CHAPTER 4: CORROSION

What is corosion?
Corrosionisametaldegradationprocessresulted
frominteractionwithitsenvironment
(Corrosionisthedeteriorationthatoccurs
whenametalreactwithitsenvironment).

Thetermofcorrosionisbasicallyrestrictedto
environmentattackofmetals,thereforenon
metalsisnotincludedinthepresentdefinition.
 Thedegradationprocessesmayresultin:
thinningofmetal
leaks
suddenfailureanddamageofequipment
decreasing/lossitsheattransferrate(e.g.of
heatexchangertubes)
brittlesurface
surfacesoftening
unpleasantappearance,or
others.(i.ethetarnishingofsilver,ironrusting,
dissolutionofmetalinacidsolution)
Allmetalsandalloysaresusceptibletocorrosion.
Nosinglematerialissuitableforallapplications.
Forexample,gold,knownforitsexcellent
resistancetotheatmosphere,willcorrodeif
exposetomercuryatambienttemperature.On
theotherhand,irondoesnotcorrodeinmercury
butrustsreadilyintheatmosphere.

Fortunately,thereareusuallyseveralmetalsthat
willperformsatisfactorilyingivenenvironment.
Alsotheyaremethodofcorrosioncontrolthat
minimizetheproblem.
 THE COST OF CORROSION
Corrosion:
--the destructive electrochemical attack of a material.
--Al Capone's
ship, Sapona,
off the coast
of Bimini.

Cost:
--4 to 5% of the Gross National Product (GNP)*
--this amounts to just over $400 billion/yr**
 Corrosionagenttometal
1. Water
2. Moisture
3. Acids
4. Bases
5. Salts
6. Oils

Disadvantage:economictermshigherexpenseto
spentforcorrosionpreventionandmaintenance/
replacement

Advantage:etching,drycellbatteries
ELECTROCHEMICAL CONSIDERATION

Corrosionprocessisnormallyelectrochemicalprocess

Involvechemicalreaction

transferfromonechemicalspeciestoanother

3importantprocessincorrosion
Electrolyte(anysolutionthatcontainsion)
Anode(oxidation)
Cathode(reduction)
 ELECTROCHEMICAL CONSIDERATIONS
Two reactions are necessary:

--oxidation reaction: Zn Zn2 2e ANODE

-- reduction reaction: 2H 2e H2(gas) CATHODE

H+
oxidation reaction
Zn Zn2+ H+
H+
Acid
Zinc flow of e-
2e- H+ solution
in the metal H+
H+
Individualoxidationand H2(gas)
H+
reductionaretermedhalfreaction reduction reaction
ZnZn2++2
2H++22H+(gas)
Zn+2H+Zn2++2H+
(gas)
 ANODE
Oxidationprocessoccurs
Oxidationmetalatomlose/giveup
MMn++n
i.e;FeFe2++2

CATHODE
Reductionreactionoccurs
Gainsof(frommetalatomthatisoxidized)
Thereactionatcathode
Mn++Mn1
OrMn++nM
i.eMg2++2Mg
 Other reduction reactions:
Itispossiblefortwoormoreofreductionreaction
occurs
Corrosioninacidsolutionwhichhaveahighconcentration
ofhydrogenions.
2H++2H2

Foranacidsolutionhavingdissolvedoxygen.The
reductionfollows
O2+4H+42H2O

Foraneutralorbasicaqueoussolution
O2+2H2O+44(OH)
 CORROSION IN A GRAPEFRUIT
Cathode Anode
Cu +
-
H+ Zn
H+ Zn2+

reduction 2e- oxidation

2H 2e H2(gas)
H+
O2 4H 4e 2H2O H+
Acid H+
H+ H+
STANDARD HYDROGEN (EMF) TEST
Two outcomes:
--Metal sample mass --Metal sample mass

e- e- e- e-
H2(gas) - H+ 2e-
ne- 2e ne-
H+
Platinum

Platinum
metal, M
metal, M

Mn+ H+ Mn+
ions ions
H+
25C 25C
1M Mn+ soln 1M H+ soln 1M Mn+soln 1M H+ soln
--Metal is the anode (-) --Metal is the cathode (+)
o o
Vmetal 0 (relative to Pt) Vmetal 0 (relative to Pt)

