CORROSION PREVENTION AND CONTROL

Corrosion is a natural process that occurs when metal is exposed to oxygen and other
environmental factors. It is a major problem in many industries, including infrastructure, transportation,
and manufacturing. Corrosion can cause significant damage to equipment and structures, leading to
increased maintenance costs, reduced efficiency, and even safety hazards. Preventing and controlling
corrosion is essential to ensure the longevity and reliability of these assets.

Significance of Corrosion Prevention and Control

 Cost Reduction

Corrosion prevention and control measures can significantly reduce maintenance costs
by extending the lifespan of equipment and structures. It is much more cost-effective to prevent
corrosion from occurring than to repair or replace corroded materials.

 Safety

Corrosion can weaken the structural integrity of equipment and structures, leading to
safety hazards. Corrosion prevention and control measures can help ensure the safety of
personnel and prevent accidents.

 Environmental Protection

Corrosion can also cause environmental damage, such as contamination of water or soil.
Proper corrosion prevention and control measures can help prevent such damage and protect the
environment.

 Asset Reliability:

Corrosion prevention and control measures can ensure the reliability of equipment and
structures, which is critical in many industries. Reliable assets are essential to maintaining
operational efficiency and avoiding costly downtime.

 Compliance:

Many industries are subject to regulations regarding corrosion prevention and control.
Failure to comply with these regulations can result in fines and other penalties. Proper corrosion
prevention and control measures can help ensure compliance and avoid such penalties.
Corrosion Prevention and Control Methods
There are various methods for preventing and controlling corrosion, including:

 Protective coatings
Coatings such as paint, epoxy, and polyurethane can provide a barrier to protect
the metal from the environment.
 Cathodic protection
This involves using a sacrificial metal to protect the metal being protected. This is
commonly used in pipelines and underground tanks.
 Corrosion inhibitors
These are chemicals that can be added to the environment to slow down or
prevent corrosion.
 Design and Material Selection
Choosing materials that are less susceptible to corrosion and designing structures
to minimize corrosion-prone areas can also be effective.

ELECTROCHEMICAL NATURE OF AQUEOUS CORROSION

Aqueous corrosion is a common type of corrosion that occurs when a metal is exposed to water
or a solution that contains water. It is an electrochemical process that involves the transfer of electrons
between the metal and the surrounding environment.

Mechanism of corrosion

Aqueous corrosion occurs through an electrochemical reaction known as oxidation-reduction.

This reaction involves the transfer of electrons between the metal and the surrounding environment. At
the anode, metal atoms are oxidized, releasing electrons, and forming metal ions. These metal ions then
dissolve into the aqueous solution. At the cathode, oxygen molecules or other oxidizing agents in the
solution react with the electrons released from the metal, forming hydroxide ions. The hydroxide ions
then react with the metal ions to form metal hydroxides, which are soluble and can be washed away. This
process is known as metal dissolution or corrosion.

 Factors that affect corrosion

a. Composition of the metal - Different metals have different corrosion rates due to their
inherent properties. For example, noble metals such as gold and platinum have low
corrosion rates, while reactive metals such as iron and aluminum have higher
corrosion rates.
b. Composition of the solution - The composition of the solution also affects corrosion,
with acidic and alkaline solutions being more corrosive than neutral solutions.
 c. Temperature and pH - Temperature and pH also play a significant role in corrosion,
with higher temperatures and lower pH values increasing the rate of corrosion.
d. Presence of impurities - Impurities in the solution, such as salts and pollutants, can
also accelerate corrosion by providing additional electrolytes for the electrochemical
reaction to occur.

 Prevention of corrosion
Several methods are used to prevent aqueous corrosion
a. Corrosion-resistant metals - such as stainless steel and titanium are often used in
applications where corrosion is a concern.
b. Coatings - such as paint, anodizing, and plating can also protect metals from corrosion
by forming a barrier between the metal and the environment.
c. Inhibitors - are chemicals that are added to the solution to slow down the
electrochemical reaction.
d. Cathodic prevention - involves connecting the metal to a sacrificial anode, which
corrodes instead of the metal, thereby preventing corrosion of the metal.

