An industrial anticorrosive coating material, a preparation method and application thereof

Abstract

The application relates to the technical field of paint, in particular to an industrial anticorrosive paint as well as a preparation method and application thereof. An industrial anticorrosive paint is provided, which comprises the following components in parts by mass: 1825 parts of epoxy resin, 2540 parts of modified coal ash, 812 parts of a curing agent, 510 parts of anti-rust pigment, 13 parts of a dispersing agent, 0.5-1.5 parts of a wetting agent, 0.3-0.8 parts of a defoaming agent, 0.2-0.6 parts of a leveling agent, 25 parts of a film-forming aid and 510 parts of a solvent. The paint has excellent anticorrosive performance, the overall raw material cost is reduced compared with traditional anticorrosive paint due to the low cost of the coal ash, the product has good construction adaptability and can be sprayed, brushed or rolled, and is conducive to wide application.

Description

Technical Field

[0001] This application belongs to the field of coating technology, and in particular relates to an industrial anti-corrosion coating, its preparation method and application. Background Technology

[0002] Industrial anti-corrosion coatings are key functional materials used to protect metal substrates from corrosion and extend the service life of related facilities and equipment. They are widely used in building steel structures, chemical equipment, marine facilities, and other fields. Currently, most traditional industrial anti-corrosion coatings use natural minerals such as talc, barite powder, and quartz sand as their main fillers. While these fillers meet protective requirements to some extent, their reliance on the mining of natural mineral resources not only consumes a large amount of non-renewable resources and increases production costs, but also often results in significant environmental impacts during the mining and processing processes. Furthermore, to ensure the protective performance of the coating, traditional formulations often rely on a high proportion of resin and expensive rust-preventive pigments, leading to high overall product costs. Additionally, some traditional coatings have high levels of volatile organic compounds (VOCs), making it difficult to meet increasingly stringent environmental standards.

[0003] However, existing technologies for applying industrial solid waste coal ash to anti-corrosion coatings still have significant shortcomings. On the one hand, most studies have not adequately pretreated the coal ash, leaving residual unburned carbon that can affect the stability and anti-corrosion effect of the coating. Furthermore, the inherent hydrophilicity of the coal ash surface makes it incompatible with hydrophobic resin matrices, easily leading to problems such as film cracking and decreased adhesion. On the other hand, the amount of coal ash added in existing formulations often lacks scientific basis; adding too little fails to demonstrate its cost advantage, while adding too much affects the coating's application performance and final protective effect. In terms of preparation processes, existing methods are generally quite crude, failing to achieve uniform dispersion of fillers, resulting in insufficient film density and high porosity, thus limiting the actual anti-corrosion performance of the coating.

[0004] Therefore, there is an urgent need to develop an industrial anti-corrosion coating that can make full use of coal ash, achieve efficient resource utilization of coal ash through reasonable formula design and optimized preparation process, and simultaneously improve the anti-corrosion performance, environmental protection and economy of the coating. Summary of the Invention

[0005] The purpose of this application is to provide an industrial anti-corrosion coating, its preparation method and application, which aims to solve the problems of poor compatibility, insufficient anti-corrosion performance and lack of cost advantage of existing coal ash-based coatings.

[0006] To achieve the above-mentioned objectives, the technical solution adopted in this application is as follows: In a first aspect, this application provides an industrial anti-corrosion coating comprising the following components in parts by weight: epoxy resin 18 25 parts, modified fly ash 25 40 parts, curing agent 8 12 parts, 5 parts anti-rust pigment 10 parts, dispersant 1 3 parts, wetting agent 0.5g 1.5 parts, defoamer 0.3 parts 0.8 parts, leveling agent 0.2 parts 0.6 parts, film-forming aid 2 parts 5 parts, solvent 5 10 copies.

[0007] In some embodiments, the method for preparing modified coal ash includes: providing industrial coal ash and subjecting it to decarbonization treatment; then pulverizing and sieving it; and adding a silane coupling agent for surface modification treatment; wherein the modified coal ash has a carbon content ≤5% and a particle size of 600 μm. 800 mesh.

[0008] In some embodiments, the silane coupling agent is selected from KH 550, KH At least one of 560.

[0009] In some embodiments, the total mass of industrial coal ash is 100%, and the content of silane coupling agent is 0.5%. 3%.

[0010] In some embodiments, the decarbonization process includes: heating to 500-700°C at a heating rate of 5-10°C / min and treating for 1-4 hours.

