CORROSION

What is corosion?
Corrosion is a metal degradation process
resulted from interaction with its environment
(Corrosion is the deterioration that occurs
when a metal react with its environment).

The term of corrosion is basically restricted to

environment attack of metals, therefore non
metals is not included in the present definition.
• The degradation processes may result in:
- thinning of metal
- leaks
- sudden failure and damage of equipment
- decreasing/loss its heat transfer rate (e.g. of
heat exchanger tubes)
- brittle surface
- surface softening
- unpleasant appearance, or
- others. (i.e the tarnishing of silver, iron rusting,
dissolution of metal in acid solution)
All metals and alloys are susceptible to corrosion.
No single material is suitable for all applications.
For example, gold, known for its excellent
resistance to the atmosphere, will corrode if
expose to mercury at ambient temperature. On
the other hand, iron does not corrode in mercury
but rusts readily in the atmosphere.

Fortunately, there are usually several metals that

will perform satisfactorily in given environment.
Also they are method of corrosion control that
minimize the problem .
 THE COST OF CORROSION
• Corrosion:
--the destructive electrochemical attack of a material.
--Al Capone's
ship, Sapona,
off the coast
of Bimini.

• Cost:
--4 to 5% of the Gross National Product (GNP)*
--this amounts to just over $400 billion/yr**
• Corrosion agent to metal
1. Water
2. Moisture
3. Acids
4. Bases
5. Salts
6. Oils

• Disadvantage: economic terms higher expense to

spent for corrosion prevention and maintenance/
replacement

• Advantage: etching, dry cell batteries

 FORMS OF CORROSION
CORROSION

UNIFORM LOCALIZED

MACROSCOPIC MICROSCOPIC
GALVANIC INTERGRANULAR CORROSION
CREVICE STRESS CORROSION CRACKING
PITTING
EROSION CORROSION
 FORMS OF CORROSION
• Stress corrosion
Stress & corrosion
• Uniform Attack work together • Erosion-corrosion
Oxidation & reduction at crack tips. Break down of passivating
occur uniformly over layer by erosion (pipe
surface. elbows).
• Selective Leaching • Pitting
Preferred corrosion of Downward propagation
one element/constituent of small pits & holes.
(e.g., Zn from brass (Cu-Zn)).
• Intergranular
Corrosion along
grain boundaries, • Galvanic
often where special Dissimilar metals are
• Crevice Between two
phases exist. pieces of the same metal.
physically joined. The
Rivet holes
more anodic one
corrodes.(see Table
17.2) Zn & Mg
very anodic.
Schematic figure of forms of corrosion
 Uniform corrosion
(most common form of corrosion)

• A uniform, regular removal from the surface is the

usually expected on the mode of corrosion.
• The corrosive environment must have the same
access to all parts of the metal surface, and the metal
its self must be metallurgically and compositionally
uniform.
• Interface potential is in active corrosion region.
• The corrosion rate is predictable and thus acceptable
for design.
 Uniform corrosion
Examples:

 Corrosion of steel in hydrochloric acid solution

 Thinning and penetration of carbon steel storage
tank for sour (H2S containing) crude oil
 Atmospheric corrosion

Control

 Select proper material

 Coating
 Use of inhibitor
 Anodic/cathodic protection
 Uniform corrosion
The reaction starts at the surface and proceeds
uniformly.
 Galvanic corrosion

• Galvanic corrosion occurs when dissimilar metallic

materials are brought into contact in the presence of
electrolyte. Therefore galvanic corrosion is the major
suspect when attack at the junction between two
dissimilar metals/alloys
• Such damage can also occur between metal and other
conducting materials such as carbon and graphite.
• Corrosion is greatest on the more active metal near
the junction between two metals.
• Note that in extreme case the more noble metal can
be damaged by hydrogen.
 Galvanic corrosion
• Factors affecting a galvanic corrosion:

 Electrode potential
 Surface characteristic
 Reaction kinetics
 Bulk of solution properties including its flow rate
properties
 Geometry
 Type of joint
 Alloy composition
 Galvanic series of some commercial metals and alloys
in seawater

