Yacov saban The department of chemical engineering Class: English advance 2, Friday Lecturer: Dr.

Noy-Abrahams Guy Summer 2011

Table of Contents
Structure of work ................................................................................................................................... 3 Introduction ............................................................................................................................................ 4 The body ................................................................................................................................................ 5 Conclusion ........................................................................................................................................... 10 Sources of information ......................................................................................................................... 11

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Structure of work
Introduction: Why corrosion? How am I going to explain it?

Body:

Understanding the mechanism of corrosion What is corrosion Why corrosion occurs Why does chemical reaction "prefers" a certain direction Describing the mechanism of corrosion The results of corrosion Describing corrosion in a chemical way Presenting corrosion prevention methods The use of coating methods

Electrochemical protection Presenting electrochemical reactions Describing galvanic corrosion Nobility of metallic alloys

Glass lining: Basic information Advantages Disadvantages

Sheet lining: Basic information Advantages Disadvantages

Inhibitors: Basic information Advantages Disadvantages

Anodic protection: Basic information Advantages Disadvantages

Cathodic protection: Basic information Advantages Disadvantages

Paint: Basic information Advantages Disadvantages

Conclusion Which method to choose in a given situation How to predict the cost of corrosion

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Introduction
1

The progressive deterioration, due to corrosion and wear, of metallic surfaces as used by major

industrial plants ultimately leads to loss of plant efficiency and at worst a shutdown. Corrosion and wear damage to materials, both directly and indirectly, costs the United States hundreds of billions of dollars annually. For example, Corrosion of metals costs the U.S. economy almost $300 billion per year. This amounts to about 4.2% of the gross national product. However, about 40% of the total cost could be avoided by proper corrosion prevention methods. One of the key factors in any corrosion situation is the environment. The definition and characteristics of this variable can be quite complex. One can use several techniques to evaluate the theoretical activity of a given metal or alloy provided the chemical makeup of the environment is known. For practical situations, it is important to realize that the environment is a variable that can change with time and conditions. It is also important to understand that the environment which actually affects a metal is the microenvironment conditions that the metal really "sees", i.e., the local environment at the surface of the metal.

In order to prevent corrosion one needs to understand why corrosion occurs. Only by interrupting the corrosion mechanism one can prevent it. That is why the road I chose to present this information for the reader starts with basic information about the corrosion process. The road leads the reader to different techniques showing the advantages and disadvantages each technique provides. At the end of the road the reader will read my opinion on which technique is the best and why.

P.R.Roberge. Handbook of Corrosion Engineering. McGraw-Hill. 2000. Page1-3

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The Body
In order to protect a metallic element from corrosion, one needs to understand the mechanism which it occurs. Only by interrupting the corrosion mechanism one can prevent it. Preventing corrosion can only be done by understanding several important concepts. The first concept is that most of the materials in our world react with one another. The majority of those reactions can be classified as "Redox" reactions. In the year 1896, the British physicist J. J. Thomson performed experiments which led to the discovery of the electron which in turn gave birth to a new branch of chemistry, which is known as electrochemistry. 2 This branch studies the chemical reactions which in the process one atom "donates" an electron while the other "accepts". Chemists call the donor atom as "Reductant" which goes through an oxidation process which is best described by the following equation: .While the one who accepts an electron is . For example the reaction of zinc at acid (H+ rich environment) { }.

called "Oxidant". He goes a reduction process which can be described by this equation:

The second concept is that 3electrochemical reactions tend to go a certain way. For example zinc tends to "give" an electron rather than receiving one. To be more precise, in order "to make it" take an electron it is essential to give the chemical cell an electric current. Chemists decided that the potential at which hydrogen ion takes an electron (at standard conditions) will be the zero, so they could predict the reaction process. Every reaction which has in it less potential (at standard conditions) is a process which the atom tends to stay at his original state (also called "electrolytic reaction"). While every reaction which has higher potential in it (at standard conditions) is a process which the atom tends to react in a chemical process (also called "galvanic reaction"). The phenomenon at which a chemical process tends to go a certain way can be explained by the definition of entropy.4 Entropy is a thermodynamic property which used to determine the energy available for work in a thermodynamic process, such as in energy conversion devices. Such devices can only be driven by convertible energy, and have a theoretical maximum efficiency when