[0011] In some embodiments, the crushing and sieving step includes: crushing at a speed of 60-120 rpm for 30-90 minutes.

[0012] In some embodiments, the surface modification treatment step includes: diluting the silane coupling agent with anhydrous ethanol and slowly adding it dropwise to pulverized industrial coal ash under stirring conditions for 5-10 minutes, and then keeping it at 85-95°C and stirring for 30-60 minutes after the addition is complete.

[0013] In some embodiments, epoxy resins include bisphenol A type epoxy resin E. 44. Bisphenol A type epoxy resin E At least one of 51.

[0014] In some embodiments, the curing agent includes at least one of polyamide 650 and polyamide 651.

[0015] In some embodiments, the rust-preventive pigment is selected from at least one of zinc phosphate and aluminum tripolyphosphate.

[0016] In some embodiments, the dispersant includes a polycarboxylate dispersant.

[0017] In some embodiments, the wetting agent comprises a polyether siloxane copolymer.

[0018] In some embodiments, the defoamer includes silicone-based defoamers.

[0019] In some embodiments, the leveling agent includes an acrylate leveling agent.

[0020] In some embodiments, the film-forming aid includes at least one of ethylene glycol ethyl ether acetate and propylene glycol methyl ether acetate.

[0021] In some embodiments, the solvent comprises a mixture of xylene and cyclohexanone in a mass ratio of (1-1.1):(1-1.1).

[0022] Secondly, this application provides a method for preparing the above-mentioned industrial anti-corrosion coating, comprising the following steps: A first mixture is obtained by first mixing the dispersant, wetting agent, defoamer, film-forming aid and part of the solvent; the first mixture is then mixed with modified fly ash and anti-rust pigment to obtain a pre-dispersed slurry. The pre-dispersed slurry was ground to obtain the first slurry; After the epoxy resin and the remaining solvent are mixed in a third process, they are mixed with the first slurry in a fourth process to obtain the coating base material. The coating base is cooled, mixed with a curing agent and a leveling agent in a fifth stage, and then filtered to obtain an industrial anti-corrosion coating.

[0023] In some embodiments, the first mixing process is carried out at a rotation speed of 800-1000 rpm for 5-10 minutes.

[0024] In some embodiments, the second mixing process is carried out at a rotation speed of 1500-2000 rpm for a time of 30-45 minutes; and the second mixing process is carried out under a nitrogen protective atmosphere, wherein the nitrogen flow rate is 0.3-0.5 L / min.

[0025] In some embodiments, the third mixing process is performed at a rotation speed of 500-800 rpm for 10-15 minutes.

[0026] In some embodiments, the fourth mixing process is performed at a rotation speed of 500-800 rpm for 60-90 minutes.

[0027] In some embodiments, the fifth mixing process is performed at a speed of 1000-1200 rpm for 20-30 minutes.

[0028] Thirdly, this application provides the application of the above-mentioned industrial anti-corrosion coatings in the anti-corrosion coating of steel structures, chemical reactors, offshore platforms or bridge steel components.

[0029] The industrial anti-corrosion coating provided in the first aspect of this application uses industrial solid waste coal ash as the core functional filler, combined with epoxy resin, curing agent, and anti-rust pigments to ensure that the coating has both excellent mechanical properties and chemical stability. Through the optimized combination of polycarboxylate dispersant, polyether siloxane wetting agent, organosilicon defoamer, and acrylic leveling agent, the uniformity of filler dispersion and the smoothness of the paint film are effectively improved. At the same time, this coating has excellent salt spray resistance and acid and alkali resistance, adhesion of Grade 1, and hardness ≥2H; high solid content, VOC emission ≤100g / L, meeting national environmental protection standards, and the low cost of coal ash reduces the overall raw material cost compared with traditional anti-corrosion coatings; the product has good application adaptability, can be sprayed, brushed, or rolled, which is conducive to wide application.

[0030] The second aspect of this application provides a method for preparing industrial anti-corrosion coatings. This method employs a step-by-step process of "pre-dispersion-grinding-resin mixing-finished product preparation." By controlling the rotation speed and time of each different mixing process, the method ensures uniform mixing of all components, thereby improving the stability and application performance of the coating. This preparation method is simple, does not require large-scale equipment, and is beneficial for industrial applications.

