Corrosion Engineering and Cathodic Protection Handbook With Extensive Question and Answer Section

The Corrosion Engineering and Cathodic Protection Handbook combines the author's previous three works, Corrosion Chemistry, Cathodic Protection, and Corrosion Engineering to offer, in one place, the most comprehensive and thorough work available to the engineer or student. The author has also added a tremendous and exhaustive list of questions and answers based on the text, which can be used in university courses or industry courses, something that has never been offered before in this format.

The Corrosion Engineering and Cathodic Protection Handbook is a must-have reference book for the engineer in the field, covering the process of corrosion from a scientific and engineering aspect, along with the prevention of corrosion in industrial applications. It is also a valuable textbook, with the addition of the questions and answers section creating a unique book that is nothing short of groundbreaking. Useful in solving day-to-day problems for the engineer, and serving as a valuable learning tool for the student, this is sure to be an instant contemporary classic and belongs in any engineer's library.

Volkan Cicek, PhD, is a chemist and corrosion scientist and received his B. Sc. in Bogazici University, Istanbul, Turkey and his PhD from Oklahoma State University, Stillwater, OK, US. After working as a dean of academics and vice principal in US public schools for several years, Dr. Cicek is currently the vice president for scientific affairs at Ishik University, Erbil, Iraq.

Preface xv

Part 1 Corrosion Chemistry

1 Corrosion and its Definition 3

2 The Corrosion Process and Affecting Factors 5

3 Corrosion Types Based on Mechanism 7

3.1 Uniform Corrosion 7

3.2 Pitting Corrosion 7

3.3 Crevice Corrosion 8

3.4 Galvanic Corrosion 8

3.5 Intergranular Corrosion 8

3.6 Selective Corrosion 9

3.7 Erosion or Abrasion Corrosion 9

3.8 Cavitation Corrosion 9

3.9 Fretting Corrosion 9

3.10 Stress Corrosion Cracking 9

3.11 Microbial Corrosion 9

4 Corrosion Types of Based on the Media 11

4.1 Atmospheric Corrosion 11

4.2 Corrosion in Water 12

4.3 Corrosion in Soil 13

5 Nature of Protective Metal Oxide Films 15

6 Effect of Aggressive Anions on Corrosion 17

7 Corrosion Prevention Methods 19

8 Commonly Used Alloys and their Properties 21

8.1 Aluminum 2024 Alloy 21

8.2 Aluminum 7075 Alloy 22

8.3 Aluminum 6061 Alloy 22

9 Cost of Corrosion and Use of Corrosion Inhibitors 23

10 Types of Corrosion Inhibitors 25

10.1 Anodic Inhibitors 25

10.2 Cathodic Inhibitors 25

11 Chromates: Best Corrosion Inhibitors to Date 27

11.1 Limitations on the Use of Chromates due to Toxicity 27

11.2 Corrosion Inhibition Mechanism of Chromates 29

12 Chromate Inhibitor Replacements: Current and Potential Applications 31

12.1 Nitrites 31

12.2 Trivalent Chromium Compounds 31

12.3 Oxyanions Analogous to Chromate 32

12.4 Synergistic Use of Oxyanions Analogues of Chromate 34

13 Sol-Gels (Ormosils): Properties and Uses 35

13.1 Types of Sol-Gels 35

13.2 Corrosion Inhibition Mechanism of Sol-Gel Coatings 36

13.3 Synthesis of Sol-Gels 37

13.4 Incorporation of Corrosion Inhibitive Pigments into Sol-Gel Coatings 38

14 Corrosion in Engineering Materials 39

14.1 Introduction 39

14.2 Steel Structures 39

14.3 Concrete Structures 40

14.4 Protection Against Corrosion in Concrete Construction 44

14.5 Corrosion of Unbonded Prestressing Tendons 51

