Anodic Protection : Liquid Environment

Name : Muhammad Emir Rafiansyah Akbar

NPM : 2006489193
 Table contents
1. What is Corrosion?
2. Harmful effects of corrosion
3. Components of a corrosion cell
4. Commonly Affected Structures
5. Factors Affecting Corrosion Cell Formation
6. Corrosion Prevention Methods
7. Coating Types  
8. Fundamentals of Anodic Protection
9. Galvanic CP or Sacrificial Anode
10. Application od Anodic Protection
11. Arrangement of Anodes for Impressed Current
 What is 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.

• Metallic Corrosion: A process in which a metal is destroyed by an

electrochemical reaction (oxidation) forming an oxide layer on
the metal surface.

• This process requires that the metal surface be exposed to

oxygen, and is favored in the presence of water.

• In the case of iron and steel, corrosion is often referred to as

rusting.
3
In the case of iron and steel,
corrosion is often referred to as rusting.

anode

Gialanella, S.; Malandruccolo, A. Aerospace Alloys; Topics in Mining, Metallurgy and Materials Engineering;
Springer International Publishing: Basel, Switzerland, 2019; ISBN 978-3-030-24440-8. 
Some of the major harmful effects of corrosion
can be summarised as follows:
1. Reduction of metal thickness leading to loss of mechanical strength and Structural
Failure or breakdown. Considerable weakening may result from a small amount of
metal loss.
2. Hazards or injuries to people arising from structural failure or breakdown (e.g.
bridges, cars, aircraft, ships etc.)
3. Loss of time in availability of costly & dependable industrial equipment.
4. Reduced value of goods due to deterioration of appearance.
5. Contamination of fluids in vessels and pipes .
6. Perforation of vessels and pipes allowing escape of their contents and possible
harm to the surroundings.
7. Loss of technically important surface properties of a metallic component.
8. Mechanical damage to valves, pumps, etc, or blockage of pipes by solid corrosion
products.
9. Cost of equipments increased which needs to be designed to last for prolonged
life.
 Components of a corrosion cell
• Anode
–At anode metal goes into solution as metal ions (oxidation reaction) and Metal
loss or corrosion occurs .
• Cathode
– At cathode metal deposition or reduction of gases occur s(reduction reaction)
- Little or no corrosion occurs at the cathode
• Return Circuit/Metallic Path
– Provides a path for electrons to flow, between the anode and cathode
• Electrolyte
– Ionized solution capable of conducting electricity
 Components of a corrosion cell
• Anodic sites have a more negative potential than cathodic sites in the same
electrolyte.
• Current flow through the electrolyte is due to ion movement & current flow
through the metal is due to movement of electron.

Thus any corrosion phenomenon is associated with passage of D.C. Current from
anode to electrolyte.

Suzuki, Y.; Kawahara, K.; Kikuchi, T.; Suzuki, R.O.; Natsui, S. Corrosion-Resistant Porous Alumina Formed via Anodizing
Aluminum in Etidronic Acid and Its Pore-Sealing Behavior in Boiling Water. J. Electrochem. Soc. 2019, 166, C261–C269.
 Corrosion Type
 Uniform or near uniform - Corrosion attacks all areas of the metal at the
same or similar rate.
 Localized - Some areas of the metal corrode at different rates due to
heterogeneities in the metal or environment. This type of attack can
approach pitting.
 Pitting - Very highly localized attack resulting in small pits that may
penetrate to perforation.
 Erosion: Removal of surface material by the action of numerous individual
impacts of solid or liquid particles
 Stress cracking: Service failures in materials that occur by slow
environmentally induced crack propagation
 Methods to Control Corrosion

 Use of Corrosion resistant materials (plastic, stainless alloys, fiberglass).

 Use of the same or similar metals per the galvanic series.
 Altering the environment (utilizing homogeneous high resistivity backfill or
inhibitors).
 Utilize coatings and linings that electrically insulate the structure from the
electrolyte (paints, plastic films, etc).
 Use of Cathodic Protection.
 Corrosion Prevention Methods for Metal against
Electrolyte Corrosion

Coating
• Painting of surface by Anti-corrosive primers. Primers may be lead-based or
lead-free zinc rich primer types.

• Finishing with paints/enamels.