[0031] The industrial anti-corrosion coatings provided in the third aspect of this application are used in the anti-corrosion coating of steel structures, chemical reactors, offshore platforms, or bridge steel components. Because the provided industrial anti-corrosion coatings have excellent anti-corrosion performance and can effectively block the penetration of corrosive media such as water, oxygen, and salt, they are suitable for construction in various structures, applicable to the coating needs of different industrial scenarios, and have a fast drying speed and high construction efficiency, which is conducive to their wide application. Detailed Implementation

[0032] To make the technical problems, technical solutions, and beneficial effects of this application clearer, the following detailed description is provided in conjunction with embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0033] In this application, the term "and / or" describes the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, or B existing alone. A and B can be singular or plural. The character " / " generally indicates that the preceding and following related objects have an "or" relationship.

[0034] In this application, "at least one" means one or more, and "more than one" means two or more. "At least one of the following" or similar expressions refer to any combination of these items, including any combination of single or multiple items. For example, "at least one of a, b, or c", or "at least one of a, b, and c", can both mean: a, b, c, ab (i.e., a and b), ac, bc, or abc, where a, b, and c can be single or multiple.

[0035] It should be understood that in the various embodiments of this application, the order of the above processes does not imply the order of execution. Some or all steps may be executed in parallel or sequentially. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of this application.

[0036] The terminology used in the embodiments of this application is for the purpose of describing particular embodiments only and is not intended to be limiting of this application. The singular forms "a" and "the" as used in the embodiments of this application and the appended claims are also intended to include the plural forms, unless the context clearly indicates otherwise.

[0037] The weights of the relevant components mentioned in the embodiments of this application can refer not only to the specific content of each component, but also to the proportional relationship between the weights of the components. Therefore, any scaling up or down of the content of the relevant components according to the embodiments of this application is within the scope disclosed in the embodiments of this application. Specifically, the mass in the embodiments of this application can be a well-known unit of mass in the chemical industry, such as µg, mg, g, or kg.

[0038] The terms "first" and "second" are used for descriptive purposes only, to distinguish objects, such as substances, from one another, and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. For example, without departing from the scope of the embodiments of this application, "first XX" may also be referred to as "second XX," and similarly, "second XX" may also be referred to as "first XX." Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of that feature.

[0039] The first aspect of this application provides an industrial anti-corrosion coating, comprising the following components in parts by weight: epoxy resin 18 25 parts, modified fly ash 25 40 parts, curing agent 8 12 parts, 5 parts anti-rust pigment 10 parts, dispersant 1 3 parts, wetting agent 0.5g 1.5 parts, defoamer 0.3 parts 0.8 parts, leveling agent 0.2 parts 0.6 parts, film-forming aid 2 parts 5 parts, solvent 5 10 copies.

[0040] The industrial method coatings provided in this application realize the resource utilization of solid waste, with significant environmental advantages. Specifically, using industrial solid waste coal ash as the core filler, replacing traditional natural mineral fillers, not only solves the pollution problem caused by coal ash accumulation but also reduces the consumption of natural mineral resources, aligning with the concepts of "circular economy" and "green development." Simultaneously, optimized solvent and additive selection results in VOC emissions ≤100g / L, lower than the limits set by GB 18581-2020 "Limits of Hazardous Substances in Wood Coatings" and GB 30981-2024 "Limits of Hazardous Substances in Industrial Protective Coatings," demonstrating excellent environmental performance.

[0041] Meanwhile, modified fly ash is widely available and inexpensive (about 1 / 3 to 1 / 2 the cost of traditional fillers), and its addition accounts for 25% to 40% of the total mass of the coating, which greatly reduces the cost of raw materials. Compared with traditional industrial anti-corrosion coatings, the overall cost is reduced by 15% to 25%, making it highly competitive in the market.

[0042] In terms of performance, through the synergistic effect of the physical filling effect of modified coal ash and the chemical rust-preventing effect of rust-preventing pigments, the coating exhibits salt spray resistance ≥500h, acid and alkali resistance ≥300h, adhesion ≤1 grade, and pencil hardness ≥2H. It effectively blocks the penetration of corrosive media such as water, oxygen, and salt, providing long-term and reliable anti-corrosion protection for metal substrates. Furthermore, the coating has a moderate viscosity and can be applied using various methods such as spraying, brushing, and rolling, making it suitable for coating needs in different industrial scenarios. It also dries quickly and has high construction efficiency.

[0043] In some embodiments, the industrial anti-corrosion coating includes 18 25 parts epoxy resin. In some embodiments, the epoxy resin comprises bisphenol A type epoxy resin E. 44. Bisphenol A type epoxy resin E At least one of 51.

