CATHODIC COATING ON STEEL METAL

BY
DENNIS EDUKIT
INDEX NO. 5031110410

A REPORT SUBMITTED TO THE KENYA NATIONAL EXAMINATION COUNCIL IN

PARTIAL FULFILLMENT FOR THE AWARD OF CERTIFICATE IN SCIENCE LABORATORY
TECHNOLOGY
NOVEMBER, 2021
DECLARATION
I declare that the work reported is my original work.
NAME
Dennis Edukit
Signature …………………….
Date ……………………
SUPERVISOR
Mr Bera D.B
Signature ……………….
Date ………………….
DEDICATION
I dedicate this project in Lennon of my beloved dad and entire family more so my lecturer .For his
fully support in my project

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ACKNOWLEDGEMENT
I sincerely appreciate my beloved parents for financial support .My supervisor Mr Bera for his
guideline throughout the project, The Kitale National fraternity for teaching me art of writing
nurturing my mind to appreciate the world of academic and students for their support and assistance
for completion of this project .May God bless them abundantly
Table of Contents
DECLARATION..................................................................................................................................ii
DEDICATION....................................................................................................................................iii
ACKNOWLEDGEMENT..................................................................................................................iv
TABLE OF CONTENTS......................................................................................................................v
LIST OF TABLES...............................................................................................................................vi
LIST OF FIGURES............................................................................................................................vii
ABBREVIATIONS...........................................................................................................................viii
ABSTRACT........................................................................................................................................ix
CHAPTER ONE...................................................................................................................................1
1.1 INTRODUCTION..........................................................................................................................1
1.2 OBJECTIVES................................................................................................................................1
CHAPTER TWO..................................................................................................................................2
2. O LITERATURE REVIEW.............................................................................................................2
CHAPTER THREE..............................................................................................................................3
3.0 THEORETICAL CONSIDERATION............................................................................................3
3.1 SYNTHESIS TECHNIQUES OF CATHODIC PROTECTION...................................................3
CHAPTER FOUR................................................................................................................................4
4.0 MATERIALS AND METHOD......................................................................................................4
CHAPTER FIVE..................................................................................................................................5
5.0 RESULTS AND DISCUSSION.....................................................................................................5
CHAPTER SIX....................................................................................................................................6
6.0 CONCLUSION..............................................................................................................................6
6.1 RECOMMENDATION..................................................................................................................6
REFERENCES.....................................................................................................................................7

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LIST OF TABLES
Table 1:mass on coated steel
LIST OF FIGURES
Figure 1:- Cathodic protection circuit
Figure 2:- Graph of mass against current

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ABBREVIATIONS
CP-Cathodic protection.
DC –direct current
PPY-polypyrrole
A- Amperes
V-volts
ABSTRACT
There are two types of cathodic protection system: galvanic and impressed current. In this research,
the effect of coating in impressed current was studied. The selection of coating process for a
specific application depends on several factors including corrosion resistance is required, the
anticipated lifetime of the coated material and environment considerations. When using cathodic
protection on the coated pipeline, the problem that exists if coating is disband must be considered.
The aqueous solution of 3.5% sodium chloride were studied in this research

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CHAPTER ONE
1.1 INTRODUCTION
Steel pipeline plays an important role in the world as means of transporting gases and liquids over
long distance from their sources to the ultimate consumers. Steel oil pipeline suffer from corrosion
cracking and other problems. One of the problems face the steel oil pipeline is the most external
corrosion is caused by disbanded coatings which shield cathodic protection because it is effective
when there is rout to pipe structure.

1.2 OBJECTIVES
 To protect steel pipe metal from corrosion by cathodic coating.
 To determine efficiency ratio during cathodic coating of steel pipe metal.

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CHAPTER TWO
2. O LITERATURE REVIEW
Zedin, N.K. (2015) investigated the effect of coating on impressed current on cathodic protection on
steel pipeline in saline environment. He said that coating can be solved using cathodic protection by
Tafel extapolation on epoxy-coating thus solving problems of corrosion in oil pipeline companies.
They play an important role in increase of corrosion resistant on steel pipeline surface. Norman
subekti, (2012) Investigated corrosion rate of carbon steel as flow line and pipeline in natural gas
production with Co2 content. Research conducted by polarization test and simulation method using
PREDICTTM software. The result of this research is used to illustrate the level of corrosion rate of
typical carbon steel occurred in natural gas pipeline due to the effect of dissolved Co2 which
appropriate with the lifetime that have been designed. Rincon, O.T. (2005) Investigated that zinc
has traditionally been the metallic material most widely used to protect steel against atmospheric
corrosion due to its ability to afford cathodic protection to steel in all types natural atmospheres.
Results shows that this coating becomes active thus preventing corrosion. Anil c Ranveer in the year
2015 investigate the build up of greenhouse effect particularly increase in Co2 affect corrosion on
metals. Therefore protection by reducing greenhouse effect.
Gusti Ayu Arwati investigated that cadothic protection in onshore pipe networks gas pagardewa
receiving station when exposed to environment it corrodes thus it should be prevented from
continuing by apply the cathodic protection method.
CHAPTER THREE
3.0 THEORETICAL CONSIDERATION
Surface preparation is the most important step in application of any coating, in this work the
specimens cut from the oil steel pipeline, the cutting is achieved by cutting machines and it’s taken
from Oil Company. The specimens prepared for coating by mounting process with dimensions (1.5
cm length and 1.5 cm width). Grinding process was carried out using disk rotary instrument with
different grades in increasing sequence.

