Corrosion Prevention

PREVENTION
OF
CORROSION
1
Prepared by: Mr Ali Abbas

2
PREVENTION
OF
CORROSION
 The huge annual loss due to corrosion is a national waste and should
be minimized
 Materials already exist which, if properly used, can eliminate 80 %

of corrosion loss
 Proper understanding of the basics of corrosion and incorporation in

the initial design of metallic structures is essential
3
Factors that affect the rate of
corrosion
Temperature Oxygen
Humidity Chemical Salts
Chemicals and airborne gases

4 How to avoid (or control)
Corrosion?
 Material Selection! Remember – environment key.

Look at potential pH diagrams!!!
 Eliminate any one of the 4 requirements for

corrosion!
 Galvanic - Avoid using dissimilar metals.

 Or close together as possible
 Or electrically isolate one from the other
 Or MAKE ANODE BIG!!!
5
How to avoid (or control)
Corrosion?
 Pitting/Crevice: Watch for stagnate water/ electrolyte.

 Use gaskets
 Use good welding practices
 Intergranular – watch grain size, environment,

temperature, etc.. Careful with Stainless Steels and AL.
6
How to avoid (or control)
Corrosion?
 Consider organic coating (paint, ceramic, chrome,

etc.) – DANGER IF IT GETS SCRACTHED!!
 OR BETTER YET, consider cathodic protection:

 such as zinc (or galvanized) plating on steel
 Mg sacrificial anode on steel boat hull
 Impressed current, etc..
7 Methodes To Control
Corrosion
 Design of structures
 Material selection
 Cathodic Protection
 Reduce the activity of the cathode and or electrolyte. (Polarization)
 Protection of the Anode. (Passivation)
 Alteration of environment
 Inhibitors
• Protective Coatings
DESIGN OF STRUCTURES
8
 Avoid sharp corners
 Complete draining of vessels
 Avoid sudden changes in section
 Avoid contact between dissimilar metals
 Weld rather than rivet
 Easy replacement of vulnerable parts
 Avoid excessive mechanical stress

Design Do’s & Don’ts
9
 Wall thickness – allowance to accommodate for corrosion effect.
 Avoid excessive mechanical stresses and stress concentrations in components

exposed to corrosive mediums. Esp when using materials susceptible to SCC.
 Avoid galvanic contact / electrical contact between dissimilar metals to prevent

galvanic corrosion.
 Avoid sharp bends in piping systems when high velocities and/or solid in
suspension are involved – erosion corrosion.
 Avoid crevices – e.g weld rather than rivet tanks and other containers, proper
trimming of gasket, etc.
 Avoid sharp corners – paint tends to be thinner at sharp
10
corners and often starts to fail.
 Provide for easy drainage (esp tanks) – avoid remaining

liquids collect at bottom. E.g steel is resistant against
concentrated sulfuric acid but if remaining liquid is exposed to
air, acid tend to absorb moisture, resulting in dilution and
rapid attack occurs.
 Avoid hot spots during heat transfer operations – localized

heating and high corrosion rates. Hot spots also tend to
produce stresses – SCC failures.
 Design to exclude air – except for active-passive metals and

alloys coz they require O2 for protective films.
 Most general rule : AVOID HETEROGENEITY!!!

11
DESIGN for Corrosion

12
DESIGN for Corrosion
Bracket easier to
replace than
pipe!
13
14
15
Material Selection
16
MATERIAL SELECTION
(selection of proper material for a particular corrosive service)
Metallic : [metal and alloy]

Nonmetallic : [rubbers (natural and synthetic),
plastics, ceramics, carbon and graphite, and wood]
17
IMPROVEMENTS OF
MATERIALS
 Purification of metals: Al , Zr
 Making more noble, e.g. Pt in Ti
 Passivating, e.g. Cr in steel
 Inhibiting, e.g. As & Sb in brass
 Scavenging, e.g. Ti & Nb in S.S
 Improving other properties

