Negative terminal connected to tank and positive to inert anode graphite or

Duriron
Electric leads insulated to prevent current leakage
Anode surrounded by backfill consisting of coke breeze, gypsum, or
bentonite which improves electric contact between anode an surrounding
soil
Cathodic protection by galvanic coupling to g !ig" #$%
Anode is called sacrificial anode since consumed during protection
Also used to protect buried pipe lines
&rotective currents determined empirically
Aggressive corrosives hot acids re'uire high currents lower currents
needed in less severe environments (concrete)
Anode selection for cathodic protection based on engineering and economic
considerations
g $ most widely used
Considerable variety of impressed$current anodes ranging from lowest cost
scrap steel, which suffers large losses to inert platinized *i efficient and
e+pensive
,teel, graphite and silicon$iron most widely used &b and platinized *i
marine environments
,tray current effects encountered in cathodic protection systems
,tray current e+traneous direct currents in earth
-f a metallic ob.ect is placed in strong current field, potential difference
develops across it and accelerated corrosion occurs at points where current
leaves ob.ect and enters soil
!ig" #$# stray current resulting from cathodic protection system
*his problem of pipe getting corroded prevented by electrically connecting
tank and pipe by a buss connector and rearranging anodes !ig" #$/
5.4.2 Anodic Protection
&revention of corrosion by impressed anodic current recent
innovation and its development based on electrode kinetic principles
*o illustrate principles !ig" 01$0/
Consider se'uence of events in anodically protecting a system
,ince mi+ed potential theory re'uires charge conservation, applied anodic
current density is e'ual to difference between total o+idation and reduction
rates2
i
app
(anodic) 3 i
o+id
$ i
red
(4"4)
*o anodically protect, potentiostat re'uired
&otentiostat electronic device which maintains metal at constant potential
Anodic protection of a steel tank containing 5
%
,6
7
!ig"#$8
&otentiostat has three terminals9 one connected to tank, another to au+iliary
cathode (&t or &t clad electrode) and third to reference electrode (calomel
cell)
&otentiostat maintains constant potential between tank and reference
electrode
6ptimum potential determined by measurements
Anodic protection causes 011111$fold decrease in corrosive attack in some
systems
Although limited to passive metals and alloys (Ni, !e, Cr, *i, and their
alloys), most structural materials contain these elements
&rimary advantages applicability in e+tremely corrosive environments and
its low current re'uirements
4.1Coatings
5.5.1 Metallic coatings
*hin coatings of metallic materials can provide satisfactory between
metal and environment
etal coatings applied by electro$deposition, flame spraying, cladding, hot
dipping and vapour deposition
E+amples of metal$coated articles are automobile bumpers and trim,
household appliances and fi+tures, silverware, galvanized steel and tin cans
(1) Electro-deposition. *his process, also called electroplating,
consists of immersing a part to be coated in a solution of the metal to be
plated and passing direct current between part and another electrode
Character of deposit depends on temperature, current density, time and
composition of bath
*hese variables ad.usted to produce coatings thick or thin, dull or bright,
soft (lead) or hard (Cr) and ductile or brittle
5ard platings utilized to combat erosion corrosion
Electroplate single metal, layers of several metals or alloy composition
E"g" automobile bumper inner flash of Cu (for adhesion), intermediate
layer of Ni (for corrosion protection) and thin top layer of Cr (for
appearance)
(2) Flame spraying. Also called metallizing, consists of feeding
metal wire or powder through melting flame metal in finely divided li'uid
particles blown onto surface
6
%
and acetylene or propane are commonly used for melting flame
,urface roughened (sand blast) mechanical bond
,ometimes paint coating applied over sprayed metal to fill voids and provide
better barrier
&orous metal good base for paint and good bond obtained
5igh melting metals deposited by plasma .et spraying
!lame sprayed applications tank cars and vessels of all kinds, bridges, ship
hulls and superstructures, refrigeration e'uipment and many fabricated steel
products
(0) Cladding. -nvolves a surface layer of sheet metal put on by
rolling two sheets of metal together
E"g" Ni and steel sheets hot$rolled together to produce a composite
sheet
5igh strength Al alloys cladded with commercially pure Al skin to
provide corrosion barrier because susceptible to stress corrosion
Cladding great economic advantage e+pensive material
relatively thin and backed up by ine+pensive material
Ni, Al, Cu, *i and ,"," used as cladding for steel
(%) Hot dipping" Applied by immersing in molten bath of low melting
point metals :n, ,n, &b, and Al
;alvanized steel e+ample
*hickness of coating is much greater than electroplates because
very thin dip coatings difficult
(<) apo!r deposition" Accomplished in high vacuum chamber
Coating metals vapourized by heating electrically and vapour
deposits on parts
ore e+pensive than others limited to critical parts high
strength parts for missiles and rockets
"i##!sion. Diffusion coatings involve heat treatment to cause alloy
