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10/13/2011


PREVENTIUN UF CURRUSIUN BY
ANUDIC PRUTECTIUN
ANOIC PROTICTION ls Lhe mosL recenLly developed of all Lhe
varlous corroslon conLrol meLhods avallable 1hls meLhod was flrsL used ln Lhe
fleld ln Lhe laLe 1930s Anodlc proLecLlon dld noL become commerclally successful
unLll Lhe early 1970s And lL ls currenLly used on a smaller scale Lhan oLher
corroslon conLrol Lechnlques

WHAT IS CORROSION ?

TIe ucL or process oI corrodIng.

TIe condILIon produced by corrodIng.

A subsLunce, sucI us rusL, Iormed by corrodIng.

CorrosIon Is derIved Irom LIe uLIn "corrosus" meunIng gnuwed uwuy.
CorrosIon muy be IurLIer deIIned us u gruduuI desLrucLIon oI u muLerIuI, u
subsLunce, or un enLILy, usuuIIy by soIuLIon or oLIer meuns uLLrIbuLed Lo u
cIemIcuI process.

Corroslon peneLraLlon for a sLeel plpe plle (20 years of marlne lmmerslon)

AcLlve corroslon aL numerous locaLlons were coaLlng has falled
vlpul Mevaslya
8oll no 942



Slmply corroslon ls an LlecLrochemlcal reacLlon and ls deflned as a chemlcal
reacLlon lnvolvlng Lhe Lransfer of elecLrons Whlle corroslon can Lake any one of
several forms Lhe mechanlsm of aLLack ln an aqueous soluLlon wlll lnvolve some
aspecL of elecLrochemlsLry 1here wlll be a flow of elecLrlclLy from cerLaln areas
of Lhe meLal surface Lo oLher areas Lhrough a soluLlon capable of conducLlng
elecLrlclLy llke seawaLer fresh waLer solls eLc
1he Lerm anode ls used Lo descrlbe Lhe porLlon of Lhe meLal surface LhaL ls
corroded and from whlch currenL leaves Lhe meLal Lo enLer Lhe soluLlon 1he
Lerm caLhode ls used Lo descrlbe Lhe meLal surface from whlch currenL leaves Lhe
soluLlon and reLurns Lo Lhe meLal 1he clrculL ls compleLed ouLslde Lhe soluLlon
Lhrough Lhe dlrecL meLal conLacL or Lhrough a conducLor [olnlng Lhe Lwo pleces of
meLal


TYRES OE CORROSION
1) alvanlc Corroslon
2) unlform Corroslon
3) Lroslon Corroslon
4) lLLlng Corroslon
3) lreLLlng Corroslon
6) SLress Corroslon Cracklng
7) CavlLaLlon Corroslon
8) Pydrogen LmbrlLlemenL
9) Crevlce Corroslon eLc

CORROSION ECONOMY


corroslon ls deLerloraLlon of meLal lL desLroys Lhe meLal whlch ls noL deslrable So
for proLecLlon of lL huge amounL of money ls spend worldwlde
1he sLudy showed LhaL for 1988 Lhe LoLal annual esLlmaLed dlrecL cosL of
corroslon ln Lhe uS was approxlmaLely $276 bllllon So corroslon prevenLlon ls
musL 1here are many Lechnlques for corroslon prevenLlon as follows

CORROSION RREVENTION TECHNIQUES:
1) Apply CoaLlng
2) 8eacLlve CoaLlng
3) CaLhodlc roLecLlon
Sacrlflclal anode proLecLlon
lmpressed currenL caLhodlc proLecLlon
4) Anodlc roLecLlon