14.6 Cathodic Protection 52

14.7 Corrosion in Industrial Projects 57

References 61

Part 2 Cathodic Protection

15 Corrosion of Materials 75

15.1 Deterioration or Corrosion of Ceramic Materials 75

15.2 Degradation or Deterioration of Polymers 76

15.3 Corrosion or Deterioration of Metals 76

16 Factors Influencing Corrosion 83

16.1 Nature of the Metal 83

16.2 Nature of the Corroding Environment 84

17 Corrosion Mechanisms 87

17.1 Direct Chemical Attack or Chemical or Dry Corrosion 87

17.2 Electrochemical or Aqueous or Wet Corrosion 88

17.3 Differences between Chemical and Electrochemical Corrosion 90

18 Corrosion Types 91

18.1 Uniform Corrosion 91

18.2 Non-Uniform Corrosion 95

19 Thermodynamics of Corrosion 107

19.1 Gibbs Free Energy (ΔG) 107

19.2 Passivity 108

19.3 Pourbaix Diagrams 109

19.4 Corrosion Equilibrium and Adsorptions 110

19.5 Concentration Corrosion Cells 110

19.6 Polarization 111

19.7 Polarization Curves 113

20 Corrosion Prevention and Protection 117

20.1 Proper Design 117

20.2 Choice of Material 118

20.3 Protective Coatings 120

20.4 Changing the Environmental Factors that Accelerate Corrosion 123

20.5 Changing the Electrochemical Characteristic of the Metal Surface 126

21 Cost of Corrosion 129

21.1 Corrosion Preventative Measures 129

21.2 Lost Production Due to Plants Going out of Service or Shutdowns 129

21.3 Product Loss Due to Leakages 129

21.4 Contamination of the Product 130

21.5 Maintenance Costs 130

21.6 Overprotective Measures 130

22 Cathodic Protection 131

22.1 Sacrificial Anode Cathodic Protection Systems 131

22.2 Impressed Current Cathodic Protection Systems 132

22.3 Cathodic Protection Current Need 133

22.4 Effect of Coatings on Cathodic Protection 134

22.5 Effect of Passivation on Cathodic Protection 134

22.6 Automated Cathodic Protection Systems 134

22.7 Cathodic Protection Criteria 134

22.8 Reliability of Cathodic Protection Criteria 135

22.9 Interference Effects of Cathodic Protection Systems 135

22.10 Criteria for Cathodic Protection Projects 138

22.11 Cost of Cathodic Protection 138

22.12 Comparison of Cathodic Protection Systems 139

23 Sacrificial Anode or Galvanic Cathodic Protection Systems 141

23.1 Anodic Potentials and Anodic Polarization 141

23.2 Galvanic Cathodic Protection Current Need 142

23.3 Anodic Current Capacity and Anodic Current Efficiency 142

23.4 Service Life of an Anode 142

23.5 Minimum Number of Galvanic Anodes 142

23.6 Commonly Used Galvanic Anodes 143

23.7 Performance Measurements of Galvanic Anodes 145

23.8 Galvanic Anodic Beds 146

23.9 Sacrificial Anode Cathodic Protection Projects 148

23.10 Maintenance of Sacrificial Anode Cathodic Protection Systems 148

24 Impressed Current Cathodic Protection Systems 151

24.1 T/R Units 151

24.2 Types of Anodes 153

24.3 Anodic Bed Resistance 154

24.4 Types of Anodic Beds 155

24.5 Cable Cross-Sections 156

24.6 Impressed Current Cathodic Protection Projects 156

24.7 Maintenance of Impressed Current Cathodic Protection Systems 157

25 Corrosion and Corrosion Prevention of Concrete Structures 159

25.1 Concrete’s Chemical Composition 159

25.2 Corrosion Reactions of Concrete 160

25.3 Factors Affecting Corrosion Rate in Reinforced Concrete Structures 160

25.4 Corrosion Measurements in Reinforced Concrete Structures 164

25.5 Corrosion Prevention of Reinforced Concrete 166

26 Cathodic Protection of Reinforced Concrete Steels 167

26.1 Current Needed for Cathodic Protection of Steel Structures 168

