Corrosion Control Measures Research Articles

An Eco-friendly Mangifera indica Leaves Extract Corrosion Inhibitor for Stainless Steel in Acidic Medium

Corrosion of metals and alloys is one of the most frequent problems encountered in chemical and process industries. Inefficient corrosion control measures typically lead to an increased risk of unplanned downtime, huge economic loss, environmental damage, and health and safety hazards. Hence, it is essential to develop environment-friendly and cost-effective corrosion inhibitors over existing toxic anticorrosive agents. The main objective of this work is to examine the efficacy of eco-friendly ethanolic extract of Mangifera indica leaves (MIL) in different concentrations as a green corrosion inhibitor for stainless steel (SS-316L) under an acidic environment. The inhibition efficiency of Mangifera indica leaves extract in 1 M hydrochloric acid (HCl) was evaluated by conventional weight loss method along with adsorption isotherm analysis. Chemical compounds present in leaf extract and changes in surface morphology of SS-316L samples were assessed using Fourier Transform Infrared spectroscopy (FTIR) and Field Emission Scanning Electron Microscopy (FE-SEM) provided with elemental analysis. The results of the weight loss method revealed that the inhibition efficiency increases with increasing MIL extract concentration due to higher surface coverage. The highest inhibition efficiency of almost 63.43% in 14 days and minimum corrosion rate of 0.433 mm per year was obtained for SS-316 L in 1.0 M HCl with 1000 ppm concentration. The adsorption of MIL extract on SS-316L surface followed Freundlich adsorption isotherm, and the obtained value of free Energy of adsorption (ΔG˚ads = – 9.20 kJ.mol-1) indicates the physical adsorption mechanism. The developed regression-based models can predict the corrosion rate as a function of inhibitor concentration and exposure time with good accuracy (>80%). Thus, the present findings demonstrate that Mangifera indica L. leaves extract can suitably be applied as an inexpensive, non-toxic, biodegradable, efficient green corrosion inhibitor for the protection of stainless steel in acidic media.

ASSESSMENT OF INHIBITORS' PERFORMANCE ON CORROSION DEGRADATION OF CARBON STEEL IN FLOW ENVIRONMENTS USING ROTATING CYLINDER ELECTRODE (RCE)

This study investigates sweet corrosion mitigation methods focusing on the efficacy of inhibitors. Specifically, it examines the performance of two types of inhibitors: water-soluble and oil-soluble. Utilising a Rotating Cylinder Electrode (RCE) setup, turbulence is induced in saline solutions to assess the impact of inhibitors on the corrosion of carbon steel. Scanning Electron Microscopy (SEM) is employed to analyse corrosion degradation patterns and material damage mechanisms. Given the prevalent use of inhibitor injection in the oil sector, it is crucial to evaluate and compare the effectiveness of various inhibitors to recommend optimal options and further studies. The findings contribute to advancing corrosion mitigation strategies, providing insights into the performance of inhibitors in flow environments and aiding in the development of more effective corrosion control measures for carbon steel structures. The inhibitors under study are sourced from local oil company vendors. With a projected duration of six months and a total budget of KD 9850, this investigation aims to provide valuable insights into corrosion mitigation strategies

Mapping soil corrosivity in an Australian arid environment and comparing corrosion rates of exclusion fence netting with different zinc coatings