Standard Electrode Potential

 dc

STANDARD EMF SERIES

EMF series o
Metal with smaller
o

metal Vmetal o
h

Vmetal corrodes.
i

Au +1.420 V Ex: Cd-Ni cell

a
ct

Cu +0.340
- +
m
e

Pb - 0.126
o
r

Sn - 0.136
Ni - 0.250 o
Co - 0.277 V =
c
d

Cd - 0.403 0.153V
o

Cd 25C Ni
ni

Fe - 0.440
a

Cr - 0.744
m
e

Zn - 0.763 1.0 M 1.0 M

o
r

Al - 1.662 Cd 2+ solutionNi 2+solution

Mg - 2.262
Na - 2.714 Example Problem 17.1
K - 2.924
 ELECTRODE POTENTIAL
Thepotentialofmetallicmaterialsoxidizetoformions
donothavethesamedegreeofease

twohalfcellreactionsforA
FeFe2++2 V1anode=0.440
Cu2++2Cu V2cathode=+0.340
Fe+Cu2+Fe2++Cu

Overallcellpotential
V=V2V1
=0.340(0.440)

=0.780
 ELECTRODE POTENTIAL
twohalfcellreactionsforB
ZnZn2++2V1anode=0.763
Fe2++2Fe V2cathode=0.440
Zn+Fe2+Zn2++Fe

Overallcellpotential
V=V2V1
=0.440+0.763

=0.323

Variouselectrodepairhavediff.voltages
 Example 1

Onehalfofanelectrochemicalcellconsistsofapure
copperelectrodeinasolutionofaCu2+ions;the
otherhalfisamagnesiumelectrodeimmersedin
aMg2+solution.Thestandardreduction
potentialofCu2+andMg2+are0.34Vand2.37
Vrespectively.
i)Writethespontaneousoverallreaction.
ii)Calculatethestandardemfthatisgenerated.
 c
GALVANIC SERIES
Ranks the reactivity of metals/alloys in seawater
hd
oi

Platinum
)
a

et

Gold
t

n r
c

Graphite
e
m

Titanium
(
o

i
r

Silver
316 Stainless Steel
Nickel (passive)
Copper
dc

Nickel (active)
o

e
i

Tin
)
n

Lead
a

316 Stainless Steel

e

ac
ti
m

Iron/Steel
o
r

Aluminum Alloys
Cadmium
Zinc
Magnesium
 CORROSION RATE
Theweightlosscanbeconvertedtoacorrosionratein
units:
mm/yr(milimetersperyear)
mpy(milsperyear)
TodeterminethecorrosionrateatestcalledaTafel
extrapolationisconducted.ItbasiclyobeysFaradaysLaw:
whereQCoulombs
nnumberofelectronsinvolvedinhalfcell
reaction
nFW FFaradaysConstant(96,500coulombs/mol)
Q Wweightofelectronegativespecies;
M Mmolecularweight
 CORROSION RATE
Equivalentweight(EW)=M/n
QM W=(QxEW)/F
W Q=it
nF whereicurrentinAmps,
ttimeinseconds

WhereW/tisthecorrosionrateingmpersec.
itEWW=VwheredensityandVvolume
W
F V=itEW/F
V=TA,whereTthicknessandAisthesurfacearea
T/t=iEW/(FdA)

T/tismilsperyearwhenappropriateconstantare imposed
forthenumberofsecondsinayearandfor theunitchangesfor
length.
 CORROSION RATE
Corrosionrate(CR)inmilsperyear

ixEWx31.6 x109
CR
xFxAx2.5 x106

wherei/AiscurrentdensityinAmps/cm2

(icorr xEW )
CR 0.13

ForunitsofCRinmilsperyear,icorrinA.cm2.