• Platinum
• Gold
• Graphite
• Titanium
• Silver
• Chlorimet 3 (62 Ni, 18 Cr, 18 Mo)
NOBLE OR • Hastelloy C (62 Ni, 17 Cr, 15 Mo)
MORE
CATHODIC • 18-8 Mo stainless steel (passive)
18-8 Stainless steel (passive)
Chromium stainless steel 11,30% Cr (passive)
• Inconel (passive) (80 Ni, 13 Cr, 7 Fe)
Nickel (passive)
• Silver solder
 • Monel (70 Ni, 30 Cu)
Cupronickels (60-90 Cu, 40-10 Ni)
Bronzes (Cu-Sn)
Copper
Brasses (Cu-Zn)
• Chlorimet 2 (66 Ni, 32 Mo, 1 Fe)
Hastelloy B (60 Ni, 30 Mo, 6 Fe, 1 Mn)
• Inconel (active) Nickel (active)
• Tin
• Lead
• Tin-lead solder
• 18-8 Mo stainless steel (active)
18-8 stainless steel (active)
• Ni-Resist (high Ni cast iron)
ACTIVE OR • Chromium stainless steel, 13% Cr (active)
MORE ANODIC • Cast iron
Steel or iron
• 2024 aluminium (4.5 Cu, 1.5 Mg, 0.6 Mn)
• Cadmium
• Commercially pure aluminium (1100)
• Zinc
• Magnesium and magnesium alloys
 Galvanic corrosion
• Galvanic corrosion will be significant if the corrosion
potentials difference between two metals/alloys ≥
250mV
• If two different metals/alloys have to be used in
contact, it is suggested to select alloys with their
corrosion potentials are as close as possible

• Another important in galvanic corrosion is the area

effect, or the ratio of the cathodic to anodic areas. An
unfavorable area ratio consists of a large cathode and
a small anode, because the corrosion of metal will be
taking palace with high current density
Galvanic corrosion

aluminum
helicopter blade
has corroded near
where it was in
contact with a
steel
counterbalance.
 Galvanic corrosion
The nature and aggressiveness of the environment determine to a large extent
the degree of two metal corrosion.

• The distance affected depends on the conductivity of the

solution.
 Stress corrosion
• acceleration of corrosion in certain environments

• important and difficult to predict the failure

• Cracking present due to corrosive environment and stress

induce

• Stress corrosion cracking (SCC)

• stress either internal tensile stresses (cold work) or external

stressed
 Stress corrosion
• The magnitude of stress necessary to cause
failure depends on the corrosive medium and
on the structure of the base metal

• In the microstructure, these cracks can have an

intergranular (fig. A) or a transgranular (fig.
B) morphology.

• Macroscopically, SCC fractures have a brittle

appearance.
 Stress corrosion

Figure A Figure B
• i.e material:
– steel containing aluminium have better resistance to stress
corrosion
– Stainless steels are susceptible to stress corrosion cracking
in the presence of chlorides
Stress corrosion
 Erosion-corrosion

Rapidly flowing solutions can often disrupt adherence surface

films and deposits that would otherwise offer protection against
corrosion.
Thinning or removal of surface film or adherence corrosion
product layer by erosion from the flowing stream results in
accelerated corrosion, called erosion-corrosion or impingement
attack. The attack is accelerated at elbows, turbines, pumps, tubes
constrictions, and other structural features that alter flow direction
or velocity and increase turbulence.
 Erosion-corrosion
Erosion corrosion often occurs when corrodent is in
liquid phase. Suspended solids further aggravate the
erosion of surface films and increase erosion-
corrosion.
Attack may be especially serious in two phase flow,
in which steam and water vapor condensate droplets
are present together
The lower-strength, less resistance alloys, such as
carbon steel, copper and aluminium are especially
susceptible to erosion-corrosion. The stainless steel,
nickel alloys and titanium are usually resistant,
because their tenacious and durable passive films.
 Erosion-corrosion
• Erosion-corrosion takes the form of grooves, waves,
gullies, teardrop-shape pits and horseshoe-shaped
depression in the surface.
Impingement
corrosion pits
Fluid flow

• Tear drop shaped pits with under cutting in the down

stream direction, formed on brass condenser tubing
 Erosion-corrosion
Turbulent eddy mechanism for downstream undercutting of
erosion corrosion pits

The attack was seasonal and unpredictable and could be

simulated only with water containing a combination of
dissolved bicarbonate and silicate
 Erosion-corrosion

•
ELECTROCHEMICAL CONSIDERATION

• Corrosion process is normally electrochemical process

• Involve chemical reaction

• ē transfer from one chemical species to another

• 3 important process in corrosion

– Electrolyte (any solution that contains ion)
– Anode (oxidation)
– Cathode (reduction)
 ELECTROCHEMICAL CONSIDERATIONS
• Two reactions are necessary:

--oxidation reaction: Zn  Zn2  2e ANODE

 
-- reduction reaction: 2H  2e  H2 (gas ) CATHODE

Individual oxidation and

reduction are termed half reaction
Zn  Zn2+ + 2ē
2H+ + 2ē  2H+ (gas)
Zn + 2H+  Zn2+ + 2H+
(gas)
 ANODE
• Oxidation process occurs
• Oxidation –metal atom lose/ give up ē
– M  M n+ + n ē
– i.e ; Fe  Fe 2+ + 2 ē

CATHODE
• Reduction reaction occurs
• Gains of ē (ē from metal atom that is oxidized)
• The reaction at cathode
– M n+ + ē  M n-1
– Or M n+ + nē  M
– i.e Mg 2+ + 2ē  Mg
 Other reduction reactions:
• It is possible for two or more of reduction reaction
occurs
– Corrosion in acid solution which have a high concentration
of hydrogen ions.
– 2H+ + 2ē  H2

• For an acid solution having dissolved oxygen. The

reduction follows
– O2 + 4H+ 4ē  2H2O

• For a neutral or basic aqueous solution

– O2 + 2H2O + 4ē  4(OH- )
 CORROSION IN A GRAPEFRUIT
Cathode Anode
Cu +
-
H+ Zn
H+ Zn2+

reduction 2e - oxidation
2H  2e  H2 (gas )
H+
O2  4H  4e   2H2O H+
Acid H+
H+ H+
STANDARD HYDROGEN (EMF) TEST
• Two outcomes:
--Metal sample mass --Metal sample mass

--Metal is the anode (-) --Metal is the cathode (+)

o o
Vmetal  0 (relative to Pt) Vmetal  0 (relative to Pt)

Standard Electrode Potential

 STANDARD EMF SERIES
• EMF series o
• Metal with smaller
metal Vmetal o
Vmetal corrodes.
Au +1.420 V • Ex: Cd-Ni cell
Cu +0.340
Pb - 0.126
Sn - 0.136
Ni - 0.250 o
Co - 0.277 DV =
Cd - 0.403 0.153V
Fe - 0.440
Cr - 0.744
Zn - 0.763
Al - 1.662
Mg - 2.262
Na - 2.714 Example Problem 17.1
K - 2.924
 ELECTRODE POTENTIAL
• The potential of metallic materials oxidize to form ions
do not have the same degree of ease

• two half-cell reactions for A

Fe  Fe2+ + 2ē
◦
V1 anode = -0.440
Cu2+ + 2ē  Cu
◦
V2 cathode = +0.340
Fe + Cu2+  Fe2+ + Cu

Overall cell potential

ΔV◦ = V2◦ - V1◦
= 0.340-(- 0.440 )

= 0.780
 ELECTRODE POTENTIAL
• two half-cell reactions for B
Zn  Zn2+ + 2ē
◦
V1 anode = -0.763
Fe2+ + 2ē  Fe
◦
V2 cathode = -0.440
Zn + Fe2+  Zn2+ + Fe

Overall cell potential

ΔV◦ = V2◦ - V1◦
= -0.440+0.763

= 0.323

– Various electrode pair have diff. voltages

 Example 1

One-half of an electrochemical cell consists of a pure

copper electrode in a solution of a Cu 2+ ions; the
other half is a magnesium electrode immersed in
a Mg 2+ solution. The standard reduction
potential of Cu 2+ and Mg 2+ are 0.34 V and -
2.37 V respectively.
i) Write the spontaneous overall reaction.
ii) Calculate the standard emf that is generated.
 GALVANIC SERIES
• Ranks the reactivity of metals/alloys in seawater
Platinum
Gold
Graphite
Titanium
Silver
316 Stainless Steel
Nickel (passive)
Copper
Nickel (active)
Tin
Lead
316 Stainless Steel
Iron/Steel
Aluminum Alloys
Cadmium
Zinc
Magnesium
 CORROSION RATE
• The weight loss can be converted to a corrosion rate
in units:
– mm/yr (milimeters per year)
– mpy (mils per year)
• To determine the corrosion rate a test called a Tafel
extrapolation is conducted. It basicly obeys Faraday’s
Law:
where Q – Coulombs
nFW n – number of electrons involved in half cell
Q reaction
M
F – Faradays Constant (96,500 coulombs/mol)
W – weight of electronegative species;
M – molecular weight
 CORROSION RATE
Equivalent weight (EW) = M/n
QM W = (Q x EW)/F
W Q = it
nF where i –current in Amps,
t – time in seconds