26.2 Cathodic Protection Criteria 168

26.3 Determination of Protection Potential 168

26.4 Cathodic Protection Methods for Reinforced Concrete Steels 168

26.5 Cathodic Protection of Pre-Stressed Steel Concrete Pipes 169

27 Corrosion in Petroleum Industry 171

27.1 Hydrochloric Acid (HCl) and Chlorides 172

27.2 Hydrogen (H₂) Gas 172

27.3 Hydrogen Sulfide (H₂S) and Other Sulfur Compounds 173

27.4 Sulfuric Acid (H₂SO₄) 173

27.5 Hydrogen Fluoride (HF) 173

27.6 Carbon Dioxide (CO₂) 173

27.7 Dissolved Oxygen (O₂) and Water (H₂O) 174

27.8 Organic Acids 175

27.9 Nitrogen (N₂) Compounds and Ammonia (NH₃) 175

27.10 Phenols 175

27.11 Phosphoric Acid (H₃PO₄) 175

27.12 Caustic Soda (NaOH) 176

27.13 Mercury (Hg) 176

27.14 Aluminum Chloride (AlCl₃) 176

27.15 Sulfate Reducing Bacteria (SRB) 176

28 Corrosion in Pipeline Systems 177

28.1 Pipes Made of Iron and its Alloys 177

28.2 Petroleum or Crude Oil Pipeline Systems 178

28.3 Water Pipeline Systems 179

29 Cathodic Protection of Pipeline Systems 181

29.1 Measurement of Terrain’s Resistivity 181

29.2 Potential Measurements 182

29.3 Determination of Coating Failures Based on Potential Measurements 183

29.4 Measuring Potential Along the Pipeline 183

29.5 Maintenance of Pipeline Cathodic Protection Systems 183

29.6 Measurement Stations 184

29.8 Cathodic Protection of Airport Fuel Distribution Lines 185

29.9 Cathodic Protection of Water Pipelines 185

30 Corrosion and Cathodic Protection of Crude Oil or Petroleum Storage Tanks 187

30.1 Cathodic Protection of Inner Surfaces of Crude Oil Storage Tanks 187

31 Corrosion and Cathodic Protection of Metallic Structures in Seawater 191

31.1 Factors Affecting Corrosion Rate of Metallic Structures in Seawater 191

31.2 Cathodic Protection of Metallic Structures in the Sea 193

31.3 Cathodic Protection of Ships 193

31.4 Cathodic Protection of Pier Poles with Galvanic Anodes 196

32 Cathodic Protection of the Potable Water Tanks 197

33 Corrosion and Corrosion Prevention in Boilers 199

33.1 Corrosion in Boilers 199

33.2 Corrosion Prevention in Boilers 200

34 Corrosion and Corrosion Prevention in Geothermal Systems 203

34.1 Corrosion in Geothermal Systems 203

34.2 Corrosion Prevention in Geothermal Systems 203

References 205

Part 3 Corrosion Engineering

35 Corrosion of Materials 215

35.1 Deterioration or Corrosion of Ceramic Materials 216

35.2 Degradation or Deterioration of Polymers 216

35.3 Corrosion or Deterioration of Metals 216

36 Cost of Corrosion 225

36.1 Corrosion Preventative Measures 225

36.2 Lost Production Due to Plants Going out of Service or Shutdowns 226

36.3 Product Loss Due to Leakages 226

36.4 Contamination of the Product 226

36.5 Maintenance Costs 226

36.6 Overprotective Measures 226

37 Factors Influencing Corrosion 227

37.1 Nature of the Metal 228

37.2 Nature of the Corroding Environment 229

38 Corrosion Mechanisms 231

38.1 Direct Chemical Attack or Chemical or Dry Corrosion 231

38.2 Electrochemical or Aqueous or Wet Corrosion 232

38.3 Differences between Chemical and Electrochemical Corrosion 234

39 Types of Corrosion 235

39.1 Uniform Corrosion 235

39.2 Non-Uniform Corrosion 241

40 The Thermodynamics of Corrosion 253

40.1 Gibbs Free Energy (ΔG) 253

40.2 Passivity 254

40.3 Pourbaix Diagrams 255

40.4 Corrosion Equilibrium and Adsorptions 256

40.5 Concentration Corrosion Cells 256

40.6 Polarization 257

40.7 Polarization Curves 259