EWistheequilibriumweightandisthedensityofthemetal.
 Example 2

Acadmiumelectroplatingprocessuses10A
ofcurrentandchemicallycorrodesa
cadmiumanode.Howlongwillittaketo
corrode8.2gofcadmiumfromthe
anode?
 Example 3
Amildsteelrectangulartank1.25mlengthx1.25m
widthx1mhighcontainsaeratedwatertothe
790mmlevelandshowsalossinweightdueto
corrosionof405gafter8weeks.Assumeuniform
corrosiononthetank'sinnersurfaceandthatthe
steelcorrodesinthesamemanneraspureiron.
Thedensityofmildsteelis7.9g/cm3.Calculate,
i)thecorrosioncurrent.
ii)thecurrentdensity.
iii)thecorrosionrateofthetank.
 EFFECT OF SOLUTION CONCENTRATION
Ex: Cd-Ni cell with Ex: Cd-Ni cell with
standard 1M solutions non-standard solutions
o o o o RT X
VNi VCd 0.153 VNi VCd VNi VCd ln
nF Y
- + - +
n = #e-
per unit
oxid/red
Cd 25C Ni Cd T Ni reaction
(=2 here)
F=
1.0 M 1.0 M XM YM Faraday's
Cd2+ solution Ni2+solution Cd2+ solution Ni2+solution constant
Reduce VNi - VCd by =96,500
C/mol.
--increasing X
--decreasing Y
 FORMS OF CORROSION
CORROSION

UNIFORM LOCALIZED

MACROSCOPIC MICROSCOPIC
GALVANIC INTERGRANULAR CORROSION
CREVICE STRESS CORROSION CRACKING
PITTING
EROSION CORROSION
Schematic figure of forms of corrosion
 Uniform corrosion
(most common form of
corrosion)

Auniform,regularremovalfromthesurfaceisthe
usuallyexpectedonthemodeofcorrosion.
Thecorrosiveenvironmentmusthavethesame
accesstoallpartsofthemetalsurface,andthemetal
itsselfmustbemetallurgicallyandcompositionally
uniform.
Interfacepotentialisinactivecorrosionregion.
Thecorrosionrateispredictableandthusacceptable
fordesign.

 Uniform corrosion
Examples:

Corrosionofsteelinhydrochloricacidsolution
Thinningandpenetrationofcarbonsteelstorage
tankforsour(H2Scontaining)crudeoil
Atmosphericcorrosion

Control

Selectpropermaterial
Coating
Useofinhibitor
Anodic/cathodicprotection

 Uniform corrosion
Thereactionstartsatthesurfaceandproceeds
uniformly.
 Galvanic corrosion

Galvaniccorrosionoccurswhendissimilarmetallic
materialsarebroughtintocontactinthepresenceof
electrolyte.Thereforegalvaniccorrosionisthemajor
suspectwhenattackatthejunctionbetweentwo
dissimilarmetals/alloys
Suchdamagecanalsooccurbetweenmetalandother
conductingmaterialssuchascarbonandgraphite.
Corrosionisgreatestonthemoreactivemetalnear
thejunctionbetweentwometals.
Notethatinextremecasethemorenoblemetalcan
bedamagedbyhydrogen.
 Galvanic corrosion
Factorsaffectingagalvaniccorrosion:

Electrodepotential
Surfacecharacteristic
Reactionkinetics
Bulkofsolutionpropertiesincludingitsflowrate
properties
Geometry
Typeofjoint
Alloycomposition
 Galvanic series of some commercial metals and
alloys in seawater

Platinum
Gold
Graphite
Titanium
Silver
Chlorimet3(62Ni,18Cr,18Mo)
NOBLE OR
HastelloyC(62Ni,17Cr,15Mo)
MORE
CATHODIC 188Mostainlesssteel(passive)
188Stainlesssteel(passive)
Chromiumstainlesssteel11,30%Cr(passive)
Inconel(passive)(80Ni,13Cr,7Fe)
Nickel(passive)
Silversolder

 Monel(70Ni,30Cu)
Cupronickels(6090Cu,4010Ni)
Bronzes(CuSn)
Copper
Brasses(CuZn)
Chlorimet2(66Ni,32Mo,1Fe)
HastelloyB(60Ni,30Mo,6Fe,1Mn)
Inconel(active)Nickel(active)
Tin
Lead
Tinleadsolder
188Mostainlesssteel(active)
188stainlesssteel(active)
NiResist(highNicastiron)
ACTIVE OR Chromiumstainlesssteel,13%Cr(active)
MORE ANODIC Castiron
Steeloriron
2024aluminium(4.5Cu,1.5Mg,0.6Mn)
Cadmium
Commerciallypurealuminium(1100)
Zinc
Magnesiumandmagnesiumalloys
 Galvanic corrosion
Galvaniccorrosionwillbesignificantifthecorrosion
potentialsdifferencebetweentwometals/alloys
250mV
Iftwodifferentmetals/alloyshavetobeusedin
contact,itissuggestedtoselectalloyswiththeir
corrosionpotentialsareascloseaspossible