CORROSION RATE DETERMINATES

Corrosion is a major problem in many industries, including oil and gas, transportation, and
construction. The rate of corrosion is an important factor to consider when designing materials and
structures, as it can affect their performance, safety, and longevity.

Factors that affects the rate of corrosion

a. Environmental factors
Environmental factors play a significant role in determining the rate of corrosion.
The presence of water, oxygen, and other corrosive substances in the environment can
accelerate the rate of corrosion. Temperature and humidity can also affect the rate of
corrosion, with higher temperatures and humidity levels increasing the rate of corrosion.
Other environmental factors, such as exposure to sunlight, saltwater, and pollutants, can
also accelerate corrosion.

b. Material factors
The properties of the material being corroded can also affect the rate of corrosion.
Different materials have different corrosion rates due to their inherent properties. For
example, noble metals such as gold and platinum have low corrosion rates, while reactive
metals such as iron and aluminum have higher corrosion rates.
The purity of the material can also affect the rate of corrosion, as impurities can act
as sites for corrosion initiation. Additionally, the microstructure and surface finish of the
 material can affect the rate of corrosion, with rougher surfaces being more prone to
corrosion.

c. Electrochemical factors
Corrosion is an electrochemical process that involves the transfer of electrons
between the metal and the surrounding environment. The rate of corrosion can be
influenced by electrochemical factors such as the potential difference between the metal
and the environment, the concentration of electrolytes in the environment, and the pH
of the environment. The potential difference between the metal and the environment
can be affected by factors such as the composition of the metal, the presence of other
metals in contact with the metal, and the temperature. The concentration of electrolytes
in the environment can also affect the rate of corrosion, with higher concentrations
increasing the rate of corrosion. The pH of the environment can also affect the rate of
corrosion, with acidic and alkaline environments being more corrosive than neutral
environments.

GALVANIC AND CONCENTRATION CELL CORROSION

Galvanic corrosion and concentration cell corrosion are two common types of corrosion that occur
in metals. Galvanic corrosion occurs when two different metals are in contact with each other in an
electrolyte solution, while concentration cell corrosion occurs when differences in concentration of
electrolytes exist between different parts of the same metal surface. This report will provide an overview
of both types of corrosion, including their causes, mechanisms, and prevention measures.

Galvanic Corrosion

Galvanic corrosion occurs when two different metals are in contact with each other in an
electrolyte solution. One of the metals, called the anode, will corrode more quickly than the other metal,
called the cathode. This is because the anode has a lower electrode potential than the cathode, which
causes it to lose electrons and corrode.

The mechanism of galvanic corrosion

It involves the transfer of electrons from the anode to the cathode. This creates a flow of
electrical current through the electrolyte solution, which accelerates the corrosion of the anode.
The rate of galvanic corrosion is influenced by factors such as the size of the anode, the type of
electrolyte solution, and the distance between the anode and cathode.
 Prevention measures for galvanic corrosion

It includes using metals that have similar electrode potentials, coating the metals with a
non-conductive material, or using sacrificial anodes that will corrode in place of the more valuable
metal.

Concentration Cell Corrosion

Concentration cell corrosion occurs when differences in concentration of electrolytes exist

between different parts of the same metal surface. This can occur when a metal is in contact with different
concentrations of an electrolyte solution, or when there are differences in the flow of electrolyte solution
across the metal surface.

The mechanism of concentration cell corrosion

It involves the creation of a potential difference between different parts of the metal
surface. This potential difference can cause electrons to flow from one part of the metal to
another, which accelerates the corrosion process. The rate of concentration cell corrosion is
influenced by factors such as the size and shape of the metal surface, the type of electrolyte
solution, and the temperature.

Prevention measures for concentration cell corrosion

It includes avoiding differences in the concentration of electrolyte solutions on the metal

surface, using coatings or barriers to prevent the flow of electrolyte solution across the metal
surface, or using cathodic protection to provide a source of electrons that can slow down the
corrosion process.