Where W/t is the corrosion rate in gm per sec.

itEW W = ⍴V where ⍴- density and V- volume
W
F
⍴V = itEW/F
V = TA , where T – thickness and A is the surface area
T/t = iEW/ (FdA)

T/t is mils per year when appropriate constant are

imposed for the number of seconds in a year and for
the unit changes for length.
 CORROSION RATE
• Corrosion rate (CR) in mils per year
ixEWx31.6 x109
CR 
xFxAx2.5 x106

where i/A is current density in Amps/cm2

(icorr xEW )
CR  0.13

For units of CR in mils per year, icorr in μA.cm-2.

EW is the equilibrium weight and ⍴ is the density of the metal.

 Example 2

A cadmium electroplating process uses 10

A of current and chemically corrodes a
cadmium anode. How long will it take to
corrode 8.2 g of cadmium from the anode?
 Example 3
A mild steel rectangular tank 1.25 m length x 1.25 m
width x 1 m high contains aerated water to the
790mm level and shows a loss in weight due to
corrosion of 405 g after 8 weeks. Assume uniform
corrosion on the tank's inner surface and that the
steel corrodes in the same manner as pure iron.
The density of mild steel is 7.9 g/cm3. Calculate,
i) the corrosion current.
ii) the current density.
iii) the corrosion rate of the tank.
EFFECT OF SOLUTION CONCENTRATION
• Ex: Cd-Ni cell with • Ex: Cd-Ni cell with
standard 1M solutions non-standard solutions
o o RT X
VNi  VCd  0.153 o o
VNi  VCd  VNi  VCd  ln
- nF Y
+
n = #e-
per unit
oxid/red
Cd T Ni reaction
(=2 here)
F=
XM YM Faraday's
Cd2+ solution Ni2+ solution constant
• Reduce VNi - VCd by =96,500
C/mol.
--increasing X
--decreasing Y
 SUMMARY
• Corrosion occurs due to:
--the natural tendency of metals to give up electrons.
--electrons are given up by an oxidation reaction.
--these electrons then are part of a reduction reaction.
• Metals with a more negative Standard Electrode
Potential are more likely to corrode relative to
other metals.
• The Galvanic Series ranks the reactivity of metals in
seawater.
• Increasing T speeds up oxidation/reduction reactions.
 Prevention Methods

FIVE general techniques to consider:

1. Material selection
2. Environmental alteration
3. Design consideration
4. Coating
5. Cathodic & Anodic protection
 Material selection
• Selection of material depends on the corrosion
environment:
i.e. application in fresh water
• Suitable metal: cast iron, steel, Al, Cu, brass and some stainless
steel.
Application for seawater environment
• Titanium, brass, some bronzes, copper-nickel alloys, nickel-
chromium-molybdenum alloys.
• Suitable metal for atmospheric application
– Al alloys, cu alloys, galvanized steel
• Heat treatment for relieve the residual stress induce in
metal that formed into finished shapes by bending
• Mechanical properties
– When operation condition become aggressive,
material from combination 2/3 metal are needed

– Effect of temp. will influence the mechanical

properties
i.e. application of plain carbon steel is limited to 316-343oC
due to loss of strength and susceptibility to oxidation and
corrosion.
Highly alloyed Ni-Cr-Fe alloy are adequate to corrosion
resistance at elevated temp. compare to 18Cr-12Ni.18Cr-
12Ni sustain oxidation resistance at temperature up to
816oC and strength reduce above 650oC
• Material fabrication
– Material should be selected on the basis of their
maintainability as well as their fabrication ability
– Need to consider the ease of modification or
repaired after exposure to operating condition.

• Availability of materials
– Consideration for future availability for repairs or
replacement or alternative replacement materials

• Material cost
– Life cycle cost or cost effectiveness rather than
initial cost
 Environmental alteration
• Decrease the velocity of corrosive fluid
• Use lower temperature
• Remove O2 from water solution by de-aerated process
• Reduce the concentration of corrosive ions in a solution
• Adding inhibitors in system
– Scavengers type- react with and virtually eliminate a chemically
active species in solution such as dissolved O2

– Absorption type- attach themselves to the corroding surface and

interface with either oxidation/reduction reaction or form a very
thin protective coating
 Design consideration
• Prevent the formation of galvanic cell by using
similar metal or alloys or using non metallic
connector ( fitting, gasket) to electrically insulate the
two dissimilar metal

• Weld rather than rivets. Or choose rivets that are

cathodic to the materials being joined

• Make the anode area larger than the cathode area

 Design consideration
• Avoid sharp bends in piping system when flow
occurs. Erosion corrosion will occur at areas in which
the fluid direction changes sharply.

