Question

Corrosion Protection List three ways metals can be protected from corrosion.

Short answer

Three ways to protect metals from corrosion are: 1) Barrier Protection, which involves creating a physical barrier between the metal surface and the corrosive environment using coatings or paints; 2) Galvanic Protection, where a more reactive metal is connected to the metal needing protection, resulting in the anodic metal corroding preferentially; and 3) Inhibitors, chemicals that reduce the rate of corrosion by changing the surface properties of the metal or reacting with corrosive agents.

Step-by-step solution

1. Barrier Protection

This method involves creating a physical barrier between the metal surface and the corrosive environment. This can be achieved by using coatings or paints, which act as a barrier to minimize the contact between the metal and the environment. Examples of coatings include epoxy, polyurethane, and zinc-rich coatings. Additionally, wrapping a metal with a corrosion-resistant material can also serve as barrier protection.

2. Galvanic Protection

Galvanic protection, also known as cathodic protection, involves connecting a more reactive (anodic) metal to the metal that needs to be protected (cathode). In this setup, the anodic metal corrodes preferentially, protecting the cathodic metal. Zinc and magnesium are common anodic materials used to protect steel structures. This method is often applied to pipelines, storage tanks, and offshore platforms.

3. Inhibitors

Inhibitors are chemicals that reduce the rate of corrosion by changing the surface properties of the metal or by reacting with the corrosive agents in the environment. They can be added to the environment, such as water or oil, to slow down the corrosive process. Common inhibitors include corrosion inhibitors for water, oil and process systems or volatile corrosion inhibitors which evaporate and form a protective film on the metal surface. Inhibitors are widely used in cooling systems, engines, and industrial processes.

Key concepts

Barrier Protection

Barrier protection is one of the most common methods to prevent metal corrosion. It works by forming a physical obstacle between the metal surface and the external corrosive environment. The primary goal is to prevent direct contact between the metal and corrosive agents like water, oxygen, or chemical compounds.

This can be achieved through the use of coatings or paints. These are applied to the metal surface and act as a shield. Popular types of coatings include:

• Epoxy coatings: These provide excellent adhesion and chemical resistance, making them highly durable.
• Polyurethane coatings: Known for their flexibility and resistance to abrasion and wear.
• Zinc-rich coatings: Not only act as a physical barrier but also provide additional sacrificial protection by sacrificing zinc to protect the metal underneath.

Sometimes, metals can be wrapped with corrosion-resistant materials like plastic films or even metal wrappings, which offer additional protection. By minimizing exposure to the aggressive agents, the longevity of the metal structure is significantly increased.

Galvanic Protection

Galvanic protection, frequently referred to as cathodic protection, is a fascinating method that leverages the properties of metals in an electrochemical setup. The basic idea is to protect the target metal (cathode) by using another more easily corroded "sacrificial" metal (anode). This technique turns the protection process into a smart act of sacrifice.

When you connect the metal you want to safeguard with the sacrificial anode, the anode corrodes instead of the protected structure. Zinc and magnesium are prime examples of sacrificial metals used in this setup, particularly for steel structures. The principle here is that the less noble metal corrodes, thus saving the more valuable component.

This method is particularly effective in applications such as:

• Pipelines: Which often run underground or underwater, where corrosion risks are high.
• Storage tanks: Especially those in contact with variable environmental conditions.
• Offshore platforms: Which face constant exposure to harsh marine environments.

By using galvanic protection, the lifespan of significant metal installations can be extended appreciably, reducing maintenance costs and enhancing safety.

Corrosion Inhibitors

Corrosion inhibitors are special chemicals designed to reduce the corrosion rate when added to a corrosive environment. They work primarily by altering the environment or the metal surface. There are two main ways these inhibitors function:

1. **Passivation**: The inhibitor reacts with the metal surface, forming a protective film that passivates the surface. 2. **Neutralization**: By reacting with corrosive agents, the inhibitor neutralizes their effects, preventing them from interacting with the metal.

These chemicals find widespread use in various systems, including:

• Water systems: Cooling water systems often use corrosion inhibitors to prevent metal corrosion.
• Oil and process systems: Used to protect pieces of equipment where corrosive fluids are prevalent.
• Volatile corrosion inhibitors (VCIs): These are particularly interesting as they evaporate and form a protective layer on metal surfaces exposed to the environment.

Corrosion inhibitors are efficient and essential for prolonging the life of metal parts in many industrial applications, saving money, and avoiding the downtime associated with repairs or replacements.