ANODlC PHOTECTlON


8947
1he sclenLlflc prlnclples of passlvlLy on whlch anodlc proLecLlon ls based can be
Lraced Lo experlmenLs by laraday and Scholbeln ln Lhe 19
Lh
cenLury Work by C
Ldeleanu publlshed ln 1934 was responslble for furLher lnvesLlgaLlons and
developmenLs aL Lhe conLlnenLal Cll Company Work by C Ldeleanu publlshed ln
1934 was responslble for furLher lnvesLlgaLlons and developmenLs aL Lhe
conLlnenLal Cll Company 1hls laLer work resulLed ln Lhe several lnsLallaLlon of
anodlc proLecLlon Lo conLrol Lhe corroslon of chemlcal planL equlpmenL
AN4/. P7490.94N U80
Anodlc proLecLlon has been mosL exLenslvely applled Lo pro[ecL equlpmenL used
Lo sLore and handle sulfurlc acld (P
2
So
4
) Sales of anodlcally proLecLed heaL
exchangers used Lo cool P
2
So
4
ManufacLurlng planLs have been represenLed one
of Lhe more successful venLures ln Lhe posL few years 1hese heaL exchangers are
sold compleLe wlLh Lhe anodlc proLecLlon sysLems lnsLalled and have a
commerclal advanLage ln LhaL less cosLly maLerlals can be used
roLecLlon of sLeel P
2
So
4
(78 concenLraLlon) sLorage vessels ls perhaps
Lhe mosL common appllcaLlon of anodlc proLecLlon Companles ln norLh Amerlca
and Lurope sell sysLems prlmarlly for Lhese sLorage vessels and heaL exchanges
TH047
Anodlc proLecLlon can be used Lo conLrol Lhe corroslon of meLals ln chemlcals LhaL
exhlblL very lnLeresLlng behavlor when sub[ecLed Lo anodlc polarlzaLlon 1hls
behavlor can be sLudled wlLh an experlmenLal seLup As lllusLraLed ln llg 1 When
Lhe poLenLlal of Lhe worklng elecLrode relaLlve Lo Lhe reference elecLrode ls
conLrolled and shlfLed ln Lhe more anodlc dlrecLlon 1he currenL requlred Lo cause


LhaL shlfL wlll vary lf Lhe currenL requlred for Lhe shlfL has Lhe general Lype of
behavlor wlLh respecL Lo poLenLlal show ln llg 2 1he meLal ls Lermed acLlve
passlve and can be anodlcally proLecLed lew sysLems exhlblL Lhls Lype of
behavlor 1he meLals and soluLlons LhaL have been found Lo have acLlve passlve
properLles and LhaL can be anodlcally proLecLed lnclude
8olutions Metals
Sulfurlc acld SLeel
hosphorlc acld SLalnless SLeel
nlLrlc acld nlckel
nlLraLe SoluLlons nlckel alloys
Aqueous ammonla Chromlum
Crganlc acld
CausLlc soluLlons











1he corroslon raLe of an acLlve passlve meLal can be slgnlflcanLly reduced by
shlfLlng Lhe poLenLlal of Lhe meLal so LhaL lL ls aL a value ln Lhe passlve range show
ln llg 2 1he currenL requlred Lo shlfL Lhe poLenLlal ln Lhe anodlc dlrecLlon from
Lhe corroslon poLenLlal Lcorros several orders of magnlLude greaLer Lhan Lhe
currenL necessary Lo malnLaln Lhe poLenLlal aL a passlve value 1he currenL wlll
peak aL Lhe poLenLlal value shown as llg 2 Lhe currenL requlred achleve passlvlLy
ls Lyplcally a few hundred mllllamps per square fooL weLLed area 1he currenL
necessary Lo malnLaln passlvlLy ls usually 1076 A/m2 (1 A/ fL2) or less




IIG 2 SCnLMA1IC CI ANCDIC CLAkI2A1ICN CUkVL
1he lnLeresLlng anodlc polarlzaLlon behavlor resulLs from Lhe formaLlon of a
surface layer on Lhe meLal LhaL ln relaLlvely lnsoluble ln Lhe chemlcal
envlronmenL 1hls passlve fllm ls noL yeL compleLely undersLood
EOUPMENT REOURED FOR ANODC PROTECTON
llu8L 3 shows a schemaLlc of an anodlc proLecLlon sysLem for a sLorage vessel
Lach of Lhese componenLs has speclflc requlremenLs LhaL wlll be dlscussed below
ln addlLlon Lhe sysLem wlll be brlefly descrlbed
Electrodes
1he cathode should be a permanenL Lype elecLrode LhaL ls noL dlssolved by Lhe
soluLlon or Lhe currenLs lmpressed beLween Lhe vessel wall and elecLode 1he


caLhodes ln mosL of Lhe flrsL appllcaLlons of ANCDIC kC1LC1ICN were made of
plaLlnum clad brass 1hese elecLrodes were excellenL elecLrochemlcally 8uL
Lhey were cosLly and Lhe area conLacLlng Lhe soluLlon was llmlLed by Lhls cosL
8ecause Lhe overall clrculL reslsLance beLween caLhode and vessel ls proporLlal Lo
Lhe elecLrode surface area lL ls advanLageous Lo use large area elecLrodes
1herefore many oLher less cosLly meLals have been used for caLhodes MeLals
LhaL have been used for caLhodes ln anodlc proLecLlon sysLems as well as Lhe
chemlcal envlronmenL ln whlch Lhey were used lnclude

