Articles and methods providing liquid-impregnated scale-phobic surfaces

Abstract

This invention relates generally to articles, devices, and methods for inhibiting or preventing the formation of scale during various industrial processes. In certain embodiments, a vessel is provided for use in an industrial process, the vessel having a textured, liquid-impregnated surface in contact with a mineral solution, wherein the liquid-impregnated surface comprises a matrix of features spaced sufficiently close to stably contain an impregnating liquid lubricant therebetween or therewithin, wherein the impregnating lubricant has a low surface energy density, and wherein the spreading coefficient S os(w) of the impregnating lubricant (subscript ‘o’) on the substrate (subscript ‘s’) in the presence of the salt solution (subscript ‘w’) is greater than zero, such that the impregnating lubricant fully submerges the textured substrate.

What is claimed is: 
     
         1 . A vessel for use in an industrial process, the vessel comprising a liquid-impregnated interior surface, wherein the liquid-impregnated surface comprises a matrix of features spaced sufficiently close to stably contain an impregnating liquid therebetween or therewithin and the impregnating liquid has a surface energy density γ (as measured at 25° C.) no greater than about 35 mJ/m 2 , thereby providing resistance to mineral scale deposits thereupon. 
     
     
         2 . The vessel of  claim 1 , wherein the liquid-impregnated surface comprises the matrix of features spaced sufficiently close to contain the impregnating liquid sufficiently well such that small quantities of impregnating liquid lost due to settling, evaporation, and/or dissolution of the impregnating liquid into one or more phases coming into contact with the surface can be replenished. 
     
     
         3 . (canceled) 
     
     
         4 . The vessel of  claim 1 , wherein the surface energy density γ (as measured at 25° C.) is no greater than about 30 mJ/m 2 , no greater than about 25 mJ/m 2 , or no greater than about 20 mJ/m 2 . 
     
     
         5 .- 6 . (canceled) 
     
     
         7 . The vessel of  claim 1 , wherein the impregnating liquid is immiscible with, or negligibly miscible with, the solution comprising the scale-forming mineral with which the interior surface of the vessel is designed to come into contact. 
     
     
         8 . The vessel of  claim 1 , wherein the impregnating liquid is a lubricant and the interior surface is a textured substrate, wherein the liquid-impregnated interior surface of the vessel is configured, during operation, to come into contact with (or maintain contact with) a salt solution comprising a scale-forming mineral, and wherein the spreading coefficient S os(w)  of the impregnating lubricant (subscript ‘o’) on the substrate (subscript ‘s’) in the presence of the salt solution (subscript ‘w’) is greater than zero, such that the impregnating lubricant fully submerges the textured substrate. 
     
     
         9 . The vessel of  claim 1 , wherein the vessel is designed for use in a process in which the liquid-impregnated surface of the vessel is in contact with a salt solution comprising a scale-forming mineral, or wherein the vessel contains a salt solution comprising a scale-forming mineral or transfers a salt solution comprising a scale-forming mineral. 
     
     
         10 . The vessel of  claim 1 , wherein the impregnating liquid is a silicone oil. 
     
     
         11 . The vessel of  claim 1 , wherein the liquid-impregnated surface is a scale-phobic surface that inhibits scale formation thereupon. 
     
     
         12 . The vessel of  claim 1 , wherein the liquid-impregnated surface comprises a (solid) metal or wherein the liquid-impregnated surface comprises a metal selected from the group consisting of aluminum, steel, copper, titanium, tin, or any combination thereof. 
     
     
         13 .- 14 . (canceled) 
     
     
         15 . The vessel of  claim 1 , wherein the liquid-impregnated surface comprises a silane coating. 
     
     
         16 . The vessel of  claim 15 , wherein the silane coating is a member selected from the group consisting of methylsilane, phenylsilane, isobutylsilane, dimethylsilane, tetramethyldisilane, hexylsilane, octadecylsilane, and fluorosilane. 
     
     
         17 . The vessel of  claim 1 , wherein the liquid-impregnated surface is textured. 
     
     
         18 . The vessel of  claim 1 , wherein the liquid-impregnated surface comprises micro-scale and/or nano-scale features and/or wherein the features comprise nanograss. 
     
     
         19 . (canceled) 
     
     
         20 . The vessel of  claim 1 , wherein the liquid-impregnated surface is located on an interior wall of a heat exchanger. 
     
     
         21 . The vessel of  claim 1 , wherein the mineral scale deposits comprise at least one of calcium sulfate, calcium carbonate, barium sulfate, silica, and/or iron. 
     
     
         22 . The vessel of  claim 1 , wherein the vessel is a conduit or receptacle used in deep sea oil and/or gas recovery or wherein the vessel is a conduit or receptacle of a heat exchanger. 
     