[0044] In some embodiments, the industrial anti-corrosion coating comprises 25-40 parts of modified fly ash.

[0045] In some embodiments, the method for preparing modified coal ash includes: providing industrial coal ash and subjecting it to decarbonization treatment; then pulverizing and sieving it; and adding a silane coupling agent for surface modification treatment; wherein the modified coal ash has a carbon content ≤5% and a particle size of 600 μm. 800 mesh. Through a step-by-step process of decarbonization, crushing and screening, and surface modification, the performance of coal ash as a filler in anti-corrosion coatings is comprehensively improved.

[0046] The decarbonization treatment effectively removes unburned carbon from the coal ash that affects the stability and color of the coating, creating a pure inorganic matrix for subsequent modification. In some embodiments, the decarbonization treatment step includes: heating to 500-700°C at a heating rate of 5-10°C / min and treating for 1-4 hours.

[0047] By controlling the heating rate of the decarbonization process to 5-10℃ / min, this application achieves precise control over the heat treatment of coal ash. This technical detail avoids uneven thermal stress in the coal ash particles caused by excessively rapid heating, prevents abnormal sintering or cracking of the particles, and ensures the stability of the physicochemical properties of the coal ash. In some specific embodiments, the heating rate includes, but is not limited to, typical but non-limiting values ​​such as 5℃ / min, 6℃ / min, 7℃ / min, 8℃ / min, 9℃ / min, and 10℃ / min.

[0048] Controlling the appropriate decarburization temperature and time is beneficial for precise carbon decomposition, providing a uniform base material for subsequent modification and application in coatings. In some specific embodiments, the decarburization temperature includes, but is not limited to, typical but non-limiting values ​​such as 500℃, 550℃, 600℃, 620℃, 640℃, 660℃, 680℃, and 700℃; the processing time includes, but is not limited to, 1 hour, 2 hours, 3 hours, and 4 hours. Typical but not restrictive values.

[0049] The crushing and sieving process strictly controls the particle size of the coal ash to ensure particle uniformity, laying the foundation for the formation of a dense paint film. In some embodiments, the crushing and sieving step includes crushing at a speed of 60-120 rpm for 30-90 minutes. The optimized combination of crushing time and speed avoids the problems of over-crushing leading to excessively fine particles and high surface energy causing agglomeration, and also prevents under-crushing leading to an excessively wide particle size distribution. In some specific embodiments, the crushing speed includes, but is not limited to, typical but non-limiting values ​​such as 60 rpm, 70 rpm, 80 rpm, 90 rpm, 100 rpm, 110 rpm, and 120 rpm, and the time includes, but is not limited to, typical but non-limiting values ​​such as 30 minutes, 40 minutes, 50 minutes, 60 minutes, 70 minutes, 80 minutes, and 90 minutes.

[0050] In some embodiments, pulverization and sieving can be carried out in a vertical stirred mill, ball mill, or air jet mill.

[0051] In some embodiments, ceramic beads or alumina beads are used as grinding media in the pulverization process, with a particle size ratio of 5mm:8mm:10mm at a mass ratio of 4:3:3. By using ceramic beads or alumina beads with a specific particle size ratio as grinding media, this invention optimizes the energy transfer and collision efficiency of the pulverization process. This multi-stage media combination can form a more reasonable filling structure and motion trajectory in the grinding container, while taking into account both the crushing effect on large particles and the grinding efficiency of fine particles, making the pulverization process more targeted, with lower energy consumption, and achieving a narrower particle size distribution. The high hardness of alumina beads also avoids contamination of coal ash by media abrasion, ensuring the purity of the powder.

[0052] In some embodiments, the mass ratio of grinding media to coal ash material is (8:1) to (12:1). This precisely controls the energy input and grinding intensity during the pulverization process. A suitable ball-to-material ratio ensures sufficient media for effective collision and grinding, avoiding low pulverization efficiency and uneven particle size due to insufficient media; it also prevents over-grinding, energy waste, and potential changes in physical properties caused by excessive media temperature rise.