formation by diffusion of one metal into other
!or this reason $ also termed =surface alloying>
&arts to be coated packed in solid materials or e+posed to gaseous
environments which contain metal that forms coating
,herardizing (:n coating), chromizing (Cr), and calorizing (Al) are
e+amples
Calorizing and chromizing utilized for resistance to high temperature
o+idation
C$emical con%ersion. Coatings from chemical conversion are
produced by corroding metal surface to form adherent and protective
corrosion product
Anodizing consists of anodic o+idation in acid bath to build up an o+ide
layer
?est known product anodized Al wherein protective film is Al
%
6
<
"
,urface layer is porous
Anodized Al is used for many architectural purposes ( building wall panels)
and others where pleasing appearance prime importance
Additional e+amples are ?onderizing and &arkerizing (phosphatizing in
phosphoric acid bath), chromatizing (e+posure to chromic acid and
dichromates) and o+ide or heat coatings for steel
Automobile bodies best known e+ample of phosphatizing
*his treatment provides good base for paint and $ sometime before rusting
occurs if finishing is damaged
Chromate treatments are applied to g and :n parts and apply some
measure of corrosion resistance although the parts are painted
6+ide coatings produced on steel by heating in air or by e+posing to hot
li'uid
*hese coatings treated with a petroleum product to avoid rusting coloured
o+ide for appearance
Glassed steel or glass$lined steel important material of construction for
process industries and in home (hot water tanks)
,mooth surface advantage when ease of cleaning is a re'uirement or sticky
materials late+ handled
;lassed steel widely used in drug industry, pilot plants, wine, brewing and
food plants and many others where severe corrosive or contamination of
product involved
Concrete utilized for many corrosion applications
E+amples are encasing structural steel, concrete$lined pipe and concrete
vessels
5.5.2 &rganic coatings
-nvolve thin barrier between substrate material and environment
&aints, varnishes, lac'uers and similar coatings protect more metal on
tonnage basis than any other method for combating corrosion
*hese coatings should not be used where environment would rapidly attack
substrate material
E"g" paint would not be used to line inside of a tank car for shipping 5Cl
Aside from proper application, three main factors to consider, $ in order of
importance2 (0) surface preparation, (%) selection of primer, and selection of
top coat@coats
-f surface not properly prepared, paint may peel off poor bonding
-f primer not have good adherence or not compatible with top coat, early
failure
-f first two factors wrong, system will fail regardless of top coat
,urface preparation involves surface roughening to obtain mechanical
bonding (=teeth>) as well as removal of dirt, rust, mill scale, oil, grease,
welding flu+, crayon marks, wa+ and other impurities
?est method grit blast or sand blast steel surface
6ther methods are pickling and other types of chemical treatments,
scraping, wire brushing, flame cleaning (heat with torch and scrape off dirt
and scale), chiseling and chipping
&inholes in welds and sharp edges ground out to ensure contact between
paint and metal
6ther chemical methods are solvent degreasing, hot or cold alkali
treatments, phosphatizing, chromate treatment and electrochemical
treatments anodizing and cathodic cleaning
-n addition to economic considerations, selection of surface preparation
method depends upon metal, shape, size and accessibility of structure,
coating system and service conditions
&rimers can contain rust$inhibitive pigments zinc chromate and zinc
dust
Aettability needed so that crevices and other surface defects will be filled
rather than bridged
,hort drying times advantageous to preclude contamination before top coats
are applied, particularly in field applications
*op coat selection important
Applied for appearance cheaper to provide corrosion allowance by
making steel thicker
;ood appearance and corrosion protection in severe atmosphere obtained
at very little e+tra cost by selecting good top$coat material
Coating thickness no base metal e+posed
-mpossible to apply one coat and have completely free of pinholes or other
defects
ultiple coats needed pinhole in one coat covered by a complete film of
another
*hickness important because paint deteriorates with time
Barious methods to reduce maintenance painting costs
6ne institute touch$up programme to cover bad spots early instead of
waiting until coating is so bad that a repaint .ob is re'uired
Another apply paint by hot spray method
5igher temperature permits higher solid content and good sprayability
thicker film per coat
Another apply tape on edges edge protected
Another design structure minimum surface area and edges presented
( use channel or pipe instead of - beam)
any companies .obs to outside contractors
Cow first cost more costly in long run
-f plant has sufficient work hire and train own painters
*o sum up good paint .ob proper surface preparation, proper coating
selection and proper application
Bariety of paints available
Asphalts and bituminous paints on pipelines
,ometimes a cloth wrapping used with coating for reinforcement
Alkyds, glyptols, phenolics, lithopones and chlorinated rubber e+amples
Binyl and epo+y rubber widely adopted for corrosion application