Metals Environment
laLlnum on 8rass varlous
SLeel krafL ulgesLer Llquld
llllum P204 (78 103)
Slllcon CasL lron P
2
So
4
(89 103)
Copper Pydroxylamlne SulfaLe
SLalnless SLeel Llquld lerLlllzers (nlLraLe soluLlon)
nlckelplaLed sLeel Chemlcal nlckel plaLLlng soluLlons
PasLelloy C Llquld lerLlllzers (nlLraLe soluLlons)
P
2
So
4
krafL ulgesLer Llquld

1he elecLrode slze ls chosen Lo conflrm Lo Lhe geomeLry of Lhe vessel and Lo
provlde as large a surface area as posslble 1he locaLlon of caLhode ls noL a crlLlcal


facLor ln slmple geomeLrles Such as sLorage vessel buL ln heaL exchangers lL ls
necessary Lo exLend Lhe elecLrode around Lhe surface Lo be proLecLed MulLlple
caLhodes can be used ln parallel Lo dlsLrlbuLe Lhe currenL and Lo decrease clrculL
reslsLance
reference electrodes musL be used ln anodlc proLecLlon sysLem
because Lhe poLenLlal of Lhe vessel wall as Lhe anode musL be conLrolled 1he
reference elecLrode musL have an elecLrochemlcal poLenLlal LhaL ls consLanL wlLh
respecL Lo Llme and LhaL ls mlnlmally affecLed by changes ln LemperaLure and
soluLlon composlLlon Several references elecLrodes have been used for anodlc
proLecLlon
Electrode 8olution
Calomel P
2
So
4

AgAgCl P
2
So
4
krafL SoluLlons lerLlllzers
soluLlons
MoMoC
3
Sodlum carbonaLe soluLlons
8lsmuLh nP
4
CP
1ype 316 SLalnless SLeel lerLlllzer soluLlons Cleum
PgPgSC
4
P
2
So
4
Pydroxylamlne SulfaLe
LLC P
2
So
4






Potential Control and Power 8upply
otent|a| contro| As menLloned above Lhe poLenLlal of vessel wall wlLh respecL
Lo Lhe reference elecLrode musL be conLrolled ln anodlc proLecLlon lnsLallaLlon
1he poLenLlal conLrol clrculLry has Lwo funcLlons llrsL Lhe poLenLlal musL be
measured and compared Lo Lhe deslred preseL value Second a conLrol slgnal
musL Lhen be senL Lo Lhe power supply Lo force Lhe uC currenL beLween Lhe
caLhode and vessel wall ln early sysLems Lhls conLrol funcLlon was done ln an
onoff meLhod because of hlgh cosLs of elecLronlc clrculLry 1he more
sophlsLlcaLed and exLremely lowcosL clrculLry avallable has resulLed ln all sysLems
havlng a conLlnuous proporLlonal Lype conLrol 1he amounL of currenL forced
Lhrough Lhe clrculLry ls LhaL requlred Lo malnLaln Lhe poLenLlal aL Lhe preseL
conLrol polnL
1he DC power supp||es have Lhe ldenLlcal deslgn and requlremenL as Lhe recLlflers
for caLhodlc proLecLlon wlLh one excepLlon 8ecause of Lhe naLure of Lhe acLlve
passlve behavlor of Lhe vessel Lhe currenL requlre Lo malnLaln Lhe poLenLlal of
Lhe vessel wall ln Lhe passlve range can be become very small Some deslgns of
uC power supplles musL be speclally modlfled Lo reduce Lhe mlnlmum amounL
of currenL puL ouL of Lhe power supply
APPLCATON8
Anodlc proLecLlon has been used for sLorage vessels rocess reacLors heaL
exchangers and LransporLaLlon vessels conLalnlng varlous corroslve soluLlons
%A)S1CkAGL VLSSLLS sLorage of P
2
SC
4
ln sLrengLh of 93 and above ln low
carbon sLeel vessels has meL wlLh some success ln Lerms of vessel llfe Anodlc


