Zero Waste-acid Emission Synthesis of PANI and Composite Fillers for Enhanced Anticorrosion Performance of the Epoxy Coatings

A novel approach of fully recycling waste acid to synthesize polyaniline (PANI) and the composite fillers is introduced. The filtrates in washing procedure were precisely divided and assigned to synthesize PANI, purify PANI and fabricate composite fillers with different nanostructures, respectively. The PANI utilizing this zero-acid emission method presents similar performances compared with the newly-synthesized one. The epoxy coating embedded with PANI and 30   wt% of composite fillers of sericite/BaSO 4 by the recycling method shows excellent anticorrosion performance via electrochemical impedance spectroscopy and neutral salt spray tests due to excellent barrier and passivation effects. These findings provide a new method to produce PANI and composite fillers for anticorrosion coatings of high performance through the low-cost and large-scale manufacturing process.