     
         23 . (canceled) 
     
     
         24 . A method of retrofitting a vessel for improved resistance to mineral scale deposits, the method comprising modifying the vessel to produce a liquid-impregnated surface, wherein the liquid-impregnated surface comprises a matrix of features spaced sufficiently close to stably contain an impregnating liquid therebetween or therewithin and the impregnating liquid has a surface energy density γ (as measured at 25° C.) no greater than about 35 mJ/m 2 , thereby providing resistance to mineral scale deposits thereupon. 
     
     
         25 . The method of  claim 24 , wherein the liquid-impregnated surface comprises the matrix of features spaced sufficiently close to contain the impregnating liquid sufficiently well such that small quantities of impregnating liquid lost due to settling, evaporation, and/or dissolution of the impregnating liquid into one or more phases coming into contact with the surface can be replenished. 
     
     
         26 .- 27 . (canceled) 
     
     
         28 . The method of  claim 24 , wherein the impregnating liquid is a lubricant and the interior surface is a textured substrate, wherein the liquid-impregnated interior surface of the vessel is configured, during operation, to come into contact with (or maintain contact with) a salt solution comprising a scale-forming mineral, and wherein the spreading coefficient S os(w)  of the impregnating lubricant (subscript ‘o’) on the substrate (subscript ‘s’) in the presence of the salt solution (subscript ‘w’) is greater than zero, such that the impregnating lubricant fully submerges the textured substrate. 
     
     
         29 . The method of  claim 28 , wherein the vessel is designed for use in a process in which the liquid-impregnated surface of the vessel is in contact with a salt solution comprising a scale-forming mineral, or wherein the vessel contains a salt solution comprising a scale-forming mineral or transfers a salt solution comprising a scale-forming mineral. 
     
     
         30 . The vessel of  claim 24 , wherein the impregnating liquid is immiscible with, or negligibly miscible with, the solution comprising the scale-forming mineral with which the interior surface of the vessel is designed to come into contact. 
     
     
         31 . The method of  claim 24 , wherein the impregnating liquid is a silicone oil. 
     
     
         32 .- 35 . (canceled) 
     
     
         36 . The method of  claim 24 , wherein the liquid-impregnated surface comprises a silane coating, wherein the silane coating is a member selected from the group consisting of methylsilane, phenylsilane, isobutylsilane, dimethylsilane, tetramethyldisilane, hexylsilane, octadecylsilane, and fluorosilane. 
     
     
         37 .- 38 . (canceled) 
     
     
         39 . The method of any one of  claim 24 , wherein the liquid-impregnated surface comprises micro-scale and/or nano-scale features. 
     
     
         40 .- 44 . (canceled) 
     
     
         45 . A method of using a vessel in an industrial process, the method comprising:
 (a) providing a vessel comprising a liquid-impregnated surface, wherein the liquid-impregnated surface comprises a matrix of features spaced sufficiently close to stably contain an impregnating liquid therebetween or and the impregnating liquid has a surface energy density γ (as measured at 25° C.) no greater than about 35 mJ/m 2 , thereby providing resistance to mineral scale deposits thereupon; and   (b) contacting the liquid-impregnated surface with a solution comprising a scale-forming mineral.   
     
     
         46 . The method of  claim 45 , wherein the impregnating liquid is immiscible with, or negligibly miscible with, the solution comprising the scale forming mineral with which the interior surface of the vessel is designed to come into contact. 
     
     
         47 . The method of  claim 45 , further comprising contacting the liquid-impregnated surface with a reservoir containing the impregnating liquid to replenish any impregnating liquid lost due to settling, evaporation, and/or dissolution into one or more other phases coming into contact with the liquid-impregnated surface. 
     
     
         48 . The method of  claim 45 , wherein the impregnating liquid is a lubricant and the interior surface is a textured substrate, wherein the liquid-impregnated interior surface of the vessel is configured, during operation, to come into contact with (or maintain contact with) a salt solution comprising a scale-forming mineral (e.g., wherein the vessel is designed for use in a process in which the liquid-impregnated surface of the vessel is in contact with a salt solution comprising a scale-forming mineral, or wherein the vessel contains a salt solution comprising a scale-forming mineral or transfers a salt solution comprising a scale-forming mineral), and wherein the spreading coefficient S os(w)  of the impregnating lubricant (subscript ‘o’) on the substrate (subscript ‘s’) in the presence of the salt solution (subscript ‘w’) is greater than zero, such that the impregnating lubricant fully submerges the textured substrate. 
     
     
         49 . The method of  claim 45 , wherein the impregnating liquid is a silicone oil. 
     
     
         50 . The method of  claim 45 , wherein the liquid-impregnated surface is a scale-phobic surface that inhibits scale formation thereupon. 
     
     
         51 .- 53 . (canceled) 
     
     
         54 . The method of  claim 45 , wherein the liquid-impregnated surface comprises a silane coating. 
     
     
         55 .- 56 . (canceled) 
     
     
         57 . The method of  claim 45 , wherein the liquid-impregnated surface comprises micro-scale and/or nano-scale features and/or nanograss. 
     
     
         58 .- 64 . (canceled)