Background
Microbial corrosion occurs when microbes attack the surface on which they are fixed. It is responsible for billions of dollars in damage annually, much of it to pipelines, tanks, and ships.
Corrolytics developed a biochemical test that is capable of instantly and accurately detecting the presence, type, and even the rate of microbial corrosion. That knowledge would be invaluable on-site, so they approached Porticos to implement their process in a robust and easy-to-use field test kit.
Challenges
The patented detection process had been proven, but the testbed relied on a delicate integration of laboratory glassware. It was necessary to rethink the entire apparatus in the context of a tough, compact, cost-effective device.
Porticos started with a material study to determine what polymers could meet the functional and environmental requirements, and identified combinations that could tolerate the chemicals, pressures, and target diffusion rates. This data provided a path to a test-kit that could be manufactured in high volumes at reasonable cost.
Finally, the Porticos team explored different geometric and functional architectures to minimize size while ensuring the device remains both durable and simple to use.
Outcomes
Porticos proposed two different configurations, and worked with Corrolytics to select the one that best fit their business plan. The team ultimately fabricated ten prototypes and ensured that each one met all functional goals.
Results from field-testing have been extremely positive. Porticos continues to work with Corrolytics anticipating a modest redesign based on user feedback. The eventual product launch will change the way pipelines are maintained around the globe.