Anotherimportantingalvaniccorrosionisthearea
effect,ortheratioofthecathodictoanodicareas.An
unfavorablearearatioconsistsofalargecathodeand
asmallanode,becausethecorrosionofmetalwillbe
takingpalacewithhighcurrentdensity
Galvanic corrosion

aluminum
helicopter blade
has corroded
near where it
was in contact
with a steel
counterbalance.
 Galvanic corrosion
The nature and aggressiveness of the environment determine to a
large extent the degree of two metal corrosion.

Thedistanceaffecteddependsontheconductivityofthe
solution.
 Stress corrosion
accelerationofcorrosionincertainenvironments

importantanddifficulttopredictthefailure

Crackingpresentduetocorrosiveenvironmentandstressinduce

Stresscorrosioncracking(SCC)

stresseitherinternaltensilestresses(coldwork)orexternal
stressed
 Stress corrosion
Themagnitudeofstressnecessarytocause
failuredependsonthecorrosivemediumand
onthestructureofthebasemetal

Inthemicrostructure,thesecrackscanhavean
intergranular(fig.A)oratransgranular(fig.
B)morphology.

Macroscopically,SCCfractureshaveabrittle
appearance.
 Stress corrosion

Figure A Figure B
i.ematerial:
steelcontainingaluminiumhavebetterresistancetostress
corrosion
Stainlesssteelsaresusceptibletostresscorrosioncracking
inthepresenceofchlorides
Stress corrosion
 Erosion-corrosion

Rapidlyflowingsolutionscanoftendisruptadherencesurface
filmsanddepositsthatwouldotherwiseofferprotectionagainst
corrosion.
Thinningorremovalofsurfacefilmoradherencecorrosion
productlayerbyerosionfromtheflowingstreamresultsin
acceleratedcorrosion,callederosioncorrosionorimpingement
attack.Theattackisacceleratedatelbows,turbines,pumps,tubes
constrictions,andotherstructuralfeaturesthatalterflow
directionorvelocityandincreaseturbulence.

 Erosion-corrosion
Erosioncorrosionoftenoccurswhencorrodentisin
liquidphase.Suspendedsolidsfurtheraggravatethe
erosionofsurfacefilmsandincreaseerosion
corrosion.
Attackmaybeespeciallyseriousintwophaseflow,
inwhichsteamandwatervaporcondensatedroplets
arepresenttogether
Thelowerstrength,lessresistancealloys,suchas
carbonsteel,copperandaluminiumareespecially
susceptibletoerosioncorrosion.Thestainlesssteel,
nickelalloysandtitaniumareusuallyresistant,
becausetheirtenaciousanddurablepassivefilms.
 Erosion-corrosion
Erosioncorrosiontakestheformofgrooves,waves,
gullies,teardropshapepitsandhorseshoeshaped
depressioninthesurface.
Impingement
corrosion pits
Fluid flow

Teardropshapedpitswithundercuttinginthedown
streamdirection,formedonbrasscondensertubing
 Erosion-corrosion
Turbulent eddy mechanism for downstream
undercutting of erosion corrosion pits

The attack was seasonal and unpredictable and could be

simulated only with water containing a combination of
dissolved bicarbonate and silicate
 Erosion-corrosion

 FORMS OF CORROSION
Stress corrosion
Stress & corrosion
Uniform Attack work together Erosion-corrosion
Oxidation & reduction at crack tips. Break down of passivating
occur uniformly over layer by erosion (pipe
surface. elbows).
Selective Leaching Pitting
Preferred corrosion of Forms Downward propagation
one element/constituent of of small pits & holes.
(e.g., Zn from brass (Cu-Zn)).
corrosion
Intergranular
Corrosion along
grain boundaries, Galvanic
often where special Dissimilar metals are Crevice Between two
phases exist. pieces of the same metal.
physically joined. The
Rivet holes
g.b. more anodic one
prec.
corrodes.(see Table
17.2) Zn & Mg
attacked
zones very anodic.
 SUMMARY
Corrosion occurs due to:
--the natural tendency of metals to give up electrons.
--electrons are given up by an oxidation reaction.
--these electrons then are part of a reduction reaction.
Metals with a more negative Standard Electrode
Potential are more likely to corrode relative to
other metals.
The Galvanic Series ranks the reactivity of metals in
seawater.
Increasing T speeds up oxidation/reduction reactions.
 Prevention Methods