CATHODIC PROTECTION
Cathodic protection is a common method of corrosion prevention employed in pipelines where the
metal behaves entirely as a cathode and hence corrosion is averted. This can be achieved in two
ways;
 IMPRESSED VOLTAGE: as shown in the figure1an external dc power supply connected to
the metal to be protected. The negative terminal of the power supply is connected to the
metal and the positive terminal to zinc anode. The process can be described as the passage
of a suitable electric current in an opposite direction at an equal or a greater rate than it was
flowing in the metal was not protected.
 Sacrificial anode; a metal which has a higher tendency to corrode anodic from the emf series
is coupled with the metal to be protected. The sacrificial anode corrodes and supplies
electrons to the metal thus preventing anode reaction at the metal thereby sacrificial anode is
consumed and must eventually be replaced.

3.1 SYNTHESIS TECHNIQUES OF CATHODIC PROTECTION

Cathodic protection is a convenient technique of protecting formation of a polypyrrole film on
biodegradable metal. Metal was suppressed by applying negative potential to the cathode then
oxidant nitrosyl ion was generated on metal surface through redox reaction that obtain electron from
the metal. Pyrrole was oxidized to polypyrrole on metal nitrosyl. Subsequent corrosion test showed
that the ppy coating could slow down the metal corrosion in physiological saline, but could not stop
corrosion completely, which is useful for a coating material of biodegradable metal implants.

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CHAPTER FOUR
4.0 MATERIALS AND METHOD
4.1 Material
1) dc power supply
2) zinc anode
3) steel pipe
4) connecting wires
5) sea water as electrolyte
4.2 Methods

D.C
POWER
SUPPLY

ZINC STEEL
ANODE PIPE

SEAWATERASELECTROLYTE BASIN

……………………………………………………………………………………………………….

Figure 1: cathodic protection circuit

When the circuit was complete, the anode gives up electrons to the circuit and corrodes.
The cathode receives electrons from the circuit by means of a chemical reactionions that combines
with electrons produce a byproduct at the cathode.
The electrolyte is liquid in contact with both the anode and cathode. It provides the means by which
the metallic ions leaves the anode surface and assures that ions move to the cathode to accept the
electrons.
REACTION OF AN ELECTROCHEMICAL CELL
OXIDATION
M Mn++ne-
Because metal ions leave the anode and corrodes.
REDUCTION
Mn++ne M

The metal ions intentionally added to the electrolyte in the anode reaction combine with cathodic
electrons. The metal plates out and covers the cathode surface.
Zinc exposed to sea water containing sodium chloride shows the reaction in the equation below;
Zn ZnCl2

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CHAPTER FIVE
5.0 RESULTS AND DISCUSSION
TABLE1; mass on coated steel
Current in A 0.2 0.6 1.0 1.4 1.8
Mass in g 1.0 1.1 1.2 1.3 1.4

GRAPH OF MASS AGAINST CURRENT

Figure 2: graph of mass on coated steel against current

Chart Title
1.4

1.2

0.8

0.6

0.4

0.2

0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2

ΔM=q (Am)/nF
M=1.095(a) I (t)
a=current efficiency ratio
M=atomic weight of metal deposit
f=faradays constant 96500c
M=1.095*at
32.85ai
The slope=32.85a
a=slope/32.5
a=0.12

It was initially discussed the results taking in to account the corrosivity categories of ISO
classification of the atmospheres after analysis the coatings within same corrosivity category could
behave differently and furthermore could be similar. These observation showed protection of steel
since the appearance of rust is observed at the bottom of the basin. However, after 30 Mins the rust
formation ceases and the coating starts to galvanically protect the underlying steel pipe. This is the
case of zinc-rich aluminum coatings exposed in the atmospheres with low and medium high
chloride contents.
Coatings that do not afford cathodic protection to the steel base during their atmospheric exposure.
This is the case of aluminum coatings exposed in atmospheres with low and medium high chloride
ion contents in figure1.

DISCUSSION
The results of exposure tests show that zinc afford cathodic protection to steel in all atmospheres a
fact that is very well known. At the start of atmospheric exposure in non-polluted atmospheres or
less contamination with chloride ion content, it is possible to see a fine film of ‘incipient’ rust in the
bottom of the basin. The low conductivity of aqueous film.

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CHAPTER SIX
6.0 CONCLUSION
Zinc coatings can afford cathodic protection to the steel as they remain active in natural
atmospheres. However, aluminum coatings are not able to provide effective cathodic protection to
steel. Only in atmospheres with very high chloride contamination these coatings can afford
cathodic protection to steel as they become active in the presence of very high chloride ion
concentration.

6.1 RECOMMENDATION
I recommend that cathodic protection is the most convenient method that prevent corrosion. It is
most appropriate in steel pipeline thus highly recommend
REFERENCES
Zedin, N.K. (2015).effect of cathodic protection on coating steel pipeline in saline environment.
Diyala journal of engineering sciences 3:88-9.
Norman,S.K(2015). corrosion rate of steel as flow line and natural gas pipeline. Journal of software
technology.2439-3843.
Rincon,O.T(2005).zinc material most widely used to protect steel from corrosion. Journal of
corrosion protection petroleum sciences.(4348-5034).
Anil,C.R(2015).Greenhouse effect to corrosion and its impacts to environment. International
journal of innovative research and creative technology vol1 2454-5988
Gusti,A.A.(2019) .Cathodic protection in onshore pipe networks gas pagardewa receiving station.
world chemical engineering journal.vol3 24-29.

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