme ajani 1 bir kaba eklenerek 600 devirde karistirilmaktadir. Ardindan Aktivatör 1 eklenerek 600 devirde 10 dakika karistirilmaktadir. Sonrasinda Aktivatör 2 eklenerek, 800 devirde 15 dakika karistirilmaktadir. Son adimda epoksi kürleme ajani 2 eklenerek, 800 devirde 15-20 dakika karistirilmaktadir. Bulus konusu ürün gelistirilen plural airless uygulama ile uygulanabilmektedir. Bunun için uygulama viskozitesine sicaklik uygulanarak getirilen kaplama hizli bir sekilde uygulanabilmektedir. Ortam kosullarinda ve düsük sicakliklarda hizlica kürlenebilmektedir. Bulus konusu kaplama 300°C`lere kadar olan sicakliklara dayanim göstermektedir. Hizli kuruma özelligi sayesinde borularin servise hizlica dönmesini saglamaktadir. Bulus epoksi karisimi (A komponenti) ile isi dayanimini saglamakta; sertlestirici (B komponenti) karisim kisim ise elastikiyet kazandirmaktadir. Bulus konusu kaplamanin VOC içerigi solvent bazli ürünlere göre oldukça azdir. Bulus konusu kaplama BS EN 10301 :2003(E), konusu ürünümüz belirtilen standartlara uygun gerçeklestirilen Adezyon, sertlik, tuz sprey, bükme, Yaslandirma, Suya daldirmaya karsi direnç, kimyasal direnç vb. testlerin tümünü geçmistir. Bulus konusu ürüne uygulanan test sonuçlari asagida tablo 3 de verilmektedir. Tablo 3 Test Analiz sonuçlari Test Method Standard Result Adhesion test/ Cross-cut test ISO 2409 GÄLI Buchholz hardness EN ISO 2815 G_eçLi Neutral salt spray (480 hours) EN ISO 7253/ BS EN ISO GÄLI Neutral salt spray (500 hours) ASTM B117 - API 5L2 GÄLI Appendix #2 Bend test- Conical Mandrel EN ISO 6860 GÄLI Bend test- Conical Mandrel ASTM D 522 GÄLI Ageing test (& bend test) EN10301:2003(E) Paragraph GÄLI 4.2.12 Resistance to hydraulic blistering EN 10301 Annex D GÄLI Hydraulic Blistering API 5L2 Appendix #6 GÄLI ± 2°C) Water lmmersion (21 days) (Saturated API 5L2 GÄLI with CaC03) glycol 2°C) Chemical Resistance (50% Methanol 5 API 5L2 GÄLI Stripping API 5L2 Appendix #3 GÄLI Gas BIistering API 5L2 Appendix #5 GÄLI Abrasion ASTM D 968 Method A TR TR TR TR TR TR TR DESCRIPTION SOLVENT-FREE EPOXY-BASED COATING WITH INCREASED CORROSION RESISTANCE Technical Field The invention relates to a new solvent-free epoxy-based coating for use as a corrosion inhibitor and flow efficiency coating on steel surfaces, and its production method. The invention relates to a solvent-free epoxy-based coating that has been developed specifically for use on the exterior and interior surfaces of steel gas transmission pipelines, with increased corrosion resistance while reducing environmental impact. State of the Art In the current art, solvent-based epoxy coatings are generally preferred for the protection of gas and oil transmission lines on external surfaces. These coatings are applied to the exterior surfaces of pipelines to provide corrosion resistance and aim to minimize damage caused by environmental factors. Solvent-based coatings harden by solvent evaporation during curing and subsequent cross-linking of the chemical components. This structure is particularly suitable for thin-film coatings and is frequently used in interior surface coatings to increase flow efficiency. However, existing solvent-based epoxy coatings release volatile organic compounds (VOCs) into the environment during solvent evaporation. This poses a threat to both worker health and challenges compliance with environmental regulations. Furthermore, because solvent-based coatings require longer curing times in thick-film applications, they are generally less resistant to harsh environmental conditions such as high temperatures. This reduces the long-term performance of the protective coating, reducing its durability. Therefore, an environmentally friendly product that provides high corrosion resistance and durability to prevent these problems is needed in the current state of the art. Document number TR2017/15987 can be cited as an example of the current state of the art in the literature. The application relates to a steel pipe coating. The document in question specifies that at least one first coating containing at least 200 g/m² of zinc metal, thermally sprayed onto the outer surface of the cylindrical main body developed for use in gas and liquid transmission in urban networks and transmission lines, is applied; at least one second coating containing an adhesive material, coated over the first coating to enclose the first coating; and at least one third coating, coated over the second coating to enclose the second coating, comprising individual or combinations selected from polyethylene, polypropylene, polyurethane, epoxy, and