FIVEgeneraltechniquestoconsider:
1. Materialselection
2. Environmentalalteration
3. Designconsideration
4. Coating
5. Cathodic&Anodicprotection
 Material selection
Selectionofmaterialdependsonthecorrosion
environment:
i.e.applicationinfreshwater
Suitablemetal:castiron,steel,Al,Cu,brassandsomestainless
steel.
Applicationforseawaterenvironment
Titanium,brass,somebronzes,coppernickelalloys,nickel
chromiummolybdenumalloys.
Suitablemetalforatmosphericapplication
Alalloys,cualloys,galvanizedsteel
Heattreatmentforrelievetheresidualstressinducein
metalthatformedintofinishedshapesbybending
 Mechanicalproperties
Whenoperationconditionbecomeaggressive,
materialfromcombination2/3metalareneeded

Effectoftemp.willinfluencethemechanical
properties
i.e.applicationofplaincarbonsteelislimitedto316343oC
duetolossofstrengthandsusceptibilitytooxidationand
corrosion.
HighlyalloyedNiCrFealloyareadequatetocorrosion
resistanceatelevatedtemp.compareto18Cr12Ni.18Cr
12Nisustainoxidationresistanceattemperatureupto
816oCandstrengthreduceabove650oC
 Materialfabrication
Materialshouldbeselectedonthebasisoftheir
maintainabilityaswellastheirfabricationability
Needtoconsidertheeaseofmodificationor
repairedafterexposuretooperatingcondition.

Availabilityofmaterials
Considerationforfutureavailabilityforrepairsor
replacementoralternativereplacementmaterials

Materialcost
Lifecyclecostorcosteffectivenessratherthan
initialcost
 Environmental alteration
Decreasethevelocityofcorrosivefluid
Uselowertemperature
RemoveO2fromwatersolutionbydeaeratedprocess
Reducetheconcentrationofcorrosiveionsinasolution
Addinginhibitorsinsystem
Scavengerstypereactwithandvirtuallyeliminateachemically
activespeciesinsolutionsuchasdissolvedO2

Absorptiontypeattachthemselvestothecorrodingsurfaceand
interfacewitheitheroxidation/reductionreactionorformavery
thinprotectivecoating
 Design consideration
Preventtheformationofgalvaniccellbyusing
similarmetaloralloysorusingnonmetallic
connector(fitting,gasket)toelectricallyinsulatethe
twodissimilarmetal

Weldratherthanrivets.Orchooserivetsthatare
cathodictothematerialsbeingjoined

Maketheanodearealargerthanthecathodearea
 Design consideration
Avoidsharpbendsinpipingsystemwhenflow
occurs.Erosioncorrosionwilloccuratareasinwhich
thefluiddirectionchangessharply.

Designcomponentssothatfluidsystemareclosedto
avoidcontinuouslydissolvegas.

Easyremovalandreplacementofpartsthatare
expectedtofailrapidlyinservice,mustbedesign

Thedesignshouldallowforcompletedrainageand
easywashing
 Coating
Physicalbarrierappliedonsurfacesintheformof
films
Usedtoisolateanodeandcathoderegion
Importantcondition:
coatingmustbenonreactiveinthecorrosiveenvironment
Resisttomechanicaldamagethatexposesthebaremetalto
corrosiveenvironment
Typesofmaterialforcoating
Metals
Ceramic
Polymers
 Metalliccoating
Actsassacrificialanodesinsteadofcoatedmetal
i.e:steelarecoatedwithZincplatedortinplated
Metalcoatingareplatedbyelectroplatingprocess
Metal/parttobeplatedismadeascathode.The
electrolyteisasolutionofasaltofthemetaltobe
platedanddirectcurrentisapplied.
 Inorganiccoating(ceramic/glass)
Porcelaincoatingwhichconsistofthinlayerofglassfused
tothesteelsurfacesothatitadhereswellandhas
coefficientofexpansionadjustedtothebasemetal
i.e.reactionvesselscanalsobelinedwithcorrosion
resistantTeflon
Stable,adherent,nonporous,nonconductingoxidelayer
i.e.glassfusedcoatingasteel