2 3

D.A.Skoog, D.M.west. Fundamentals of Analytical Chemistry. Thomson. 2004. Pages 490-492 th D.C.Harris. Quantitative Chemical Analysis. 7 edition. W.H.Freeman and company. 2007. Pages 274- 283 4 th B.cottis,M.Graham,R.Lindsay,S.Lyon,T.Richardson,D.Scantlebury,H.Stott. Shreir's Corrosion. 4 edition. 2010. Volume 1 Pages 2-5

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converting energy to work. During this work, entropy accumulates in the system, but has to be removed by dissipation in the form of waste heat. In classical thermodynamics, the concept of entropy is defined phenomenologically by the second law of thermodynamics. This states that the entropy of an isolated system always increases or remains constant. Thus, entropy is also a measure of the tendency that a process, such as a chemical reaction, can be "Entropically" favored, or to precede in a particular direction, such for instance when a zinc atom favors giving an electron rather than taking one. As we now understand, the product "rust" is contributed by some sort of a reaction between iron and an environmental element. We can find that iron reacts by donating two electrons as ( ) . In order for this to happen there is a need for an accepting element. So

we can define corrosion as the process by which a material reacts to its surrounding. It can vary from the atmosphere, water, soil, chemicals, etc. the corrosion product isnt always visible like rust, sometimes we can see pits on metal surfaces, and sometimes we notice that the metal lose its weight as a function of time. 5This happens when corrosion products are solids with a specific crystal form. If they form a shape similar to the original material then they will remain on its surface, otherwise they will fall from the surface, leaving holes. A chemical reaction can occur only when the system have a certain amount of energy. We conclude that the material is embedded with an initial energy which led it to undergo a corrosive process. In order to understand what the source of that energy, one needs to know the definition of corrosion. Scientists define corrosion as a phenomenon which the material goes back to its "natural" form. As we dig the earth for metallic ores we must provide it heat in order to extract the metal. By providing heat to those ores, we provide the extracted metal the necessary energy to go a corrosive process in the future. By that definition we conclude that corrosion of metallic elements cannot be stopped but it can be slowdown. There are several ways to slow down corrosion; one way is electrochemical approach (cathodic or anodic protection), while the other is the use of protective coatings on the material. Each technique has its own advantages and disadvantages.

D.D.Ebbing. General Chemistry. Fifth edition. Houghton Mifflin Company. 1996. Pages 456-472

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Electrochemical protection is a way to protect metals from galvanic corrosion which occurs when dissimilar metals touching each other by any physical means via fluid or even by soil. Galvanic corrosion is a phenomenon of an electrochemical nature. That implies of two important reactions that occur. The oxidation process of a metal (anodic partial reaction) and the reduction process of an oxidizing agent (cathodic partial reaction). For example iron react with oxygen in aquatic environments such as water to create rust:6

) (

Galvanic corrosion happens when a more active metal becomes an anode and corrodes, whereas, the less active metal becomes a cathode. When a metal becomes a cathode, it is protected from corrosion while the other metal corrodes. Based on the relative position of different metals in the galvanic series, one can be predict which metal will corrode. All metals or alloys have a certain built-in properties that cause them to react as an anode or cathode. Whether material will respond as cathode or anode can be determined by its relative position in the galvanic series, the higher its place in the series the greater rate of the corrosion. For example if tin touches zinc, zinc starts to corrode; conversely if tin touches copper, tin starts to corrode.

The corrosion attack rate is also affected by the relative size of the material and the presence of certain electrolytes. A small anode area in contact with a large cathode will result in a rapid and severe attack. Conversely, a large anode area in contact with a small cathode area will lessen the rate of galvanic attack since the same total electromagnetic force (the driving force of corrosion) will be spread out over a larger area. Galvanic corrosion can be stopped by means of anodic or cathodic protection.