varnish. However, the application does not mention a two-component, solvent-free epoxy coating composition that can be used as a corrosion inhibitor for exterior surfaces and as a flow-efficient coating for interior surfaces. Consequently, due to the drawbacks described above and the inadequacy of existing solutions, a development in the relevant technical field has become necessary. Purpose of the Invention The invention was inspired by current conditions and aims to address the aforementioned drawbacks. The main purpose of the invention is to provide a solvent-free epoxy-based coating that provides high corrosion resistance and durability, and its production method. The purpose of the invention is to provide a solvent-free (98%) epoxy-based coating with reduced environmental impact that can be used as a corrosion inhibitor on external surfaces and as a flow-efficient coating on internal surfaces for steel gas transmission pipelines. Another purpose of the invention is to provide a coating that can withstand temperatures up to 300°C. Another purpose of the invention is to develop a product that provides rapid drying properties. The invention aims to provide heat resistance with the epoxy mixture it contains, and elasticity with the hardener mixture. Another purpose of the invention is to provide a product with a significantly lower VOC content compared to solvent-based products. In order to achieve the above-mentioned objectives, the invention is a solvent-free epoxy-based coating that provides flow efficiency, high corrosion resistance, and durability for use in coating steel surfaces. It contains: o Component A containing liquid epoxy resin, semi-solid novolak epoxy resin, solvent 1, solvent 2, red pigment, filler 1, filler 2, filler 3, surface agent, defoamer, rheology agent 1, and rheology agent 2; and o Component B containing epoxy curing agent 1, curing agent 2, and activator 1 and activator 2. In order to fulfill the above-described purposes, the invention is a production method of solvent-free epoxy based coating that provides flow efficiency, high corrosion resistance and durability to be used in the coating of steel surfaces; For component A; i. Liquid epoxy resin, semi-solid novolak epoxy resin are added to the drum and mixed, ii. Solvent 1 is added to the drum and mixed, iii. Red pigment is added to the drum and mixed, iv. Adding filler materials to the mixture under mixing, respectively, v. Adding surface agent, rheology agent 1, defoamer and rheology agent 2 to the mixture under mixing, respectively, and mixing, vi. Crushing the mixture with a crushing machine, vii. Adding solvent 2 to the crushed mixture and mixing under vacuum; For component B; The process involves obtaining it in the following steps: a) Adding Epoxy Curing Agent 1 to the tank and mixing, b) Adding Activator 1 and Activator 2 to the tank and mixing, respectively, c) Adding Epoxy Curing Agent 2 to the mixture and mixing. The structural and characteristic features of the invention and all its advantages will be more clearly understood thanks to the detailed description provided below, and therefore, the evaluation should be made by taking this detailed description into consideration. Detailed Description of the Invention In this detailed description, the solvent-free epoxy-based coating composition providing high corrosion resistance and durability that is the subject of the invention and its preferred structures are explained only for a better understanding of the subject. The present invention relates to a solvent-free epoxy-based coating composition and its production method that provides flow efficiency, high corrosion resistance, and durability for use in coating steel surfaces. The inventive product contains components A and B. Component A (paint) contains liquid epoxy resin, semi-solid novolak epoxy resin, solvent 1, solvent 2, red pigment, filler 1, filler 2, filler 3, surface agent, defoamer, rheology agent 1, and rheology agent 2, while component B (hardener) contains epoxy curing agent 1, curing agent 2, activator 1, and activator 2. Tables 1 and 2 provide the preferred and usable amounts of these components by weight. Table 1 Component A recipe Preferred By Weight Available amount (%) amount (%) Liquid Epoxy Resin 30 20-35 Semi-Solid Novolac Epoxy 3 1-10 Solvent 1 3 0.001- 5 Red Pigment 20 5-25 Filler 1 3 0.5-5 Filler 2 10 1-15 Filler 3 10 5-25 Surface Agent 2 1-5 Rheology Agent 1 0.5 0.001-1 Defoamer 0.5 0.001-1 Rheology Agent 2 3 1-5 Solvent 2 15 5-25 Table 2 Component B recipe Preferred By Weight Available amount (%) amount (%) Epoxy