proLecLlon has been successful ln reduclng Lhe amounL of lron plcked up durlng
sLorage 1hls enhances Lhe economlc worLh of Lhe producL ln LhaL pure acld ls
more valuable Lhan conLamlnaLed acld lleld sLudles have shown LhaL Lhe lron
conLenL of P
2
SC
4
ln concenLraLlon of 93 and above lncreases LhaL raLes of 3 Lo
20 ppm per day of sLorage uependlng on acld concenLraLlon vessel slze acld
resldence Llme and sLorage LemperaLure
Powever Lanks consLrucLed slnce Lhe 1970s have been made wlLh sLeel
conLalnlng low amounLs of copper sLeel wlLh low copper conLenL wlll corrode
readlly ln Lhese aclds Anodlc proLecLlon of Lhe newer vessels has been successful
ln lowerlng Lhe corroslon raLe by a facLor of 4 Lo 3 and vessel llfe has been greaLly
exLended
%) nLA1 LkCnANGLkS A large markeL has developed for anodlcally proLecLed
heaL exchangers as replacemenL of Lhe casL lron coolers shell anL Lube splral and
plaLe Lype exchangers have been sold compleLe wlLh anodlc proLecLlon as an
lnLegral parL of Lhe equlpmenL Sulfurlc acld of 96 Lo 98 concenLraLlon aL
LemperaLures up Lo 110 C (230 l) has been handled ln AlSl Lype 316 sLalnless
sLeel exchangers by Lhe use of anodlc proLecLlon Corroslon raLes have been
reduced from unproLecLed raLes of more Lhan 3 mm/ yr (200 mlls/ yr) Lo less
0023 mm/ yr (1 mll/ yr) and cosL savlngs have been subsLanLlal because of
exLended equlpmenL llfe and Lhe hlgh lmpurlLy acld LhaL was produced by uslng
Lhese proLecLed heaL exchangers Several oLher corroslve sysLems have also been
handled ln anodlcally proLecLed heaL exchangers


%C) 1kANSCk1A1ICN VLSSLLS Sulfurlc acld wlll conLlnue Lo plck up lron durlng
LransporLaLlon ln Lrucks rallroad and barges Anodlc proLecLlon has been applled
Lo Lhese vessels Lo malnLaln Lhe purlLy of Lhe acld Lo exLend sLorage Llme
%D) GALVANIC CA1nCDLS 1he poLenLlal of meLals have been malnLalned ln Lhe
passlve reglon by uslng Lhe poLenLlal dlfferences beLween meLals Lo achleve
anodlc proLecLlon by galvanlc meLhods unllke caLhodlc proLecLlon noLhlng ls
sacrlflced buL Lhe proLecLlon ls achleved A 1lLanlum plpe has been used Lo
proLecL a sLeel vessel conLalnlng ammonlum hydroxlde (nP
4
CP) soluLlon And
plaLlnum has been used Lo proLecL a sLalnless sLeel Lank conLalnlng P
2
SC
4
A
comblnaLlon of galvanlc and lmpressed currenL proLecLlon LhaL used graphlLe
caLhodes for Lhe anodlc proLecLlon sysLem 1he graphlLe supplles sufflclenL
currenL Lo malnLaln proLecLlon 8uL addlLlonal currenL can be supplled Lhrough
Lhe graphlLe elecLrodes Lo reesLabllsh proLecLlon lf needed










CCMAkISCN CI ANCDIC kC1LC1ICN CA1nCDIC kC1LC1ICN
Anodlc proLecLlon CaLhodlc proLecLlon
AppllcablllLy AcLlvepasslve meLals
only
All meLals
Corroslves Weak Lo aggresslve Weak Lo moderaLe
8elaLlve lnvesLmenL cosL Plgh Low
8elaLlve operaLlon cosL very low Medlums Lo hlgh
LqulpmenL oLenLlosLaL + caLhode/s Sacrlflclal anodes or uC
power supply + lCC
anode/s
1hrowlng power very hlgh Low Lo hlgh
SlgnlflcanL of applled
currenL
CfLen a dlrecL measure of
proLecLed corroslon raLe
Complex does noL
lndlcaLe corroslon raLe
CperaLlng condlLlons Can be accuraLely and
rapldly deLermlned by
elecLrochemlcal
measuremenL
MusL usually be
deLermlned by emplrlcal
LesLlng






8LlL8LnCLS
1 Corroslon Lnglneerlng Mars lonLana
2 An lnLroducLlon Lo LlecLromeLallurgy Sharan naraln
3 AnLlcorroslon meLhods lWS !ones
4 wwwsulphurlcacldcom
3 wwwargenLumsoluLlonscom
6 wwwsprlngerllnkcom
7 wwwcorroslonservlececom
8 wwwgooglecom
9 wwwwlklpedlacom