• Coating by Coal Tar Enamel, Fusion Bonded Epoxy (FBE), Polyethylene or

Polyurethane are primary methods of external corrosion protection.
 Coating Types  
1. Internal Lining 2. Fusion Bonded Epoxy (FBE)
Powder Coating

Internal coating using a two component liquid

epoxy based paint.
3. Dual Fusion Bonded Epoxy (D- 4. Bitumen / Asphalt Enamel
FBE ) coating (AE) Coating

FBE primer (first layer), FBE topcoat (top layer

 Coating Types  
5. Three Layer Polypropylene (3LPP) 6. Three Layer Polyethylene
Coating (3LPE) Coating

7. Concrete Weight Coating (CWC) 8. Polyurethane Insulation Coating

 Fundamentals of Anodic Protection
 Anodic protection is the method or technique adopted to reduce the corrosion of the
surface of a metal by connecting it as an anode with respect to an inert cathode in
the cell formed due to an electrochemical reaction in the corrosive environment, and
ensuring that the electrode potential is controlled to keep the metal in a passive
state. Anodic protection is used to protect metals that exhibit passivation in
environments whereby the current density in the freely corroding state is
significantly higher than the current density in the passive state over a wide range of
potentials.
 Practical use of anodic protection
• Designing, supplying and maintaining Anodic protection systems has been a core
part of our business since the 1960s. These systems are primarily used for corrosion
prevention inside green liquor tanks, Kamyr digesters, sulfuric acid storage tanks,
heat exchangers and piping.

• Anodic protection theory is very similar

to cathodic protection, the key difference
being the structure is the anode. The
negative terminal from the rectifier is
connected to a submerged cathode made
from highly corrosion resistant specialty
rod or tube material. The greatest
advantage of utilizing an anodic
protection system is it allows the site to
minimize their capital costs by
constructing the vessel from commonly
available mild or low-carbon steel.
 Galvanic CP or Sacrificial Anode CP
When metals, which are more electronegative than protected metal (such as
magnesium or zinc) are placed in the same environment and kept in contact
with the protected metal (such as steel,) a current flows from the more active
anode (zinc) to the noble cathode (steel), protecting the cathode.

Anodes Materials Used for Sacrificial Anode CP

Sacrificial anodes have fixed driving voltage to protected metal which is in range of
0.6-0.25 volts.
 Magnesium – It is often used in soil to protect small electrically isolated
structures, such as underground storage tanks, and well coated pipelines.
 Zinc – It is often used in marine environments. They are commonly found on
boats.
 Aluminum – It can be used for a variety of marine applications.

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 Galvanic Sacrificial Anode-Installation

Simchen, F.; Sieber, M.; Kopp, A.; Lampke, T.

Introduction to plasma electrolytic oxidation—An
overview of the process and
applications. Coatings 2020, 10, 628. 
Keys to obtaining enough anodic protection in Water


Determination of amount of current required
1) Theoretical calculations based on coating quality and environment.
2) Perform physical testing of current requirement.

Calculation of expected from of anode and determination of number of
anodes required.

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 Advantages and Disadvantages of
Sacrificial Anode Protection
Advantages :
 Inexpensive
 Little Maintenance cost
 No external Power source
 Robust system, reduced maintenance
 Typically work best with electrically isolated structures.
Disadvantages :
 Limited driving voltage of 0.25 V to 1.25 V (driving potential based on the galvanic
series)
 Limited output makes it ineffective when trying to protect large uncoated surfaces.
 Require a low resistivity electrolyte (e.g sea water) to function well. Not suited for
media with high resistive soil.
 Require more no of anodes for protection
 Require more quantity of anode material for securing long operating time.
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 Application of Anodic Protection
Anodic protection is a means of preventing
corrosion of metal in low pH (acidic)
environments, usually sulfuric acid inside
steel storage tanks or process piping. The
anodic protection system creates a passive
barrier on the steel’s surface that resists
corrosion and prevents the release of
corrosion products into the acid, and this
helps maintain acid purity.

Anodic Protection has taken by placing the electrode in the electrolyte and
measuring the potential between structure and electrode with a high resistance.
Typical Current Requirements for Anodic Protection of Steel
(Bare Surface)
 Arrangement of Anodes for Impressed Current

Yabuki, A.; Nagayama, Y.; Fathona, I.W. Porous anodic oxide film with self-healing ability for corrosion protection of
aluminum. Electrochim. Acta 2019, 296, 662–668.
 Arrangement of Anodes for Impressed Current

Paz Martínez-Viademonte, Mariana; Abrahami, Shoshan T.; Hack, Theodor; Burchardt, Malte; Terryn, Herman (2020). A Review on Anodizing of
Aerospace Aluminum Alloys for Corrosion Protection. Coatings, 10(11), 1106–. doi:10.3390/coatings10111106 
 Anode Loop