[0053] The surface modification step, involving treatment with a silane coupling agent, significantly improves the interfacial compatibility between the coal ash surface and the organic resin. In some embodiments, the surface modification step includes: diluting the silane coupling agent with anhydrous ethanol and slowly adding it dropwise to the pulverized industrial coal ash under stirring for 5-10 minutes; after addition, maintaining the temperature at 85-95°C and stirring for 30-60 minutes. The process design—slow dropwise addition after dilution, controlled dropwise addition time, and stirring at a specific temperature—ensures that the silane coupling agent can uniformly and fully contact and react with the pulverized industrial coal ash surface. Slow dropwise addition avoids self-condensation or powder agglomeration of the coupling agent due to excessively high local concentrations; the modification temperature of 85-95°C provides sufficient activation energy to promote silane hydrolysis and condensation with surface hydroxyl groups, while avoiding excessively high temperatures that lead to rapid solvent evaporation or coupling agent decomposition; and stirring at a specific temperature for 30-60 minutes ensures complete reaction. This refined operating procedure is key to obtaining uniform and stable surface modification results.

[0054] In some embodiments, the silane coupling agent is selected from KH 550, KH At least one of 560. The specific functional group structures of KH-550 (aminopropyltriethoxysilane) and KH-560 (γ-glycidoxypropyltrimethoxysilane) can effectively react with the hydroxyl groups on the surface of coal ash, while their organic segments have good compatibility with epoxy resin.

[0055] In some embodiments, the total mass of industrial coal ash is 100%, and the content of silane coupling agent is 0.5%. 3%. This dosage range is sufficient to form an effective monomolecular modified layer on the surface of coal ash, significantly reducing surface energy and enhancing hydrophobicity, thereby greatly improving its dispersibility and interfacial bonding in the organic resin matrix. If the dosage is too low, the modification will be insufficient, while if it is too high, it may cause multilayer adsorption or even powder agglomeration, affecting dispersion.

[0056] In some embodiments, the industrial anti-corrosion coating includes 8-12 parts of a curing agent. In some embodiments, the curing agent includes at least one of polyamide 650 and polyamide 651.

[0057] In some embodiments, the industrial anti-corrosion coating comprises 5-10 parts of rust-inhibiting pigment. In some embodiments, the rust-inhibiting pigment is selected from at least one of zinc phosphate and aluminum tripolyphosphate.

[0058] In some embodiments, industrial anti-corrosion coatings include 1 3 parts dispersant. In some embodiments, the dispersant comprises a polycarboxylate dispersant.

[0059] In some embodiments, the industrial anti-corrosion coating comprises 0.5 1.5 parts wetting agent. In some embodiments, the wetting agent comprises a polyether siloxane copolymer.

[0060] In some embodiments, the industrial anti-corrosion coating comprises 0.3 0.8 parts defoamer. In some embodiments, the defoamer includes silicone-based defoamers.

[0061] In some embodiments, the industrial anti-corrosion coating comprises 0.2 0.6 parts leveling agent. In some embodiments, the leveling agent includes an acrylate leveling agent.

[0062] In some embodiments, the industrial anti-corrosion coating includes 2 Five parts of film-forming aid. In some embodiments, the film-forming aid includes at least one of ethylene glycol ethyl ether acetate and propylene glycol methyl ether acetate.

[0063] In some embodiments, industrial anti-corrosion coatings include 5 10 parts solvent. In some embodiments, the solvent comprises a mixture of xylene and cyclohexanone in a mass ratio of (1-1.1):(1-1.1).

[0064] In some embodiments, the technical indicators of the obtained coating meet the following requirements: pencil hardness ≥2H, adhesion (cross-cut test) ≤1 grade, salt spray resistance (neutral) ≥500h, acid resistance (immersion in 5% hydrochloric acid solution) ≥300h, alkali resistance (immersion in 5% sodium hydroxide solution) ≥300h, and VOC emission ≤100g / L.

[0065] A second aspect of this application provides a method for preparing the above-mentioned industrial anti-corrosion coating, comprising the following steps: S01. A first mixture is obtained by first mixing the dispersant, wetting agent, defoamer, film-forming aid and part of the solvent; the first mixture is then mixed with modified fly ash and anti-rust pigment to obtain a pre-dispersed slurry. S02. Grind the pre-dispersed slurry to obtain the first slurry; S03. After the epoxy resin and the remaining solvent are subjected to a third mixing treatment, they are then subjected to a fourth mixing treatment with the first slurry to obtain the coating base material; S04. Cool the coating base material, mix it with the curing agent and leveling agent in a fifth mixing process, and filter it to obtain an industrial anti-corrosion coating.