Cathodic protect is applied by coupling the structure with a more active metal, Such as zinc or magnesium, this produces a galvanic cell which in it the active metal works as an anode and provides a stream of electrons to the structure. The structure then becomes a cathode and is protected whereas the anode is destroyed progressively. The advantage of using this method is that it inexpensive and provides a good protection to galvanic corrosion. The problem comes from the fact that corrosion awareness especially in engineering fields suffer from scarcity. Moreover this technique does not provide any defense against other corrosive agents such as oxygen, bacterium, acids or alkalines.

A.Groysman. Corrosion for Everybody. Springer. 2010. Page 4-6

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Anodic protection is applied by transferring a direct current through an inert anode to the structure. The structure receives an excess of electrons which protects it. It can be applied to metals immersed in water, buried in soil or in contact with electrolytes in process application. The use of cathodic protection is widespread all over the world. There are thousands of miles of buried pipelines and cables that protected in this method. While that all the other techniques of corrosion protection only able to slow down the process, the anodic protection stops it completely. The disadvantage is obvious, there's a need to inflict an electrical current which cost money and may be unsafe to work with. Alongside electrochemical techniques there is another way to protect a metal from corrosion, the use of protective coatings over the chosen metal. There are different coating techniques that can be used in order to slow down corrosion. Each coating technique has its own advantages and disadvantages. The first technique is to use Corrosion Inhibitors. Corrosion of metallic surfaces can be reduced or controlled by the addition of chemical compounds to the corrodent. This form of corrosion control is called inhibition while the compounds are known as corrosion inhibitors. These inhibitors will reduce the rate of either anodic oxidation or cathodic reduction, or both. The inhibitors themselves form a protective film on the surface of the metal. Scientists have postulated that the inhibitors are absorbed into the metal surface either by physical adsorption or by chemical absorption. The absorbed inhibitor reduces the corrosion rate of the metal surface either by retarding the anodic dissolution reaction of the metal, or by the cathodic reaction of hydrogen, or both. Inhibitors can be classified in their chemical nature (organic or inorganic substances), their characteristics (oxidizing or non-oxidizing compounds) and by their technical field of application (pickling, descaling, acid cleaning, cooling water systems, and the like). They widely used all over the world in a wide range of fields such as motor cooling systems. The advantage is that it can be applied on every existing system. The problem starts with the fact that there a chance that some of the inhibitor particles may pollute the product, in addition inhibitors are expensive. The second technique is the use of paint. It is somewhat surprising 7that its protective action has only recently been systematically examined. Paint is impervious to water and oxygen besides it helps to prevent corrosion by preventing the pass of electrons between different substances. In order to make paint to be impervious to electrons there need to perform some modifications in it. Organic

B.cottis,M.Graham,R.Lindsay,S.Lyon,T.Richardson,D.Scantlebury,H.Stott. Shreir's Corrosion. 4 edition. 2010. volume 4 Page 2667