Yu, M.; Dong, H.; Shi, H.; Xiong, L.; He, C.; Liu,
J.; Li, S. Effects of graphene oxide-filled sol-gel
sealing on the corrosion resistance and paint
adhesion of anodized aluminum. Appl. Surf.
Sci. 2019, 479, 105–113. 
 Impressed Current - Design
• Calculate total area to be protected (Ap)
• Determine current density (ρ)
• Calculate total protection current (Ip)
• Calculate total anode needed (N)
 Initial
 Lifetime
• Calculate total anode resistance
(Rtotal = f(N, ρ, d, L, spacing))
• Calculate rectifier specification (Vdc, Idc, Pdc = f(Rtot,Ip)
Corrosion Rate for Uniform Attack :
Corrosion rate expressed as mm /yr or mils/year (MPY) or mg/dm 2/day (MDD). The
above units represent average rate of metal penetration or weight loss of metal
excluding any adherent or non adherent corrosion products.

For Mild Steel in soil rate is = 0.021 mm/ yr.

For Mild Steel in sea water rate is = 0.13 mm/ yr.
CLASSIFICATION ON BASIS OF CORROSION RATE:
a)   0.15 mm/yr – EXCELLENT CORROSION RESISTANCE.
b)   0.15-0.5 mm/yr – GOOD
c)    0.5 – 1.0 mm/yr – FAIR
d)    1.0 mm/yr – UNACCEPTABLE.
 Resistance of Common Electrolytes
 Soils – High resistivity soil reduces the corrosion rate, while low
resistivity soil increases the corrosion rate.

ELECTROLYTE ANTICIPATED
RESISTIVITY CORROSIVITY
CLASSIFICATION (ohm-cm)

Low Resistance 0 to 2,000 Severe

Medium 2,000 to 10,000 Moderate

High 10,000 to 30,000 Mild

Very High Above 30,000 Increasingly Less

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 Resistance of Common Electrolytes
 Water – Approximate resistivity values

Water Resistivity Ohms-cm

Open sea 20-25
Tea water (coastal) 30-40
River water 500-10,000
Tap water 1,000-10,000
Rain water 20,000
Distilled water 500,000
Pure water 20,000,000

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 References
Journal:
1. Yu, M.; Dong, H.; Shi, H.; Xiong, L.; He, C.; Liu, J.; Li, S. Effects of graphene oxide-filled sol-
gel sealing on the corrosion resistance and paint adhesion of anodized aluminum. Appl.
Surf. Sci. 2019, 479, 105–113. 
2. Yabuki, A.; Nagayama, Y.; Fathona, I.W. Porous anodic oxide film with self-healing ability for
corrosion protection of aluminum. Electrochim. Acta 2019, 296, 662–668.
3. Paz Martínez-Viademonte, Mariana; Abrahami, Shoshan T.; Hack, Theodor; Burchardt,
Malte; Terryn, Herman (2020). A Review on Anodizing of Aerospace Aluminum Alloys for
Corrosion Protection. Coatings, 10(11), 1106–.
4. Suzuki, Y.; Kawahara, K.; Kikuchi, T.; Suzuki, R.O.; Natsui, S. Corrosion-Resistant Porous
Alumina Formed via Anodizing Aluminum in Etidronic Acid and Its Pore-Sealing Behavior in
Boiling Water. J. Electrochem. Soc. 2019, 166, C261–C269.
5. Gialanella, S.; Malandruccolo, A. Aerospace Alloys; Topics in Mining, Metallurgy and
Materials Engineering; Springer International Publishing: Basel, Switzerland, 2019; ISBN
978-3-030-24440-8. 
6. Simchen, F.; Sieber, M.; Kopp, A.; Lampke, T. Introduction to plasma electrolytic oxidation—
An overview of the process and applications. Coatings 2020, 10, 628. 
Book:
1. Carl E. Locke, Jr., Anodic Protection, Corrosion: Fundamentals, Testing, and Protection, Vol
13A, ASM Handbook, Edited By Stephen D. Cramer, Bernard S. Covino, Jr., ASM
International, 2003, p 851–854.
2. Corrosion Control by Cathodic and Anodic Protection, Corrosion: Understanding the Basics,
Edited By J.R. Davis, ASM International, 2000, p 407–426,
3. Anodic Protection, Corrosion in the Petrochemical Industry, 2nd ed., Edited By Victoria Burt,
ASM International, 2015, p 180–183,
Thanks For Your
Attention !