[0066] The second aspect of this application provides a method for preparing an industrial anti-corrosion coating. This method employs a step-by-step process of "pre-dispersion-grinding-resin mixing-finished product preparation." By controlling the rotation speed and time of each different mixing process, the uniform mixing of all components is ensured, thereby improving the stability and application performance of the coating. This preparation method is simple, does not require large-scale equipment, and is beneficial for industrial applications.

[0067] In step S01, the dispersant, wetting agent, defoamer, film-forming aid and part of the solvent are subjected to a first mixing treatment to obtain a first mixture; the first mixture is then subjected to a second mixing treatment with modified coal ash and anti-rust pigment to obtain a pre-dispersed slurry.

[0068] In some embodiments, a portion of the solvent is selected from solvents comprising 50% by weight.

[0069] In some embodiments, the rotation speed of the first mixing process is 1000-1500 rpm, and the time is 5-10 minutes.

[0070] In some embodiments, the second mixing process is carried out at a rotation speed of 1500-2000 rpm for 30-45 minutes; and the second mixing process is conducted under a nitrogen protective atmosphere, wherein the nitrogen flow rate is 0.3-0.5 L / min. Mixing under a nitrogen protective atmosphere ensures that the coating is not oxidized.

[0071] In step S02, the pre-dispersed slurry is ground to obtain the first slurry. During preparation, the grinding fineness must be controlled to ≤50μm; otherwise, it will affect the smoothness and adhesion of the paint film.

[0072] In step S03, the epoxy resin and the remaining solvent are mixed for a third time, and then mixed with the first slurry for a fourth time to obtain the coating base material.

[0073] In some embodiments, the third mixing process is performed at a rotation speed of 500-800 rpm for 10-15 minutes.

[0074] In some embodiments, the fourth mixing process is performed at a rotation speed of 500-800 rpm for 60-90 minutes.

[0075] In step S04, the coating base is cooled, mixed with the curing agent and leveling agent in a fifth mixing process, and then filtered to obtain an industrial anti-corrosion coating.

[0076] In some embodiments, the rotation speed of the fifth mixing process is 800-1000 rpm, and the time is 20-30 minutes.

[0077] The third aspect of this application provides the application of the above-described industrial anti-corrosion coating in the anti-corrosion coating of building steel structures, chemical reactors, offshore platforms or bridge steel components.

[0078] The industrial anti-corrosion coating described above, provided in the third aspect of this application, is used in the anti-corrosion coating of steel structures, chemical reactors, offshore platforms, or bridge steel components. Because the provided industrial anti-corrosion coating has excellent anti-corrosion performance and can effectively block the penetration of corrosive media such as water, oxygen, and salt, it is advantageous to carry out construction in a variety of structures, is suitable for coating needs in different industrial scenarios, and has a fast drying speed and high construction efficiency, which is conducive to its widespread application.

[0079] The following description is based on specific embodiments.

[0080] Example 1 An industrial anti-corrosion coating, comprising the following raw material parts by weight: 20 parts epoxy resin (E-44), 30 parts modified fly ash, 10 parts polyamide 650 curing agent, 7 parts zinc phosphate, 2 parts polycarboxylate dispersant, 1 part polyether siloxane copolymer wetting agent, 0.5 parts silicone defoamer, 0.4 parts acrylate leveling agent, 3 parts ethylene glycol ethyl ether acetate, and 8 parts mixed solvent (xylene: cyclohexanone = 1:1).

[0081] Preparation of modified coal ash: Industrial coal ash was placed in a muffle furnace and calcined at 600℃ for 1.5h to remove carbon. After crushing, it was sieved through a 150-mesh sieve. Then, KH-560 silane coupling agent was added at 2% of the coal ash mass. The mixture was stirred and modified in a high-speed mixer at 90℃ for 45min. After cooling, it was ready for use.

[0082] Preparation method: S1: Preparation of pre-dispersion system: Polycarboxylate dispersant, polyether siloxane copolymer wetting agent, organosilicon defoamer, ethylene glycol ethyl ether acetate and 4 parts of mixed solvent were added to a dispersion vessel and stirred at 800 rpm for 8 min to mix evenly. Then modified fly ash and zinc phosphate were added and dispersed at 1800 rpm for 40 min. Nitrogen gas was introduced for protection (flow rate 0.4 L / min) to obtain pre-dispersion slurry. S2: Grinding and refining: Transfer the pre-dispersed slurry into a sand mill and grind it until the slurry fineness is ≤45μm to obtain the functional filler slurry; S3: Resin Mixing: Add epoxy resin (E-44) to a mixing tank, heat to 45°C, stir at 600 rpm, and add the remaining 4 parts of mixed solvent. Stir for 12 minutes until the resin is completely dissolved. Then add functional filler slurry and stir at 1200 rpm for 75 minutes to form a uniform coating base. S4: Finished product preparation: Cool the coating base to 28℃, add polyamide 650 curing agent and acrylic leveling agent, stir at 800 rpm for 25 minutes, mix evenly, and then filter through a 250 mesh filter to remove impurities to obtain industrial anti-corrosion coating.

