Module 8, Objective 4

(Part 1 of 2)
Corrosion Inhibitors, pg. 35-37

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 Module 8- Objective 4

When you complete this section you will be able to:

• Identify methods of inhibiting corrosion.
• Explain the effect of applying an external impressed
current to a galvanic cell.
• Identify NACE corrosion codes and standards.

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 Controlling Corrosion in Design
• Select an appropriate material that is resistant to the corrosive
environment.
• Adopt a corrosion allowance in component sizes.
• Make proper drainage in tanks.
• Avoid direct connection of dissimilar metals.
• Avoid having concentration cells.
• Apply proper welding techniques.
• Avoid the use of small anode and large cathode areas.
• Avoid sharp bends in pipes carrying high-velocity flow.
• Specify proper procedures for testing, monitoring and preventive
maintenance schedules.
• Make surfaces smooth to prevent localized corrosion cells.

Can you name the type of corrosion that might occur in each of the
marked cases?

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Controlling Corrosion During Operation
• Apply protective coatings
– Epoxy, paint, extruded polyethylene, etc.
• Use oxygen scavengers or de-aerator systems
– Remove all O2 from a closed system (ex: a boiler)
so the cathode reaction cannot exist.
– O2 + 2H20 + 4e- → 4OH-
• Use chemical inhibitors
– Reduce the aggressiveness of the environment.
– Control the pH.
• Use cathodic protection
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 Corrosion Inhibitors
• A corrosion inhibitor is a substance that
retards corrosion when low concentrations are
added to an environment.
• Inhibition is accomplished by one or more of
the following mechanisms:
1. Adsorbed films
2. Passivating inhibitors (passivation)
3. Cathodic precipitates
4. Neutralization

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 1. Adsorbed Films
• Add an organic to the environment to create a
protective film on the surface of the metal
• Some form a very thin film only a few molecules
thick, while some build up to form very thick films.

A long organic molecule with a positive polarity end

• The positive end of the molecule is attracted to the
metal surface.
– Adsorbs (sticks) on contact.
• The long organic portion is hydrophobic.
– Keeps electrolyte away from the metal.

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 1. Adsorbed Films
Adsorbed film showing the positive end of the long organic
molecule attaching to the metal surface.

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 1. Adsorbed Films
• Some organic films instead incorporate
themselves into the corrosion product
• Add a carboxyl group, RCOO-
– R is a long organic chain

2RCOO- + Fe2+ → Fe(RCOO)2

• The carboxyl part of the resin (RCOO-) attaches to

the newly formed Fe2+ cations.
• The new corrosion product is adherent to the
surface
– coats the piece, preventing further corrosion.
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 2. Passivating Inhibitors
• Addition of inorganic chromates and
phosphates.
• Creates a protective chromate or phosphate
film that forms a barrier to corrosion.
- Chromate (CrO42-) for stainless steels
- Phosphate (PO43-) for iron or other steels

• The film is a product of the reaction at either

the anode or the cathode
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 2. Passivating Inhibitors
Example: A zinc phosphate [Zn(H2PO4)2] solution
is added to protect iron or steel
• First, iron is dissolved in phosphoric acid
Phosphoric Acid
Fe + 2H3PO4 → Fe(H2PO4)2 + H2

• Second, a phosphate passivating film is created.

Phosphate Passive Film
Fe(H2PO4)2 + 2Zn(H2PO4)2 + 4H2O → Zn2Fe(PO4)2(4H2O) + 4H3PO4

• This reaction occurs at the anode.

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 2. Passivating Inhibitors
Anodic Inhibitors vs. Cathodic Inhibitors
• Anodic inhibitors are cheaper and can work in the
absence of oxygen.
• They can be dangerous, however.
– If insufficient quantities of anodic inhibitor are
used, the protective film will not completely cover
the metal surface.
– The passivating film formed is cathodic to the
uncoated metal so now you have a small anode
and a large cathode.
➢ Increased corrosion rate!
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 3. Cathodic Precipitates
• Inorganic inhibitors (such as calcium
carbonate, polyphosphates and zinc salts)
form precipitates on cathodic areas

➢A new reduction reaction is created with a

precipitate product
➢The precipitate product covers the cathode,
blocking access to the electrolyte
– Stops the cathode reaction at that location

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 3. Cathodic Precipitates
Downside: More expensive
• The cathodic area that must be protected is usually
much larger.
• Larger quantities of cathodic inhibitors must be used
(compared to anodic inhibitors).

Upside: Safer to use

• Corrosion will not be intensified if there is a low
concentration of inhibitor.
• If the cathode is not fully covered, that still slows the
reaction.
• More coverage = larger anode to cathode ratio

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 4. Neutralization
Increasing the pH decreases the corrosion rate.
Neutralization: OH- + H+ → H2O

So, we add some basic solution!

• Amines are used in corrosion control of
systems containing gas or steam that
condenses.
• Ammonia, lime and soda ash are commonly
used as neutralizers of acidic water.

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 Exercise 4 (pg. 41)

1. List the various mechanisms whereby

corrosion inhibitors accomplish their job.
– Adsorbed films
– Passivating Inhibitors
– Cathodic Precipitates
– Neutralization

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 Bonus Question
Explain how these two other operational methods work
to control corrosion. Which of the four required
components of a corrosion cell are they affecting?
1) Apply protective coatings

2) Use oxygen scavengers or de-aerator systems

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 Bonus Question
Explain how these two other operational methods work
to control corrosion. Which of the four required
components of a corrosion cell are they affecting?
1) Apply protective coatings
– Applying a coating to the surface of your metal prevents
the electrolyte from coming into contact.

2) Use oxygen scavengers or de-aerator systems

– Removing oxygen prevents the oxygen/water reduction
reaction (O2 + 2H20 + 4e- → 4OH-) from occurring at the
cathode.
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