• Design components so that fluid system are closed to

avoid continuously dissolve gas.

• Easy removal and replacement of parts that are

expected to fail rapidly in service, must be design

• The design should allow for complete drainage and

easy washing
 Coating
• Physical barrier applied on surfaces in the form of
films
• Used to isolate anode and cathode region
• Important condition:
– coating must be non-reactive in the corrosive environment
– Resist to mechanical damage that exposes the bare metal to
corrosive environment
• Types of material for coating
– Metals
– Ceramic
– Polymers
• Metallic coating
– Acts as sacrificial anodes instead of coated metal
i.e: steel are coated with Zinc-plated or tin-plated
– Metal coating are plated by electro plating process
– Metal/ part to be plated is made as cathode. The
electrolyte is a solution of a salt of the metal to be
plated and direct current is applied.
• Inorganic coating (ceramic/glass)
– Porcelain coating which consist of thin layer of glass fused
to the steel surface so that it adheres well and has
coefficient of expansion adjusted to the base metal
– i.e. reaction vessels can also be lined with corrosion-
resistant Teflon™
– Stable, adherent, nonporous, non-conducting oxide layer
– i.e. glass fused coating a steel

• Organic coating
– Provide thin, tough and durable barrier to protect substrate
metal from corrosion environmental
– Polymeric material, pints, Paints, varnishes, lacquers
Cheaper
 CATHODIC PROTECTION
(is one of the most widely used methods of corrosion
prevention)

• The principle of cathodic protection is in connecting an

external anode to the metal to be protected and the passing of
an electrical dc current so that all areas of the metal surface
become cathodic and therefore do not corrode.
– Process reversing the corrosion current to stop damaging
corrosion process
– Involves supply electrons (from external source) to the
metal protected, making it cathode.
SACRIFICIAL ANODES CATHODIC
PROTECTION (SACP)
IMPRESSED CURRENT CATHODIC
PROTECTION (ICCP)
 SACRIFICIAL ANODES CATHODIC
PROTECTION (SACP)
• Employ reactive metals as auxiliary anodes that
are directly electrically connected to the metal to
be protected.

• The sacrificial anode corrodes, supplies ē to the

metal and thereby prevents an anode reaction at
metal

• The metals commonly used, as sacrificial anodes

are aluminium, zinc and magnesium.
 Schematic figure of SACP

Sacrificial anodes
used for steel
structured:
Aluminium anode
Magnesium anode
Zinc anode
 GALVANIC SERIES
• Ranks the reactivity of metals/alloys in seawater
Platinum
Gold
Graphite
Titanium
Silver
316 Stainless Steel
Nickel (passive)
Copper
Nickel (active)
Tin
Lead
316 Stainless Steel
Iron/Steel
Aluminum Alloys
Cadmium
Zinc
Magnesium
 SACRIFICIAL ANODES CATHODIC PROTECTION (SACP)

• A galvanic or sacrificial anode

system requires:
i) Sacrificial anodes
ii) Direct welding to the structure
or a conductor connecting the
anode to the structure
iii) Secure and minimum
resistance connections between
conductor and structure, and
between conductor and anode.
 SACRIFICIAL ANODES CATHODIC PROTECTION (SACP)

• The current has to flow in a loop and therefore the

surface of structure that can be protected is the
submerged surface that are received protection current
from anodes.

STEEL PROTECTED
PIPE SURFACE
UNPROTEC-
TED SURFACE
 SACRIFICIAL ANODES CATHODIC PROTECTION
(SACP)

Criteria for sacrificial anodes

• A corrosion potential that is sufficiently negative
for the specific application; in general, alloying
additions are made to make the potential more
negative than that of the unalloyed basis metal

• A high anode efficiency, which means that

impurities that result in self corrosion must be
absent or minimum.

