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Outcomes
Normally aqueous
Anodic reaction normally metal dissolution
Fe => Fe2+ + 2e-
Cathodic reaction normally oxygen or
hydrogen reduction
4e- + O2 => 2O2-
2e- + 2H+ => H2
General Corrosion
General Corrosion
Metal Solution
Anode
m
2+
m
-
e
H2O
O2
Cathode +
H3O
Uniform
Metal may look new - but thinner
Non uniform
Shallow depressions and undulations
What many people call pitting
Not pitting in an electrochemical sense
Pits deeper than wide
Take care with descriptions of corrosion
Refinery Examples
Many locations
Liquid water
Acids or oxygen
Sites of condensation
Crude tower overhead
Exterior corrosion
Walkways
Handrails
Remember
Characteristics
Solution
Zn 2+
Zn
-
e
-
4OH
O2
Cu 2H O
2
Galvanic Series
Example
In galvanic corrosion
Both metals continue to corrode
Anodic metal faster than if no galvanic couple
Cathodic metal slower than if no galvanic
couple
y May approach 0
Rate depends on
Corrosivity of the environment
Separation of metals on EMF or galvanic series
Other factors beyond the scope of the course
Area Effects
Area Effects
Corrosive
Environment
Coating
Control Techniques
Insulating
Washer
Flange
Bolt
Gasket
Flange
Insulating Nut
Sleeve
Crevice Corrosion
Crevice Corrosion
High Oxygen
Low Oxygen
Cathode
Anode
Gasket
Rolling
Grooves
Tube
Sheet
Tube
Crevices Crevices
Example
Drain valve
Environment
H2S, oxygen, chlorides, water
Narrow crevice accelerated attack
Note that the retaining bolts have been
completely corroded
Example
Control Techniques
Water Drop
en
Hig
yg
De xyg
hO
Ox
cr
ea n
xyg
O
h
Hig
sin
en
O
g
e 2+ OH - 2
Fe
Fe2O3
e-
Wet Dirt
rust
Metal Loss
Refinery Examples
Eliminate deposits
Metallurgy upgrade if deposits are corrosion
products
Anti foulant may help for other foulants
Stay within specified fluid velocities
Minimize interfaces
Liquid / vapor etc.
Control Techniques
Baffle Design
Pitting Characteristics
Example
Control Techniques
Understand environment
Avoid material/environment combinations
prone to pitting
If unavoidable or exist in present design watch:
velocity
temperature
cleanliness
Environmental Cracking
Two forms
Specific metal environment interaction
Usually involves marginal passivation of
an active passive metal
Hydrogen charging
Hydrogen from aqueous corrosion
Caustic Cracks
Four forms
Hydrogen blistering (not actually cracking)
Hydrogen induced cracking
Stress oriented hydrogen induced cracking
Sulfide stress cracking
Hydrogen embrittlement
Does not require a blister to initiate as
others do
H0 H+
Void
or H2
Inclusion
H0 H+
H2
H0 H+
S2-
H0 H+
Steel Solution
Hydrogen Blister
H2
H2
H2
Stress Stress
Stress Stress
For steels with hard heat affected zones, crack will be in HAZ