Curing Agent 1 70 50-93 Activator 1 7 1_10 Activator 2 3 1_5 Epoxy Curing Agent 2 20 5-15 In one application of the coating composition according to the invention; said component A contains by weight 20-35% liquid epoxy resin, 1-10% semi-solid novolak red pigment, 0.5-5% filler material 1, 1-15% filler material 2, 5-25% filler material 3, 1-5% surface agent, rheology agent 2. Here, solvent 1 is preferably reactive solvent and solvent 2 is preferably Monoepoxy reactive solvent. In one application of the coating composition according to the invention; The said component B contains Epoxy curing agent 1 in the range of 50-93% by weight, curing agent 2 in the range of 5-15% and Activator 1 in the range of 1-10% and Activator 2 in the range of 1-5%. The invention is applied by directly mixing component A and component B. The mixture is applied by mixing at a ratio of 2.5/1-5 by weight. Components A and B of the invention are directly mixed and used with an airless gun. The properties of the component A components of the coating composition which is the subject of the invention are given below. Liquid Epoxy Resin: It is a medium viscosity epoxy resin which is liquid at room temperature and produced by using bisphenol A and epichlorohydrin. It does not contain diluent. This resin provides good pigment wetting and resists filler settling. After curing, it offers high mechanical and chemical resistance properties. Semi-Solid Novolac Epoxy Resin: A multifunctional novolac epoxy resin, generally associated with solid novolac epoxy resins. It contains functional epoxy groups that exhibit good adhesion, forming fully cross-linked structures that provide excellent heat and chemical resistance. Solvent 1: A reactive solvent added to the formulation to reduce viscosity and increase corrosion, moisture, and chemical resistance. Red Pigment: A pigment that provides high hiding power. The invention contains three different filler materials: Filler 1: A filler that improves corrosion and moisture resistance. Filler 2: A filler that improves corrosion and moisture resistance. Filler 3: It is a filler and provides corrosion and moisture resistance as well as flexibility. Surface Agent: It is an additive and increases adhesion strength thanks to its special epoxy-silane properties. The invention contains 2 different materials as Rheology Agents. Rheology Agent 1: It is an additive and improves sag resistance. Defoamer: It is an additive and prevents foam formation. Rheology Agent 2: It is a rheological additive and improves sag resistance. Solvent 2: It is a monoepoxy reactive solvent; it contributes to the improvement of flexibility and mechanical properties. The properties of the components of component B of the coating composition which is the subject of the invention are given below. Epoxy Curing Agent 1: It is an epoxy hardener that provides fast curing, low viscosity, environmentally friendly content and high mechanical and chemical resistance with its bio-based phenalkamine structure. Activator 1: It has a Tris-2,4,6-dimethylaminomethyl phenol structure and is an effective activator in the curing process. Activator 2: It accelerates the curing process and/or acts as an auxiliary hardener. Epoxy Curing Agent 2: It is a high-functional aliphatic amine designed for use in two-component epoxy formulations. It is especially suitable for use with multifunctional epoxy novolak resins. Epoxy curing agent 2 offers formulations that provide excellent chemical resistance. The production method of the solvent-free epoxy-based coating which provides flow efficiency, high corrosion resistance and durability to be used in the coating of steel surfaces which is the subject of the invention includes the following process steps; Component A; i. Liquid epoxy resin, semi-solid novolak epoxy resin are added to the boiler and mixed, ii. Solvent 1 is added to the boiler and mixed, iii. Red pigment is added to the boiler and mixed, iv. Adding filler materials to the mixture under mixing, respectively, v. Adding surface agent, rheology agent 1, defoamer and rheology agent 2 to the mixture under mixing, respectively, and mixing, vi. Crushing the mixture with a crushing machine, vii. Adding solvent 2 to the crushed mixture and mixing under vacuum, the process steps are as follows; Component B; a) Epoxy curing agent 1 is added to the tank and mixed, b) Activator 1 and activator 2 are added to the tank and mixed, c) Epoxy curing agent 2 is added to the mixture and mixed. Step i) of the method of the invention involves adding liquid epoxy resin, semi-solid novolak epoxy