18
Material Selection - Galvanic
Series [Seawater at 77⁰ F.]
Magnesium
Zinc
Aluminum
Mild Steel
Cast Iron
Copper
Stainless Steel
Gold
Platinum
Combining dissimilar metals can result in
19
corrosion. It may be very rapid or it may be
relatively slow, depending on the metals combined,
the environment, and the ratio of one to the other.
We can also use this concept to protect a surface,
such as when we hot dip galvanize steel. The zinc
we apply to the steel is the more active metal and
will sacrifice itself to protect the steel. When we
combine zinc and steel the zinc becomes the anode
and the steel becomes the cathode.
Metals and Alloys
No Environment Proper material
1 Nitric acid Stainless steels
2 Caustic Nickel and nickel
alloys
3 Hydrofluoric acid Monel (Ni-Cu)
4 Hot hydrochloric acid Hastelloys
(Ni-Cr-Mo)
5 Dilute sulfuric acid Lead
20
No Environment Proper material
6 Nonstaining atmospheric Aluminum
exposure
7 Distilled water Titanium
8 Hot strong oxidizing Titanium

solution
9 Ultimate resistance Tantalum
10 Concentrated sulfuric Steel

acid
21
Cathodic Protection (CP)
22
 Cathodic protection (CP) is a technique to control the corrosion of a metal surface by
making it work as a cathode of an electrochemical cell. This is achieved by placing in
contact with the metal to be protected another more easily corroded metal to act as
the anode of the electrochemical cell. Cathodic protection systems are most
commonly used to protect steel, water or fuel pipelines and storage tanks, steel pier
piles, ships, offshore oil platforms and onshore oil well casings.
 Types of CP:
 sacrificial anodes (zinc, magnesium or aluminum): The sacrificial anodes are more
active (more negative potential) than the metal of the structure they’re designed to
protect. The anode pushes the potential of the steel structure more negative and
therefore the driving force for corrosion halts. The anode continues to corrode until it
requires replacement,
 Impressed current CP: done for large structures (pipes, offshore platforms, etc)
where a galvanic (or sacrificial) anode can not economically deliver enough current.
 Galvanized steel (see previous slide): again, steel is coated with zinc and if the zinc
coating is scratched and steel exposed, the surrounding areas of zinc coating form a
galvanic cell with the exposed steel and protects in from corroding. The zinc coating
acts as a sacrificial anode.
23 CATHODIC & ANODIC
PROTECTION
 Cathodic protection: Make the structure more cathodic by
 Use of sacrificial anodes
 Impressed currents
 Galvanized steel
 Anodic protection: Make passivating metal structures more

anodic by impressed potential. e.g. 316 s.s. pipe in sulfuric acid plants.
Sacrificial Anodes
24
 Galvanization of Steel
 Dip steel sheet in molten zinc. Get a pretty thin coating.
 Zinc will be anode. Steel exposed by crack is the cathode. Since we have a
huge anode having to be served by a small cathode, corrosion rate will be
slow.
Tiny cathode (steel)
Large area
anode (zinc)
An example of a favorable area ratio. Bad deal: huge cathode, tiny anode
25
Sacrificial Anode for a Pipeline
26
27
Aluminium anodes mounted on a steel jacket

structure – using galvanic corrosion for
corrosion control! Called cathodic protection
(aka sacrificial anode)
Impressed Voltage
28
By imposing a voltage which causes electrons to flow towards the

object to be protected, we make it less anodic and protect it from
corrosion damage.
Polarization
29
 This is an effect which reduces the actual chemical potential driving of

the cell. If the thermodynamic force driving the ion into solution is
reduced, this is polarization.
 Easy example. By lowering the electrolyte temperature, we find that it

is usually less corrosive. Diffusion of ions is slowed.
 Inhibitors are chemicals which slow corrosion. Some of them do this

by promoting the polarization of the cathode.
Passivation of the anode
30
 We have two examples already. Stainless and aluminum.
 A thin oxide layer forms on the surface and isolates the metal from the
environment.
 Zn, Mg, Cu and Ti are also capable of passivation under normal

conditions of operation.
 Steel will also passivate in the presence of an alkaline environment,

such as rebar in concrete.
 Corrosion inhibitors. Some of these, such as the chromates, are

capable of coating a steel and passivating it.
 Coatings, paints, etc.

31
Effect of environmental
parameters on the rate of
corrosion
32
5.5% NaCl
33
5.5% NaCl, 5 atm

34
5.5% NaCl, 85 °C
35
5.5% NaCl, 10 °C, 15 atm

36
Alternation of Environment
 Lower temperature and velocity
 Remove oxygen/oxidizers
 Change concentration
 Add Inhibitors
 Adsorption type, e.g. Organic amines, azoles
 H evolution poisons, e.g. As & Sb
 Scavengers, e.g. Sodium sulfite & hydrazine
 Oxidizers, e.g. Chromates, nitrates, ferric salts