Organiccoating
Providethin,toughanddurablebarriertoprotectsubstrate
metalfromcorrosionenvironmental
Polymericmaterial,pints,Paints,varnishes,lacquers
Cheaper
 CATHODIC PROTECTION
(is one of the most widely used methods of corrosion
prevention)
Theprincipleofcathodicprotectionisinconnectingan
externalanodetothemetaltobeprotectedandthepassingof
anelectricaldccurrentsothatallareasofthemetalsurface
becomecathodicandthereforedonotcorrode.
Processreversingthecorrosioncurrenttostopdamaging
corrosionprocess
Involvessupplyelectrons(fromexternalsource)tothe
metalprotected,makingitcathode.
SACRIFICIALANODESCATHODIC
PROTECTION(SACP)
IMPRESSEDCURRENTCATHODIC
PROTECTION(ICCP)
SACRIFICIAL ANODES CATHODIC
PROTECTION (SACP)
Employreactivemetalsasauxiliaryanodesthat
aredirectlyelectricallyconnectedtothemetalto
beprotected.

Thesacrificialanodecorrodes,suppliestothe
metalandtherebypreventsananodereactionat
metal

Themetalscommonlyused,assacrificialanodes
arealuminium,zincandmagnesium.
 Schematic figure of SACP

Sacrificial anodes
used for steel
structured:
Aluminium anode
Magnesium anode
Zinc anode
 SACRIFICIALANODESCATHODICPROTECTION(SACP)

Agalvanicorsacrificialanode
systemrequires:
i)Sacrificialanodes
ii)Directweldingtothestructure
oraconductorconnectingthe
anodetothestructure
iii)Secureandminimum
resistanceconnectionsbetween
conductorandstructure,and
betweenconductorandanode.
 SACRIFICIALANODESCATHODICPROTECTION(SACP)

Thecurrenthastoflowinaloopandthereforethe
surfaceofstructurethatcanbeprotectedisthe
submergedsurfacethatarereceivedprotectioncurrent
fromanodes.

STEEL PROTECTED
PIPE SURFACE
UNPROTEC-
TED SURFACE
SACRIFICIAL ANODES CATHODIC PROTECTION
(SACP)

Criteriaforsacrificialanodes
Acorrosionpotentialthatissufficientlynegative
forthespecificapplication;ingeneral,alloying
additionsaremadetomakethepotentialmore
negativethanthatoftheunalloyedbasismetal

Ahighanodeefficiency,whichmeansthat
impuritiesthatresultinselfcorrosionmustbe
absentorminimum.

Anabilitytoremainactiveandtocorrode
uniformlyandnottobecomepassive
 IMPRESSED CURRENT CATHODIC
PROTECTION (ICCP)
Obtainedfromadirectcurrentsourceconnectedbetween
anodeandthemetaltobeprotected

Aconnectionfromacurrentsourcetomakeelectronflowto
metal,tocausethemetaltobecathode

Anodeisusuallysurroundedbyhighconductivitybackfill
materialsuchasgypsumorbentonitewhichimprovethe
electriccontactbetweenanodeandsurroundingsoil

Add:itwillprotectedlargearea
IMPRESSEDCURRENTCATHODICPROTECTION(ICCP)

Animpressedcurrentsystemrequires:

i)Inertanodes(clustersofwhich,connectedtogetheroftenin
abackfill,arecalledthegroundbed).

ii)Adcpowersource.

iii)Electricallywellinsulated,minimumresistanceand
secureconductorsbetweenanodesandpowersource.

iv)Secureandminimumresistanceconnections
betweenpowersourceandstructure.
 Schematic figure of ICCP
The source of electrons is an impressed current from an external power
source for an underground tank.
Negative terminal of powers source is connected to the structure to be
protected.
Positive terminal is joined to an inert anodic (I.e. graphite)
In this case cathodic protection only protect the expose
area
Why should use ICCP?

