BASF: Research into corrosion protection for less greenhouse gases

Effective protection against corrosion extends the service life of components and significantly reduces the need for raw materials and greenhouse gas emissions. "The protection of metals is an important issue in all areas of the industrial value chain. To reduce the damage caused by rust, for example, we need to work together on an interdisciplinary basis to research and develop new technologies and processes," explains Dr. Patrick Keil, an expert in corrosion protection at BASF Coatings. He is also Vice President of the organization responsible for Eurocorr, the most important international symposium for corrosion science and technology, which will be held in Stavanger, Norway, from 7 to 11 September 2025. Experts from all over the world will work together to further improve the protection of components against corrosion.

Economic damage caused by corrosion

Corrosion causes considerable economic damage worldwide. As calculated by the Impact Study of the Association for Materials Protection and Performance (AMPP), the annual costs caused by corrosion exceed 3 percent of the global gross domestic product. Corrosion affects almost all sectors such as the energy, chemical and pharmaceutical industries with their production facilities, infrastructure with bridges and pipelines, and transportation with aviation, automotive, rail and shipping. "However, the costs caused by corrosion are only part of the problem. Corrosion also contributes significantly to climate change," emphasizes Keil. This is illustrated by figures published in a study in 2022: According to estimates, 15 to 33 percent of annual steel production is spent on replacing corroded steel, which contributes to 1.6 to 3.4 percent of global CO₂ emissions. "Research into innovative corrosion technologies and improving corrosion management is therefore a crucial key to greater sustainability," says Keil.

Corrosion protection research with digital tools

At BASF Coatings' headquarters in Münster, Keil and his team are researching corrosion protection through coatings and corrosion inhibitors. "These are chemical substances that increase the corrosion resistance of metals and alloys," explains the researcher. Among other things, they work by forming a protective passivation layer that minimizes contact with corrosive elements such as chloride ions, water and oxygen. Keil also uses digital tools in his research projects. He uses machine learning and artificial intelligence to analyze historical research data and the chemical properties of molecules. These technologies help to identify patterns and predict the most promising chemical compounds for corrosion inhibition. The effects of these compounds are also simulated. Further information on Patrick Keil's research projects and the importance of corrosion protection for greater sustainability can be found in the interview in the Smart Scientists series on the BASF website.