Exclusion fencing and feral-free nature reserves are a key component of many threatened species recovery strategies in Australia. Soil corrosion damage (rust) sustained on exclusion fence netting can create entry points for feral animal incursions into areas of high conservation value. The use of soil physicochemical data to produce corrosivity risk maps is an approach used by project managers to identify the type of corrosion control measures (e.g. use of galvanised zinc coatings) needed to sufficiently limit the deterioration of buried metal infrastructure. This approach is commonly used in subsoil environments (e.g., underground piping), but very few studies have investigated the corrosivity potential of surfaces soils. This paper used surface soil pH, salinity and texture data collected from 69 field sites to map soil corrosivity potential (i.e., fence corrosion risk) at the Arid Recovery nature reserve in South Australia. The majority (72%) of soils in the reserve were predicted to be moderately corrosive and only 16% were predicted to be highly/very highly corrosive. Standard zinc-aluminium fence netting samples buried at six field sites for 18 months were used to validate map predictions. Zinc corrosion on netting samples at field sites were highly variable, particularly at the highly saline (ECe ≥ 5 dS/m) sites. Maximum predicted zinc corrosion rates were within 1.3 μm/year of measured maximum rates at four of the six sites. The fence corrosion risk mapping method used was able to reliably predict areas of low to moderate fence corrosion, but further research is needed to refine its ability to identify high risk areas. An accelerated corrosion experiment (9-month incubation at 65% WHC and elevated ambient temperatures) was used to assess the relative performance of standard zinc-aluminium (124 g/m2 zinc coating), heavy zinc-aluminium (410 g/m2) and heavy galvanised (650 g/m2) fence netting in different soil environments present on the nature reserve. The standard zinc-aluminium wire coating provided sufficient corrosion-resistance for use in the weakly saline (ECe < 5 dS/m) soils (Rhodic Arenosols, Calcic Chromic Solonetz and Chromic Cambisols). However, the increased corrosion-resistance of the heavy zinc-aluminium is needed in the highly saline (ECe ≥ 5 dS/m) Chromic Luvisol. None of the tested fence products were suitable for use in the highly saline Cambic Calcisols. A more corrosive-resistant alternative such as stainless-steel would be more suited for this very highly corrosive environment. Further research is recommended to confirm the long-term (>5 year) suitability of these products in these different soil types.

Investigation of 3-(1,3-oxazol-5-yl)aniline as a highly efficient corrosion inhibitor for mild steel in 1 M HCl solution

Abstract Mild steel corrosion in acidic environments presents a significant challenge with detrimental consequences for both industrial infrastructure and the environment. Effective corrosion control measures are crucial to prolonging the lifespan of equipment. Inhibition techniques have proven to be an efficient method for protecting mild steel from corrosion, particularly in acidic conditions. This study investigates the efficacy of 3-(1,3-oxazol-5-yl)aniline (3-OYA) as a corrosion inhibitor for mild steel in a hydrochloric acid (HCl) solution. Traditional weight-loss tests, as well as electrochemical techniques, such as potentiodynamic polarization and electrochemical impedance spectroscopy, were employed to evaluate the corrosion inhibition performance. The results reveal that 3-OYA, at a concentration of 0.05 mM, exhibits an outstanding protection efficacy of 93.5%. This remarkable performance can be attributed to the formation of a protective adsorption layer on the mild steel surface, effectively inhibiting the corrosion rate and enhancing inhibitory efficacy. The inhibition efficiency was found to increase with increasing inhibitor concentration, while it decreased with rising temperature. Langmuir adsorption isotherm analysis confirmed the high adsorption–inhibition activity of 3-OYA. The $\Delta {G}_{ads}^o$ value indicated the occurrence of both physical and chemical adsorption mechanisms on the mild steel surface. Furthermore, density functional theory (DFT) calculations were utilized to determine the quantum chemical parameters and establish a correlation between the inhibition activity and the molecular structure. The consistency between the experimental and theoretical analyses reinforces the robustness of our findings.

A review: Research on corrosive sulphur in electrical power equipment

Corrosive sulphur has been commonly regarded as an enormous threat to electrical power equipment in recent decades. Cuprous sulphide (Cu2S) deposition on the insulating oil and paper insulation caused by sulphur corrosion will bring about insulation deteriorations or failures in power transformers and shunt reactors. A large number of experiments have been carried out to investigate sulphur corrosion and some measures have been come up to solve this issue such as replacement of insulating oil, chemical removal of corrosive sulphur and the addition of passivator and so on. However, there has not been a perfect method to work out this problem completely, and the phenomenon of sulphur corrosion still occurs. This paper intends to provide thorough information of corrosive sulphur in power equipment and give detailed explanations about its corrosion mechanism, hazards and control measures, which is supposed to offer a reference for subsequent researchers.

