Taking Lessons From the Iron Pillar Into Oil and Gas: Long-Term Corrosion Prevention is Possible

All metal must rust, right? One of history’s most beguiling mysteries suggests otherwise.

The Iron Pillar of Delhi is a 23-foot wrought iron pole standing outside a mosque in India. It may look like a fairly simple structure, but what makes it special is the condition of the metal. The surface of the Iron Pillar is pristine without a spot of rust, which is truly remarkable considering that the pole has been standing outside for over 1,600 years.

Materials Performance Magazine recently highlighted the composition of the Iron Pillar and the similarities between ancient wrought iron and modern steel. Scientific analysis showed that the Iron Pillar is covered in an amorphous layer of misawite that prevents rust. The protective layer, which in this case was caused by defects in the iron, proves a powerful point — metal can be exposed to extreme conditions for centuries and remain in pristine condition. All it takes is the right coating.

If the Iron Pillar Can Stand Impervious to Rust, So Can Your Carbon Steel

The oil and gas industry is hugely dependent on steel assets deployed in high-stress situations. For decades, the industry has been forced to treat these as disposable assets because they are highly susceptible to rust, corrosion, and eventually to malfunction. Believing corrosion to be inevitable, companies focus on how often they need to replace carbon steel rather than how to prolong the life of their steel equipment for decades.

The Iron Pillar shows us that with the right layer of protection, metal assets can remain unaffected by corrosion for many years. EonCoat? provides that protection for the oil and gas industry’s carbon steel assets, with a patented dual-layer formula. When EonCoat? is applied to the surface of carbon steel, it forms a magnesium iron phosphate layer that alloys the steel. Because this layer is chemically bonded to the steel surface, oxygen and moisture cannot have any contact with the passivated steel. A ceramic layer is chemically bonded to the alloy layer for further protection from the elements. The ceramic layer also acts as a phosphate reservoir if needed.

EonCoat? is not the first anti-corrosion coating on the market, but it’s the last one you’ll ever need to apply to your steel assets.

What Makes EonCoat? So Effective Against Corrosion?

What differentiates our coating is its high durability, allowing it to last for decades and making it extremely resistant to coating failure. Other products are vulnerable to scratches, scrapes, or environmental degradation. Once a traditional coating is damaged, the steel is exposed to corrosion-causing agents that can spread uninhibited across the surface.

EonCoat? eliminates these issues in several ways. First, EonCoat? requires minimal surface preparation before applying, which not only reduces costs but also decreases the risk of errors during surface preparation that can lead to coating failure. It can even be applied on top of existing flash rust.

The outer ceramic layer is extremely resistant to damage, but even if mechanical damage does occur, environmental elements cannot reach the steel thanks to the iron phosphate layer that is chemically bonded to the steel. If the mechanical damage is so severe that it cuts through both the ceramic layer and the alloy layer, the coating heals itself by leaching phosphate to re-alloy the steel. Because EonCoat? is not only long-lasting but also self-healing, there’s no need to reapply.

With EonCoat’s patented formula, long-term protection can be applied to carbon steel. By preventing corrosion for decades, EonCoat? reduces downtime, replacement costs, and maintenance challenges for oil and gas companies. It transforms how your company leverages its steel assets.

EonCoat? in Action: An Oil & Gas Case Study

The effectiveness of EonCoat? has been put to the test by research teams across many industries.

Most recently, EonCoat? was presented at EUROCORR 2018 in a paper titled “Chevron’s Use of EonCoat? To Prevent Corrosion On Steel,” showcasing EonCoat’s effectiveness in the oil and gas industry. The paper describes how both lab and field tests were conducted over five years to determine how EonCoat? performed under a variety of stress scenarios. In actual use on storage tanks and pipelines coated with EonCoat? in locations with high humidity and salt, the corrosion protection was complete. Researchers even deliberately inflicted mechanical damage on panels coated with EonCoat? by forcefully tearing away the ceramic layer with hammer, chisel and saw — still, rust did not form due to the intact alloy layer beneath. EonCoat? performed better than organic coating options, and it provided fail-proof protection even after being exposed to extreme abuse and harsh environmental conditions.

The paper’s authors estimated that EonCoat? will provide effective protection for 30+ years, which far exceeds the typical lifespan for steel equipment in the oil and gas industry. With steel costs rising, oil and gas companies need to get serious about preserving their investments.

The Iron Pillar shows us that long-term corrosion prevention is possible; EonCoat? turns this possibility into a reality for carbon steel. Contact our team to transform your approach to maintaining your carbon steel assets.