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A Novel Strategy for Online Catalytic Synthesis and Performance Efficacy of Mannich Base Corrosion Inhibitors for Oilfield Acidization
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DOI：10.1016/j.mtphys.2026.102114.png)
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Abstract
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This study proposes an innovative online synthesis strategy for Mannich base corrosion inhibitors to address key challenges in oilfield acidizing, including lengthy synthesis times, transportation inefficiencies, and the risk of inhibitor deactivation. By directly introducing ethanolamine, acetone, and formaldehyde into the acidizing fluid (3 wt% HCl), the target inhibitor is formed online under acidic conditions. Real-time electrochemical monitoring indicates that the system achieves corrosion-inhibition performance comparable to that of pre-synthesized inhibitors within 5 h. Comprehensive evaluations, including potentiodynamic polarization, electrochemical impedance spectroscopy, weight-loss measurements, and structural characterization by FTIR and MS, confirm both the formation and effectiveness of the inhibitor. The inhibitor acts as a cathodic-type mixed inhibitor, forming a hydrophobic protective film on Q235 steel through chemisorption and following the Langmuir adsorption isotherm (ΔGads ≈ −40.32 kJ·mol-1). Molecular dynamics simulations further reveal strong adsorption on the Fe(001) surface, with an adsorption energy of −48.07 kJ·mol-1 and a parallel molecular orientation. Economic analysis demonstrates substantial cost savings, reducing the cost to 3900 ¥/ton by eliminating separate synthesis steps and increasing the active ingredient concentration by a factor of four. This strategy offers an efficient and economical approach to corrosion protection in oilfield applications.
Keywords:
Online synthesis
Mannich base
Corrosion inhibitor
Acidizing
Electrochemical performance
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