CORROSION

Food process equipment design

Module-2
 Definition of Corrosion

Corrosion is the deterioration of materials by chemical

interaction with their environment.  The term corrosion is
sometimes also applied to the degradation of plastics,
concrete and wood, but generally refers to metals.
 Mechanism or causes of corrosion
• Metals are electropositive in nature. Except few metals like
gold, platinum (noble metal) other metals are found in nature
as their compounds (such as oxides, hydroxides, carbonates,
chlorides, sulphides, phosphates, silicates etc.) which are
called their ore.
• Metals are thus obtained by extraction from their ores by
reduction process. In nature, when metals exists as their
compounds (or ore) they are stable and they are in the low
energy states.
• However, during extraction of metals from their ores, free
metals are become less stable and are in the higher energy
state than in the ionic state.
• So, metals have a tendency to back to the ionic state and
hence metal atoms are prone to get attacked by
environment . This is the main reason for corrosion of metals.
• It involves direct attack of aqueous
media (strong or dilute, acidic or
alkaline) on metal through corrosion
electrochemical reactions.
• The moisture and oxygen are also Wet
responsible.
• This type of corrosion is quite
common.
• It involves direct attack of dry gases
(Air and Oxygen) on the metal through
corrosion
chemical reactions. As a result an oxide
layer is formed over the surface.
Dry
• This type corrosion is not common.
Corrosion
 Corrosion
 Corrosion specifically refers to any process involving the
deterioration or degradation of metal components.
 The best known case is that of the rusting of steel.
 Corrosion processes are usually electrochemical in nature.
 When metal atoms are exposed to an humid (wet)
environment, they will give up electrons and make
themselves positively charged
 Factors influencing corrosion
• Solution pH (pH of the environment)
• Oxidizing agent (type and strength)
• Temperature (typically occur at High T)
• Velocity (turbulence or laminar condition)
• Surface Films (smooth/rough/with or without
protective coatings)
• Other Factors
Types of corrosion
 Types of corrosion
• Uniform corrosion
– Uniform (general) is a form of corrosion that occurs
uniformly over the entire exposed surface of a metal.
Applying a barrier coating is one of the most common
methods to mitigate this degradation
• Two metal corrosion or galvanic corrosion
– Galvanic corrosion results from the formation of a galvanic
cell by the galvanic coupling of dissimilar metals (metals
having different electrical potentials), which are exposed
to an electrolyte. This form can be very aggressive but it
may also be one of the easiest to detect and prevent
 Types of corrosion
• Crevice corrosion
– Crevice is a form of corrosion that occurs when an
electrolyte becomes trapped and stagnant in particular
locations such as in joints, corners, and under debris. It can
be hard to find and extremely aggressive causing high
pitting rates and subsequent unexpected failures
• Pitting corrosion
– Pitting is a form of localized corrosion that occurs when a
corrosive medium attacks a metal at specific points and
results in deep cavities in the metal
 Types of corrosion
• Intergranular
• Intergranular is a form of corrosion that attacks grain
boundaries in materials. It may occur as a result of a
galvanic couple between differing phases within a material
and may be prevented by avoiding susceptible alloy or
heat treatments
• Selective Leaching or De-alloying
– is a localized form of corrosion where a particular element
within a material is preferentially attacked and extracted
from the material. Many copper alloys are susceptible
alloy to this attack
 Types of corrosion
• Stress Corrosion Cracking (SCC)
– is a cracking process involving the combined factors of a
susceptible material, corrosive environment and a
sustained tensile stress
• Erosion corrosion
– is due to the increased rate of deterioration and loss of a
material from the combined effects of corrosion and the
repeated motion of the surrounding environment. Most
often found in high velocity areas or in fluids containing
abrasive materials
 Prevention and control
The corrosion may be prevented or controlled by following
ways:
 Selection of proper material
 Proper design of equipment
 Coating and lining
 Altering environment
 Inhibitors
 Cathodic protection
 Anodic protection
 1. Selection of proper material
• Corrosion should not be permitted in fine wire screen, orifice and
other items in which the dimensions are critical and change is not
permitted.
• In some cases, non metallic materials will be more economic and
have good performance. It should be considered if their strength,
temp and design is satisfactory.
• The corrosion characteristics of chemicals and limitation of
construction material can be considered.
• The processing conditions should also be considered.
 2. Proper design of equipment
• In the design of equipment, the number of fittings like, baffles, valves
and pumps should be considered.
• Corrosion can be minimized if the equipment design facilitates
 Elimination of crevices
 Complete drainage of liquids
 Ease of cleaning
 Ease of inspection and maintenance
• A direct contact between two metal is avoided, if they are seperated
widely in elecrochemical series. Or they should be insulated.
 3. Coatings and Linings
• Nonmetallic coatings and linings can be applied on steel and other
materials of construction in order to combat corrosion.
• Coating methods: electroplating, cladding, organic coating.
• The thickness of lining is important.
• Effective linings can be obtained by bonding directly to substrate
metal or building multiple layers.
• Organic coatings can be used in tanks, piping and pumping lines.
 5. Inhibitors
The corrosion inhibitors are added to the environment to decrease
corrosion of metals. This form protective films.
Adsorption type, e.g. adsorbed on metal
Scavenger phase type, e.g. remove corrosion agent
Vapor phase type, e.g. sublime and condense on metal surface.
Inhibitors are generally used in quantities less than 0.1 % by
weight.
 6. Cathodic protection
• Cathodic protection basically reduces the corrosion rate of a metallic
structure by reducing its corrosion potential, bringing the metal
closer to an immune state
• It is based on the galvanic action between the metals of the anode
and cathode suspended in the solution.
• The metals to be protected are made as cathode.
• Electrons are supplied , there by dissolution of metal is suppressed.
• It can be achieved by:
• 1. Sacrificial anode method
• 2. Impressed emf method
 Sacrificial anode method
• In this method, anodes are kept in electrical contact with the metal to
be protected.
• The anodes are sacrificed, since it goes into solution.
• E.g. for the protection of iron and steel tanks, the metals such as Zinc,
Al, Mg and their alloy are used as sacrificial anodes.
• This are used in limited pH range.
• Anode metal is selected from electrochemical series.
• The anodes should not be poisonous and not detrimental to the pdts.
 Impressed emf method
• It is also known as applied current system, i.e., external voltage is
impressed between tank and electrodes.
• The negative terminal of power is connected to the material to be
protected.
• So the natural galvanic effect is avoided and the anode is maintained
positive.
• Since anode is not consumed, metal or non corrodable material can
be used.