• An ability to remain active and to corrode

uniformly and not to become passive
 IMPRESSED CURRENT CATHODIC
PROTECTION (ICCP)
• Obtained from a direct current source connected between
anode and the metal to be protected

• A connection from a current source to make electron flow to

metal, to cause the metal to be cathode

• Anode is usually surrounded by high conductivity backfill

material such as gypsum or bentonite which improve the
electric contact between anode and surrounding soil

• Add: it will protected large area

IMPRESSED CURRENT CATHODIC PROTECTION (ICCP)
An impressed-current system requires:

i) Inert anodes (clusters of which, connected together often in a

backfill, are called the “groundbed”).

ii) A dc power source.

iii) Electrically well insulated, minimum resistance and

secure conductors between anodes and power source.

iv) Secure and minimum resistance connections

– between power source and structure.
 Schematic figure of ICCP
•The source of electrons is an impressed current from an external power
source for an underground tank.
•Negative terminal of powers source is connected to the structure to be
protected.
•Positive terminal is joined to an inert anodic (I.e. graphite)
 In this case cathodic protection only protect the expose area

Why should use ICCP?

•Steel structure that will be protected is large

•Protection current requirement is high
•Coating quality varies in a large range
•Resistivity of soil is high
•Source of electric current is available
•Field for ground bed are available
 CATHODIC PROTECTION
• Structures that are commonly protected by cathodic protection
are the exterior surfaces of:
– Pipelines
– Ships’ hulls
– Storage tank bases
– Jetties and harbour structures
– Steel sheet, tubular and foundation pilings
– Offshore platforms, floating and sub sea structures

• Cathodic protection is also used to protect the internal surfaces

of:
– Large diameter pipelines
– Ship’s tanks (product and ballast)
– Storage tanks (oil and water)
– Water-circulating systems.
 CATHODIC PROTECTION
The main advantage of cathodic protection is;
– that it is applied simply by maintaining a dc circuit
– its effectiveness may be monitored continuously.
– Can applied to a coated structure to provide corrosion control to
areas where the coating may be damaged.
– may be applied to existing structures to prolong their life.
– will avoid the need to provide a “corrosion allowance” to thin
sections.
– It may be used to afford security where even a small leak cannot be
tolerated for reasons of safety or environment.
– In practice, its main use is to protect steel structures buried in soil
or immersed in water.
– It cannot be used to prevent atmospheric corrosion on metals.
 Anodic protection
• Reduction of the corrosion rate in an anode by polarizing it
into a potential region where the dissolution rates low.
• In circumstances where cathodic protection is not practical,
such as in strongly alkaline or acidic environments, anodic
protection is a useful corrosion control technique
• In anodic protection, the metal to be protected is made the
anode
• corrosion products protective
• active-passive metals/alloys
• The passivation metal corrode at slower rates than normal
• The primary advantages of anodic protection are its
applicability in extremely corrosive environments and its low
current requirements.
• Anodic protection has been most extensively applied to protect
equipment used to store and handle sulfuric acid.
 Anodic protection
• Passivation occur by exposing the metal to highly concentrated
oxidizing solution
• i.e:
– iron is dipped in very concentrated nitric acid.
– Iron rapidly and uniformly corrodes to form a thin protective iron
hydroxide coating
– The coating will protects the iron from subsequent corrosion in nitric
acid
• Based on the formation of protective films on metal and alloy
surfaces by external impressed anodic currents.
• Can be controlled by a device (potentiostat) which is an
electronic device that maintains a metal constant potential with
respect to a reference electrode.
• Potentiostat have 3 terminals
– Connected to tank
– Connected to an auxiliary cathode
– Connected to reference electrode
ANODIC PROTECTION
 ANODIC PROTECTION
• Advantages
– Applied current of anodic protection is usually equal to
corrosion rate or the protected system
– Can decrease corrosion rate substantially (applicability in
extremely corrosive environments and low current
requirement)
– Protect equipments that are used to store and handle
sulphuric acid manufacturing plants
• Disadvantages
– Possible to accelerate corrosion if proper controls are not
implemented
– Requires complex instrumentation (not economic to apply
for a small manufacturing plant)
 Cathodic or Anodic ? A Comparison:
Cathodic Protection Anodic Protection

Advantages •can be used for all metals •can be used in

installation cost is low extremely aggressive
•corrosion rate can be reduced to zero environment
•applied current is direct
measure of corrosion
rate
•operating conditions
can be easily controlled
•operation cost low

Limitations •can only be used in weak to moderate •only applicable to

environment active-passive metals
•operating conditions must be •installation cost is high
determined by empirical testing.