Polymer–Clay Nanocomposite (PCN) coatings were prepared using the solution intercalation
method. The raw Khulays clay was treated with NaCl to produce sodium clay (NaC). Thereafter,
Cetyl Pyridinium Chloride (CPC) was used to convert NaC into the organic clay form (OC). PCN was
prepared by adding polystyrene as the matrix to different weights of OC to prepare 1 wt.% and 3 wt.%
PCN. To enhance the coating protection of C-steel in NaCl solution, PCN coatings were added to
microcapsules loaded with some corrosion inhibitors PCN (MC). The microcapsules are prepared by
the encapsulation of rare-earth metal Ce+3 ions and Isobutyl silanol into polystyrene via the Double
Emulsion Solvent Evaporation (DESE) technique. Characterization techniques such as FTIR, X-Ray
Diffraction (XRD), and Transmission Electron Microscopy (TEM) were employed. FTIR confirmed
the success of the preparation, while XRD and TEM revealed an intercalated structure of 1 wt.%
PCN while 3 wt.% PCN has a fully exfoliated structure. Electrochemical Impedance Spectroscopy
(EIS), Electrochemical Frequency Modulation (EFM), and Potentiodynamic Polarization showed an
enhanced protection efficiency of PCN (MC) coatings. The results demonstrated that the corrosion
resistance (RCorr) of 3% PCN (MC) coating was higher than all the formulations. These PCN (MC)
coatings may provide corrosion protection for C-steel pipes in many industrial applications.