th

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polymers do not contain free electrons, except in the case of some pigmentation with metallic pigments; consequently, one can assume that the conductivity of paint which contains those polymers is entirely ionic. Although paint is a fairly inexpensive method, this method does not provide a solution to corrosion from elements within the system. The third technique is the use of Glass lining. Glass on metal composite systems is far from being a recent development. Archaeological discoveries have shown that glass bounded to gold jewelry dates back to at least8 400 B.C. glass coating of metals used primarily over the years as works of art. At the early 1880's it was determined that application of a vacuum to the beer fermentation process not only accelerated the fermentation time but, more importantly, drastically improved the consistent quality of the final brew. The reason for improvement comes for the glass lining which prevents the corrosion process as corrosion products contaminate the beer; in addition the glass lining prevented the entry of bacteria into the system and thus prevent bacterial corrosion. Glass lining has a lot of structural advantages such as resistance to oxygen and temperatures, as it creates an Insulating gap of air between the metal to the surface of the glass. The disadvantages of this method come from its inability to withstand structural pressure, because it easily breaks, thus limiting its usefulness. The fourth technique is the use of Sheet linings. Industrial plants often work with precious metallic materials, but when corrosive elements involves in the process often the plant have to decide whether to use expensive methods or use coating layers of absorbent materials which are at hand. Different materials are being used for this technique such as rubbers, resins, pigments, polymers and etc. This technique is usually used in pipe like structures. The technique slows down the rate of corrosion by preventing the touch of strong acids or alkalines with the metal. As carbon steel becoming common, more plants starts to use different polymeric sheet as protection. This method provides the structure shell protection against atmospheric corrosion and corrosive materials within the system. In addition sheet lining is the most inexpensive method. The problem is that polymers have the potential to absorb varying amounts of corrodents with which they come into contact, particularly organic liquids. This can result in swelling, cracking, and penetration to the substrate. Swelling can cause softening of the polymer, introduce high stress and precipitate failure of the bound. If the polymer has a high absorption rate, permeation will probably take place. The failure due to absorption can happen by several reasons such as that the polymer may absorb process fluids, and repeated cycles of temperature or pressure can cause blisters. No matter which material is being used for lining, eventually corrodent may find its way to the metal.

P.A.Schweitzer. Corrosion Engineering Handbook. Marcel Dekker inc. 1996. page 490

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Conclusion
It is important to understand that in order to prevent corrosion; we must understand its electrochemical properties. We must prevent the process at which the metal goes back into its natural form. So we can be more efficient and save valuable resources.

There several different methods to prevent corrosion. Some provide a better protection from several corrosive elements while neglect others. Some cost more money while some are cheaper but require more planning. The selection of method for corrosion preventing should be considered on the accurate determination of the relationship between, the two main selection factors, performance versus cost. As costing data are greatly complicated as there other interrelated sub selection factors e.g., design, availability, fabrication. It is difficult to define realistic guidelines which method is better in order to prevent corrosion. After viewing the methods of protection against corrosion I believe, that only by considering the variety of the variables one can predict the cost of corrosion.

Predicting the cost of corrosion can be done only by integrative work of different fields of engineering. As that each one has his own special approach that can give a different view over the matter. In my opinion the best way to prevent corrosion is to look on the bigger picture to combine different methods such as cathodic and different linings. That can only be accomplished by a team of mechanical engineer with a chemical engineer with the aid of industrial and management engineering. That is done by predicting the substances, which flow through the machine and understanding which alloy will be better to place and where, when building the device.

To conclude there is no perfect way to prevent corrosion completely, as engineers our job is to solve difficult problems such as that. Solving those problems can only be done by looking on the bigger picture, which means to integrate different engineering fields.

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Sources of information
1. P.A.Schweitzer. Corrosion Engineering Handbook. Marcel dekker inc. 1996. 2. A.Groysman. Corrosion For Everybody. Springer. 2010. 3. D.A.Skoog, D.M.west. Fundamentals Of Analytical Chemistry. Thomson. 2004 4. D.C.Harris. Quantitative Chemical Analysis. 7th edition. W.H.Freeman and company. 2007. 5. B.cottis,M.Graham,R.Lindsay,S.Lyon,T.Richardson,D.Scantlebury,H.Stott. Shreir's Corrosion. 4th edition. Elsevier. 2010. 6. P.R.Roberge. Handbook Of Corrosion Engineering. McGraw-Hill. 2000. 7. 8. G.Kreysa, M.Schutze. Corrosion Handbook. Wiley-VCH. 2004. P.A.Schweirzer. Encyclopedia Of Corrosion Technology. Marcel Dekker inc. 1998.

9. R.R.Winston. Uhlig's Corrosion Handbook. Second edition. John Wiley & Sons inc. 2000 10. D.D.Ebbing. General Chemistry. Fifth edition. Houghton Mifflin Company. 1996.

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