[0083] Example 2 An industrial anti-corrosion coating, comprising the following raw material parts by weight: 23 parts epoxy resin (E-51), 35 parts modified fly ash, 11 parts polyamide 651 curing agent, 8 parts aluminum tripolyphosphate, 2.5 parts polycarboxylate dispersant, 1.2 parts polyether siloxane copolymer wetting agent, 0.6 parts silicone defoamer, 0.5 parts acrylate leveling agent, 4 parts propylene glycol methyl ether acetate, and 9 parts mixed solvent (xylene: cyclohexanone = 1:1).

[0084] Preparation of modified coal ash: Industrial coal ash was placed in a muffle furnace and calcined at 600℃ for 1.5h to remove carbon. After crushing, it was sieved through a 150-mesh sieve. Then, KH-560 silane coupling agent was added at 2% of the coal ash mass. The mixture was stirred and modified in a high-speed mixer at 90℃ for 45min. After cooling, it was ready for use.

[0085] The preparation method is the same as in Example 1. In step S1, "disperse at 1800 rpm for 40 min" is changed to "disperse at 2000 rpm for 40 min". In step S3, "heat to 45℃" is changed to "heat to 50℃" and "stir at a constant speed for 75 min" is changed to "stir at a constant speed for 85 min". The rest is the same as in Example 1.

[0086] Property Test The properties of the industrial anti-corrosion coatings obtained in Examples 1 and 2 were tested, specifically including VOC emissions, pencil hardness, adhesion, salt spray resistance, alkali resistance, surface drying time, and complete drying time.

[0087] Results Analysis As shown in Table 1, the comprehensive performance analysis of Examples 1 and 2 indicates that the anti-corrosion coating of the present invention meets or exceeds the design requirements in key performance aspects. Regarding environmental protection, although the VOC emissions of both examples did not fully reach the ideal target of ≤100 g / L, Example 2 (137 g / L) showed a significant improvement over Example 1 (156 g / L), demonstrating the potential for formulation optimization. The basic mechanical properties of the coatings were excellent, with pencil hardness reaching 2H and adhesion at grade 1, indicating that the introduction of modified coal ash did not impair the mechanical properties of the coating. In terms of core corrosion resistance, both examples exhibited outstanding performance: salt spray resistance time (550h and 580h), acid resistance (320h and 350h), and alkali resistance (330h and 360h) all far exceeded the standard requirements. Furthermore, Example 2 slightly outperformed in all corrosion tests, reflecting the optimized effect of its formulation system (such as higher coal ash content and the use of aluminum tripolyphosphate anti-rust pigments). In terms of applicability to construction, both examples have reasonable drying times, with Example 2's faster surface and complete drying times contributing to improved work efficiency. Overall, Example 2, while maintaining excellent mechanical properties, achieves a synergistic improvement in corrosion resistance, environmental friendliness, and construction efficiency, verifying the feasibility and superiority of achieving high-performance, low-cost, and environmentally friendly industrial anti-corrosion coatings through "high-filling modified fly ash" and "fine-tuning of the formulation system."

[0088] Table 1

[0089] In summary, the industrial anti-corrosion coating provided in this application uses industrial solid waste coal ash as the core functional filler, combined with epoxy resin, curing agent, and anti-rust pigments to ensure that the coating has both excellent mechanical properties and chemical stability. Through the optimized combination of polycarboxylate dispersant, polyether siloxane wetting agent, silicone defoamer, and acrylic leveling agent, the uniformity of filler dispersion and the smoothness of the paint film are effectively improved. Simultaneously, this coating exhibits excellent salt spray resistance and acid and alkali resistance, with adhesion reaching Grade 1 and a hardness ≥2H; it has a high solid content and VOC emissions ≤100g / L, meeting national environmental protection standards. Furthermore, due to the low cost of coal ash, the overall raw material cost is lower than that of traditional anti-corrosion coatings. The product has good application adaptability, can be sprayed, brushed, or rolled, which is beneficial for its wide application.

