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The cost effective synthesis of electroactive polyaniline (PANI) while retaining its desirable properties is one of the most debatable and challenging tasks for researchers in the field. Herein, we report a cost effective inverse emulsion polymerization pathway for the synthesis of soluble and processable PANI salt by using diesel as a novel dispersion medium. Different reaction parameters and their effects on the properties and yield of polyaniline were optimized. The polymer exhibited a highly porous morphology and was found to be stable up to 417 °C. The PANI salt showed good solubility in common solvents, such as chloroform, N -Methyl- 2 -pyrrolidone (NMP), dimethyl sulphoxide (DMSO) and in a 1:3 mixtures by volume of 2-propanol and toluene. The coating of the synthesized PANI salt on stainless steel has shown good corrosion resistant behavior in marine water by reducing the corrosion rate to 67.9% as compared to uncoated stainless steel.

Cost Effective Chemical Oxidative Synthesis of Soluble and Electroactive Polyaniline Salt and Its Application as Anticorrosive Agent for Steel