41 Corrosion Prevention and Protection 263

41.1 Proper Design 264

41.2 Choice of Material 265

41.3 Protective Coatings 267

41.4 Changing the Environmental Factors that Accelerate Corrosion 273

41.5 Changing the Electrochemical Characteristic of the Metal Surface 284

42 Corrosion and Corrosion Prevention of Concrete Structures 295

42.1 Concrete’s Chemical Composition 295

42.2 Corrosion Reactions of Concrete 296

42.3 Factors Affecting Corrosion Rate in Reinforced Concrete Structures 296

42.4 Corrosion Measurements in Reinforced Concrete Structures 300

42.5 Corrosion Prevention of Reinforced Concrete 302

43 Corrosion and Corrosion Prevention of Metallic Structures in Seawater 305

43.1 Factors Affecting Corrosion Rate of Metallic Structures in Seawater 305

43.2 Cathodic Protection of Metallic Structures in the Sea 307

44 Corrosion and Corrosion Prevention in Petroleum Industry 309

44.1 Chemicals that Cause Corrosion in Petroleum Industry 310

44.2 Petroleum or Crude Oil Pipeline Systems 314

44.3 Crude Oil or Petroleum Storage Tanks 315

45 Corrosion and Corrosion Prevention in Water Transportation and Storage Industry 317

45.1 Water Pipeline Systems 317

45.2 Cooling Water Systems 319

45.3 Potable Water Tanks 319

45.4 Boilers 319

45.5 Geothermal Systems 322

References 325

Part 4 Questions and Answers

46 Corrosion: Definition and History 341

Questions 341

Answers & Solutions 343

Answer Key 344

47 Corrosion of Materials 345

Questions 345

Answers & Solutions 356

Answer Key 364

48 Cost of Corrosion 365

Questions 365

Answers & Solutions 367

Answer Key 369

49 Factors Influencing Corrosion 371

Questions 371

Answers & Solutions 375

Answer Key 380

50 Corrosion Mechanisms 381

Questions 381

Answers & Solutions 383

Answer Key 386

51 Types of Corrosion 387

Questions 387

Answers & Solutions 409

Answer Key 431

52 Corrosion Prevention 433

Questions 433

Answers & Solutions 467

Answer Key 502

53 Corrosion in Engineering Materials 503

Questions 503

Answers & Solutions 526

Answer Key 548

54 Corrosion and Corrosion Prevention of Concrete Structures 551

Questions 551

Answers & Solutions 564

Answer Key 574

55 Corrosion and Corrosion Prevention of Metallic Structures in Seawater 575

Questions 575

Answers & Solutions 578

Answer Key 580

56 Corrosion and Corrosion Prevention in Petroleum Industry 581

Questions 581

Answers & Solutions 591

Answer Key 601

57 Corrosion and Corrosion Prevention in Water Transportation and Storage Industry 603

Questions 603

Answers & Solutions 610

Answer Key 617

58 Thermodynamics of Corrosion 619

Questions 619

Answers & Solutions 626

Answer Key 633

59 Cathodic Protection 635

Questions 635

Answers & Solutions 648

Answer Key 660

60 Sacrificial Anode or Galvanic Cathodic Protection Systems 661

Questions 661

Answers & Solutions 671

Answer Key 681

61 Impressed Current Cathodic Protection Systems 683

Questions 683

Answers & Questions 693

Answer Key 702

62 Cathodic Protection of Reinforced Concrete Steels 703

Questions 703

Answers & Solutions 707

Answer Key 710

63 Cathodic Protection of Pipeline Systems 711

Questions 711

Answers & Solutions 717

Answer Key 722

64 Cathodic Protection of Crude Oil or Petroleum Storage Tanks 723

Questions 723

Answers & Solutions 726

Answer Key 729

65 Cathodic Protection of Metallic Structures in the Sea 731

Questions 731

Answers & Solutions 737

Answer Key 741

Index 743

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