resin to the vacuum dissolver tank and mixing it for 15 minutes, preferably at 1000 rpm. Step iii) of the method of the invention involves adding red pigment to the mixture and mixing it for a minimum of 10 minutes, preferably at 1200 rpm. In one embodiment of the method of the invention, step iv) includes adding the filling material 1 under mixing and mixing for a minimum of 30 minutes, then adding the filling material 2 under mixing preferably at 1200 rpm and mixing for 30 minutes, and adding the filling material 3 under mixing preferably at 1200 rpm and mixing for 30 minutes. The mixing temperature here is in the range of 65-70 ° C. In step vi) of the method of the invention, the mixture is crushed with a crushing machine, preferably to a maximum size of 30 µm. In step vii) of the method of the invention, solvent 2 is added to the crushed mixture and mixing for 30 minutes, preferably under a vacuum of 600 mmHg. In the preparation of component A of the method according to the invention, the mixing processes are carried out at temperatures between 20-70 ° C. Things to consider when preparing a sample of component A are as follows: Step 1: Liquid epoxy and semi-solid novolak epoxy resins are taken into the vacuum dissolver (cooled) tank and mixing is started at 1000 rpm. Step 2: Solvent 1 is added to the tank under mixing and mixed. Step 3: Red pigment is added under mixing and mixed at 1200 rpm for 10 minutes. Step 4: Then the filling materials are added; first the filling material 1 is added under mixing and mixed at 1200 rpm for 30 minutes. Then, the filling material is added under mixing 2 and mixed at 1200 rpm for 30 minutes, and the filling material is added under mixing 3 and mixed at 1200 rpm for 30 minutes. In this step, temperature control (Min. 65C-Max. 70C) is carried out. . step: Surface agent is added to the mixture under mixing, then rheology agent 1 is added under mixing, defoamer is added under mixing and rheology agent 2 is added under mixing and mixed at 1200 rpm for 10 minutes. Temperature control (Min. 65C-Max. 70C) is carried out in this step. Step 6: The mixture is taken to the grinding process, at least one pass is crushed, and the particle size is checked with a grindometer. The desired particle size is below 30 pm. Grinding is continued until this value is reached. Mixing is carried out under vacuum. Foam formation is eliminated by mixing under vacuum. Precautions for preparing a component B sample: Water/destination. Hardener preparation is carried out in the set-up work center process. First, epoxy curing agent 1 is added to a container and mixed at 600 rpm. Then, Activator 1 is added and mixed at 600 rpm for 10 minutes. Activator 2 is then added and mixed at 800 rpm for 15 minutes. In the final step, epoxy curing agent 2 is added and mixed at 800 rpm for 15-20 minutes. The inventive product can be applied using the developed plural airless application system. By adjusting the application viscosity by adjusting the temperature, the coating can be applied quickly. It can cure quickly in ambient conditions and at low temperatures. The inventive coating is resistant to temperatures up to 300°C. Its rapid drying properties allow the pipes to be quickly returned to service. The inventive epoxy mixture (component A) provides heat resistance, while the hardener (component B) provides elasticity. The inventive coating has a significantly lower VOC content than solvent-based products. The coating in question is BS EN 10301:2003(E), and our subject product has passed all the tests such as adhesion, hardness, salt spray, bending, ageing, resistance to water immersion, chemical resistance, etc., carried out in accordance with the specified standards. The test results applied to the product of the invention are given in table 3 below. Table 3 Test Analysis Results Test Method Standard Result Adhesion test/ Cross-cut test ISO 2409 GÄLI Buchholz hardness EN ISO 2815 G_eçLi Neutral salt spray (480 hours) EN ISO 7253/ BS EN ISO GÄLI Neutral salt spray (500 hours) ASTM B117 - API 5L2 GÄLI Appendix #2 Bend test - Conical Mandrel EN ISO 6860 5L2 Appendix #6 GÄLI ± 2°C) Water lmmersion (21 days) (Saturated API 5L2 GÄLI with CaC03) glycol 2°C) Chemical Resistance (50% Methanol 5 API 5L2 GÄLI Stripping API 5L2 Appendix #3 GÄLI Gas BIistering API 5L2 Appendix #5 GÄLI Abrasion ASTM D 968 Method A TR TR TR TR TR TR TR

TR2025/001661 2025-02-13 COMPOSITION AND PRODUCTION METHOD OF SOLVENT-FREE EPOXY-BASED COATING WITH INCREASED CORROSION RESISTANCE TR2025001661A2 (en)

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