37 Alteration of Environment
Typical changes in medium are :
Lowering temperature – but there are cases where

increasing T decreases attack. E.g hot, fresh or salt water is raised
to boiling T and result in decreasing O2 solubility with T.
Decreasing velocity – exception ; metals & alloys that

passivate (e.g stainless steel) generally have better resistance to
flowing mediums than stagnant. Avoid very high velocity because
of erosion-corrosion effects.
Removing
38 oxygen or oxidizers – e.g vacuum treatment,
inert gas sparging, or thru the use of oxygen scavengers.
However, not recommended for active-passive metals or
alloys. These materials require oxidizers to form protective
oxide films.
Changing concentration – higher concentration of acid

has higher amount of active species (H ions). However, for
materials that exhibit passivity, effect is normally negligible.
Environment factors affecting
39
corrosion
 Dust particles and man-made pollution – CO, NO, methane, etc.
 Temperature – high T & high humidity accelerates corrosion.
 Rainfall – excess washes corrosive materials and debris but scarce may leave
water droplets.
 Proximity to sea
 Air pollution – NaCl, SO2, sulfurous acid, etc.
 Humidity – cause condensation.

Inhibitors
40
Inhibitors are materials that may be injected into the

system . They plate out on the surface and inhibit the
formation of corrosion cells. They are commonly
used in pipelines and other vessels that will contain
materials that are corrosive.
Some metals, such as gold and platinum, corrode very

slowly or not at all. Choosing a corrosion resistant
material can reduce the rate of corrosion.
41
They are sometimes injected into the water stream
that may be used for the surface preparation of steel,
as in the case of water jetting.
In the formulation of some primers inhibitive
pigments are used . These inhibitive pigments
inhibit, or interfere, with the corrosion process.
Examples of inhibitive pigments are red lead and
barium meta borate.

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PREVENTION

Prepared by: Mr Ali Abbas

 Materials already exist which, if properly used, can eliminate 80 %

 Proper understanding of the basics of corrosion and incorporation in

Humidity Chemical Salts

Chemicals and airborne gases

 Material Selection! Remember – environment key.

 Eliminate any one of the 4 requirements for

 Galvanic - Avoid using dissimilar metals.

 Pitting/Crevice: Watch for stagnate water/ electrolyte.

 Intergranular – watch grain size, environment,

 Consider organic coating (paint, ceramic, chrome,

 OR BETTER YET, consider cathodic protection:

 Reduce the activity of the cathode and or electrolyte. (Polarization)

 Protection of the Anode. (Passivation)

 Avoid sharp corners

 Complete draining of vessels

 Avoid sudden changes in section

 Avoid contact between dissimilar metals

 Weld rather than rivet

 Easy replacement of vulnerable parts

 Avoid excessive mechanical stress

 Wall thickness – allowance to accommodate for corrosion effect.

 Avoid excessive mechanical stresses and stress concentrations in components

 Avoid galvanic contact / electrical contact between dissimilar metals to prevent

 Provide for easy drainage (esp tanks) – avoid remaining

 Avoid hot spots during heat transfer operations – localized

 Design to exclude air – except for active-passive metals and

 Most general rule : AVOID HETEROGENEITY!!!

DESIGN for Corrosion

DESIGN for Corrosion

Metallic : [metal and alloy]

 Making more noble, e.g. Pt in Ti

 Passivating, e.g. Cr in steel

 Inhibiting, e.g. As & Sb in brass

 Scavenging, e.g. Ti & Nb in S.S

 Improving other properties

8 Hot strong oxidizing Titanium

10 Concentrated sulfuric Steel

 Anodic protection: Make passivating metal structures more

Tiny cathode (steel)

Aluminium anodes mounted on a steel jacket

By imposing a voltage which causes electrons to flow towards the

 This is an effect which reduces the actual chemical potential driving of

 Easy example. By lowering the electrolyte temperature, we find that it

 Inhibitors are chemicals which slow corrosion. Some of them do this

 We have two examples already. Stainless and aluminum.

 Zn, Mg, Cu and Ti are also capable of passivation under normal

 Steel will also passivate in the presence of an alkaline environment,

 Corrosion inhibitors. Some of these, such as the chromates, are

 Coatings, paints, etc.

5.5% NaCl, 5 atm

5.5% NaCl, 10 °C, 15 atm

 Lower temperature and velocity

 H evolution poisons, e.g. As & Sb

 Scavengers, e.g. Sodium sulfite & hydrazine

 Oxidizers, e.g. Chromates, nitrates, ferric salts

Typical changes in medium are :

Lowering temperature – but there are cases where