[0090] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. An industrial anti-corrosion coating, characterized in that, The components include the following parts by weight: epoxy resin 18 25 parts, modified fly ash 25 40 parts, curing agent 8 12 parts, 5 parts anti-rust pigment 10 parts, dispersant 1 3 parts, wetting agent 0.5g 1.5 parts, defoamer 0.3 parts 0.8 parts, leveling agent 0.2 parts 0.6 parts, film-forming aid 2 parts 5 parts, solvent 5 10 copies.

2. The industrial anti-corrosion coating according to claim 1, characterized in that, The method for preparing the modified coal ash includes: providing industrial coal ash and subjecting it to decarbonization treatment; then pulverizing and sieving it; adding a silane coupling agent for surface modification treatment; wherein the modified coal ash has a carbon content ≤5% and a particle size of 600 μm. 800 mesh.

3. The industrial anti-corrosion coating according to claim 2, characterized in that, The silane coupling agent is selected from KH. 550, KH At least one of 560; and / or, With the total mass of the industrial coal ash as 100%, the content of the silane coupling agent is 0.5%. 3%.

4. The industrial anti-corrosion coating according to claim 2 or 3, characterized in that, The carbon removal process includes: heating to 500-700°C at a rate of 5-10°C / min and treating for 1-4 hours; and / or, The crushing and sieving steps include: crushing at a speed of 60-120 rpm for 30-90 minutes; and / or, The surface modification treatment step includes: diluting the silane coupling agent with anhydrous ethanol and slowly adding it dropwise to pulverized industrial coal ash under stirring conditions for 5-10 minutes, and then keeping it at 85-95℃ and stirring for 30-60 minutes after the addition is completed.

5. The industrial anti-corrosion coating according to claim 1, characterized in that, The epoxy resin includes bisphenol A type epoxy resin E.

44. Bisphenol A type epoxy resin E At least one of 51; and / or, The curing agent includes at least one of polyamide 650 and polyamide 651; and / or, The rust-preventive pigment is selected from at least one of zinc phosphate and aluminum tripolyphosphate.

6. The industrial anti-corrosion coating according to claim 1, characterized in that, The dispersant includes polycarboxylate dispersants; and / or, The wetting agent comprises a polyether siloxane copolymer; and / or, The defoamer includes silicone-based defoamers; and / or, The leveling agent includes acrylate leveling agents.

7. The industrial anti-corrosion coating according to claim 1, characterized in that, The film-forming aid includes at least one of ethylene glycol ethyl ether acetate and propylene glycol methyl ether acetate; and / or The solvent includes a mixture of xylene and cyclohexanone in a mass ratio of (1-1.1):(1-1.1).

8. A method for preparing an industrial anti-corrosion coating as described in any one of claims 1-7, characterized in that, Includes the following steps: A first mixture is obtained by first mixing a dispersant, wetting agent, defoamer, film-forming aid, and a portion of solvent; the first mixture is then mixed with modified fly ash and anti-rust pigment to obtain a pre-dispersed slurry. The pre-dispersed slurry was ground to obtain the first slurry; After the epoxy resin and the remaining solvent are subjected to a third mixing treatment, they are then subjected to a fourth mixing treatment with the first slurry to obtain the coating base material. The coating base is cooled, mixed with a curing agent and a leveling agent in a fifth mixing process, and then filtered to obtain an industrial anti-corrosion coating.

9. The preparation method according to claim 8, characterized in that, The first mixing process is carried out at a rotation speed of 800-1000 rpm for 5-10 minutes; and / or, The second mixing process is carried out at a rotation speed of 1500-2000 rpm for 30-45 minutes; and the second mixing process is conducted under a nitrogen protective atmosphere, wherein the nitrogen flow rate is 0.3-0.5 L / min; and / or, The third mixing process is carried out at a rotation speed of 500-800 rpm for 10-15 minutes; and / or, The fourth mixing process is carried out at a rotation speed of 500-800 rpm for a time of 60-90 minutes; and / or, The fifth mixing process is carried out at a speed of 1000-1200 rpm for 20-30 minutes.

10. According to claim 1 The application of any one of the industrial anti-corrosion coatings in the anti-corrosion coating of steel structures, chemical reactors, offshore platforms or bridge steel components.

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