Corrosion Control Lec 7

Faculty of Engineering - Chemical Engineering Department
Diploma Course title: Corrosion Engineering
Lecture 7:
Corrosion Control
Fakhri Hamdullah Ibraheem
[email protected]
May - 2024
Paints
Corrosion Control Inhibitors
Cathodic and Anodic Protection
Paint is a surface protection coating. It isolate the metals to be in touch with corrosion main parameters moistur,
oxygen and chemicals.
Painting procedure steps:
1. Cleaning the surfaces, it is used to remove impurities by de-greasing, sand blasting, vapor degreasing, pickling
and alkaline cleaning.
Solvent cleaning, it must be non-inflammable and nontoxic

Types of Provides better and rapid cleaning by increasing hydrogen evolution resulting in agitation
Cleaners and blasting action
Alkaline and Acid cleaning, like 10 NaOH solution and low concentration of HCl, H 2SO4, H3PO4
acids Cheaper and less hazardous and used in conjunction with detergent.
Methods of Application of Metallic Coating:
1. Hot Dipping: The metal is kept in molten state and base metal is dipped into it. It is used for producing a coating of
low M.P like Tin coating on Iron (tinning). The process is followed by cooling the coating through a palm oil to
prevent oxidation of tin plate to its oxide, and then Palm oil layer is removed by alkaline cleansing agent.
2. Metal Cladding: The surface to be protected is sandwiched between two layers of the coating metals and pressed
between rollers, like Alclad Sheeting which is a plate of duralumin is sandwiched between 99.5% pure aluminum.
3. Electroplating: The pure metal is made as cathode and base metal as anode. Electrochemically coat metal is
deposited on base metal. This metal gives smooth, fine and uniform coating. It depends on (a) Temperature (b)
Current density (c) Electrolyte Concentration (d) Nature of base metal (e) Time.
4. Electrolysis Plating: A Nobel metal is deposited catalytically on less noble metal by using reducing agent without
using electrical energy. The advantage over Electro plating are: (a) More economical since no electricity required.
(b) Irregular shape can be plated uniformly. (c) Plating on plastics can also be done.
5. Metal Spraying: Coating is applied by means of spraying device, like Aluminum is plated in this way on Aircrafts.
Chemical Conversion Coating: These are formed on metal surface by chemical reaction between metal surface and
inorganic salt solution, it is converted to a protective film. These films are insoluble, adherent, crystalline or amorphous
in nature. It on three types:
1. Phosphate Coating: It is applied for Iron, Steel and Zinc that reacted with H 3PO4 .
2. Chromate Coating: It is produced by dipping the base metal in Potassium chromate (acidic) followed by immersion
in neutral chromate bath. The resulting film consist of trivalent and hexavalent chromium.
3. Anodized Coating: It is formed by anodic oxidation process. This is produced on non-ferrous metals like Al, Zn,
Mg. In this method base metal is made as anode. Process is carried out by passing moderate direct current through
a bath in which the metal is suspended as anode. Coating are formed as a result of Progressive oxidation starting at
surface of base metal.
Cathodic Protection:
By driving current to the pipe through the environment, as illustrated in Figure 1, the anodic currents can be overridden,
and the entire pipe can be made to behave like a cathode. At the same time, a benign alkaline environment is produced at
the pipe surface.
There are two types of cathodic protection systems:
1. Sacrificial anode.
2. Impressed current anode.
Sacrificial anode systems utilize an externally connected
sacrificial metal with a relative activity value greater than steel
(iron) and thereby protect steel from corrosion. Alloys of zinc and
magnesium are the sacrificial metals most commonly employed.
The sacrificial anode is connected to the pipeline via a wire and
placed some distance from the pipeline. The current flows from
the anode into the surrounding soil (electrolyte) and is picked up
Figure 1: pipe line cathodic protection
by the pipeline at coating holidays.
Impressed-current anode systems, shown in Figure 2, involve the application of direct-current voltage between an anode
and the pipeline. Impressed-current anodes can be made from graphite, high-silicon cast iron, lead-silver alloys, precious
metals, mixed-metal oxides, or steel. As with sacrificial anodes, the shapes, locations, and number depend on the geology
of the area and the nature of the pipeline system.
Figure 3: Cathodic Protection of Oil tank Figure 2: Impressed-current anode system

Figure 5: Shared Cathodic Protection Figure 4: Cathodic Protection top view

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Faculty of Engineering - Chemical Engineering Department

Diploma Course title: Corrosion Engineering

Fakhri Hamdullah Ibraheem

Corrosion Control Inhibitors

Cathodic and Anodic Protection

Solvent cleaning, it must be non-inflammable and nontoxic

Figure 3: Cathodic Protection of Oil tank Figure 2: Impressed-current anode system

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