Corrosion costs the US O&G exploration and production industry $1.4 billion (CoC) per year. Metal structures are widely used in the oil and gas industry, where harsh offshore environments lead to severe corrosion, driving up operational and maintenance costs (OPEX) and posing significant health, safety, and environmental risks (HSE). Protective coatings are essential to mitigate corrosion, but conventional hydrophobic coatings often lack the long-term durability required for such aggressive conditions. Superhydrophobic coatings, characterized by high water repellency and low water adhesion, have shown promise for multifunctional applications, including corrosion protection, self-cleaning, and friction reduction. However, challenges remain in scaling up their production to achieve the desired durability and environmental sustainability for offshore use. This project focuses on developing hydrophobic coatings tailored for offshore conditions and on protecting metal surfaces against corrosion. Commercial coatings guided new formulations, in which nanoparticles, such as graphene (nanoplates) and cerium oxide, with high specific surface area were characterized using techniques such as SEM, Thermogravimetric Analysis (TGA), and Raman spectroscopy. These nanoparticles were incorporated into commercial paint formulations to enhance their hydrophobic and anticorrosive properties. The modification of a commercial acrylic-based coating by incorporating 0.1 % graphene enhanced abrasion resistance by 63 %, while the addition of 0.5 % CeO₂ resulted in a 17 % improvement, compared to the pristine commercial paint. The increased homogeneity of the surface roughness after the abrasion test resulted in higher contact angles for all samples studied. The best-performing coatings will undergo pilot-scale production and extensive laboratory and field testing under simulated offshore conditions.