Steel structure that will be protected is large

Protection current requirement is high
Coating quality varies in a large range
Resistivity of soil is high
Source of electric current is available
Field for ground bed are available
 CATHODIC PROTECTION
Structuresthatarecommonlyprotectedbycathodicprotection
aretheexteriorsurfacesof:
Pipelines
Shipshulls
Storagetankbases
Jettiesandharbourstructures
Steelsheet,tubularandfoundationpilings
Offshoreplatforms,floatingandsubseastructures

Cathodicprotectionisalsousedtoprotecttheinternalsurfaces
of:
Largediameterpipelines
Shipstanks(productandballast)
Storagetanks(oilandwater)
Watercirculatingsystems.
 CATHODIC PROTECTION
Themainadvantageofcathodicprotectionis;
thatitisappliedsimplybymaintainingadccircuit
itseffectivenessmaybemonitoredcontinuously.
Canappliedtoacoatedstructuretoprovidecorrosioncontrolto
areaswherethecoatingmaybedamaged.
maybeappliedtoexistingstructurestoprolongtheirlife.
willavoidtheneedtoprovideacorrosionallowancetothin
sections.
Itmaybeusedtoaffordsecuritywhereevenasmallleakcannot
betoleratedforreasonsofsafetyorenvironment.
Inpractice,itsmainuseistoprotectsteelstructuresburiedinsoil
orimmersedinwater.
Itcannotbeusedtopreventatmosphericcorrosiononmetals.
 Anodic protection
Reductionofthecorrosionrateinananodebypolarizingitinto
apotentialregionwherethedissolutionrateslow.
Incircumstanceswherecathodicprotectionisnotpractical,
suchasinstronglyalkalineoracidicenvironments,anodic
protectionisausefulcorrosioncontroltechnique
Inanodicprotection,themetaltobeprotectedismadethe
anode
corrosionproductsprotective
activepassivemetals/alloys
Thepassivationmetalcorrodeatslowerratesthannormal
Theprimaryadvantagesofanodicprotectionareits
applicabilityinextremelycorrosiveenvironmentsanditslow
currentrequirements.
Anodicprotectionhasbeenmostextensivelyappliedtoprotect
equipmentusedtostoreandhandlesulfuricacid.
 Anodic protection
Passivationoccurbyexposingthemetaltohighly
concentratedoxidizingsolution
i.e:
ironisdippedinveryconcentratednitricacid.
Ironrapidlyanduniformlycorrodestoformathinprotectiveiron
hydroxidecoating
Thecoatingwillprotectstheironfromsubsequentcorrosioninnitric
acid
Basedontheformationofprotectivefilmsonmetalandalloy
surfacesbyexternalimpressedanodiccurrents.
Canbecontrolledbyadevice(potentiostat)whichisan
electronicdevicethatmaintainsametalconstantpotential
withrespecttoareferenceelectrode.
Potentiostathave3terminals
Connectedtotank
Connectedtoanauxiliarycathode
Connectedtoreferenceelectrode
ANODIC PROTECTION
 ANODIC PROTECTION
Advantages
Appliedcurrentofanodicprotectionisusuallyequalto
corrosionrateortheprotectedsystem
Candecreasecorrosionratesubstantially(applicabilityin
extremelycorrosiveenvironmentsandlowcurrent
requirement)
Protectequipmentsthatareusedtostoreandhandle
sulphuricacidmanufacturingplants
Disadvantages
Possibletoacceleratecorrosionifpropercontrolsarenot
implemented
Requirescomplexinstrumentation(noteconomictoapply
forasmallmanufacturingplant)
 Cathodic or Anodic ? A Comparison:
CathodicProtection
Advantages canbeusedforallmetals
installationcostislow
corrosionratecanbereducedtozero
Limitations canonlybeusedinweaktomoderate onlyapplicableto
environment
operatingconditionsmustbe
determinedbyempiricaltesting.
AnodicProtection
canbeusedin
extremelyaggressive
environment
appliedcurrentisdirect
measureofcorrosion
rate
operatingconditions
canbeeasilycontrolled
operationcostlow
activepassivemetals
installationcostishigh