Survey of Lead in Drinking Water from Schools and Child Care Centers Operating as Public Water Suppliers in North Carolina, USA: Implications for Future Legislation.

Few schools and child care facilities test for Pb in their drinking water. Reviewing the United States Environmental Protection Agency Lead and Copper rule data can contribute to guiding future legislation on Pb testing. This work aims to (i) identify variations in Pb levels in North Carolina school and child care drinking water by building age, (ii) evaluate the effect of corrosion control measures on reducing these levels, and (iii) evaluate the adequacy of Pb reporting limits according to modern instrumentation. To achieve these objectives, information on 26,608 water samples collected in 206 North Carolina child centers between 1991 and 2019 has been analyzed. Lead concentrations were above a recently proposed 5 μg/L trigger level in 12.3%, 10.4%, 7.5%, and 0.9% of samples from pre-1987, 1987-1990, 1991-2013, and post-2013 buildings, respectively. Thus, recently proposed legislation requiring testing only for pre-1987 (or pre-1991) buildings will fail to identify all centers at risk. The odds that a greater than 5 μg/L Pb level is detected has been decreasing over the years, with a faster decreasing rate for buildings reporting corrosion control. Over 15% of samples report a method detection limit of 5 μg/L. For accurate results, future legislation should require sub-μg/L detection limits, which are easily achievable with commonly available instrumentation.

Evaluation of Carica papaya leaf extract as a bio-corrosion inhibitor for mild steel applications in a marine environment

In this work, the weight loss technique was used to investigate the use of Carica papaya leaf extract as a bio-corrosion inhibitor for mild steel applications in a marine environment. The tested mild steel was prepared according to the recommended methods, and it consists of the as-received, cold-worked, and annealed samples. Similarly, the biomass extract was prepared according to the recommended techniques, while the authors rely on its physiochemical and phytochemical constituent analysis carried out elsewhere. Before the preparation of the bio-corrosion media, the physio-chemical analysis of the collected marine water sample was analyzed according to a standard method (APHA, 2005). Then, the bio-corrosion medium was prepared by dissolving the solid residue of the Carica papaya leaf extracts in the marine water filtrate solvent at a concentration of 10 grams per liter in a two-liter glass bottles at room temperature. During the incubation period of the experiments, the weight loss of the samples and the pH of the media were measured simultaneously at the interval of seven (7) days for forty-nine (49) days for uninhibited and inhibited conditions. The results showed that the Carica papaya leaf extract is active for the control of bio-corrosion of both untreated and treated mild steel in a marine environment. However, the annealed sample exhibited the most significant resistant to bio-corrosion activities for both conditions. Therefore, the authors strongly recommend that annealing should be carried out as a primary corrosion control measure with biomass inhibition as a secondary measure in the material treatment of mild steel for marine environment applications.

Current state and future perspectives of sewer networks in urban China

Chinese authorities and the public have largely ignored sewer networks; however, various problems are emerging nationwide with the increase construction of new sewers. The current state of sewer network construction, administration, and maintenance in China is comprehensively reviewed in this study. Serving about 444 million people, 511,200 km of sewer lines are located in urban areas. In 2014, $7 billion was invested in sewer network construction. However, both the sewer pervasion rate and the per capita sewer length were significantly lower than those in developed countries. Sewer administrative agencies in local governments are uncoordinated. Laws, regulations, and standards are incomplete, and some practices are unscientific. The future situation of sewer maintenance is extremely grim because sewer corrosion control measures have not been launched. Moreover, inspection and rehabilitation chiefly rely on traditional approaches. In contrast, the overall market share of innovative technologies is very low owing to high cost, funds shortage, and technical limitations. Approaches such as liner inversion cured-in-place pipe, pull-in ultraviolet light cured liners, and spiral wound lining are applied mostly in economically developed regions. According to status and problem analyses, China’s top priority will be to conduct aggressive maintenance work in sewer networks in the future. New technical route, corrosion control - periodic visualized inspection - trenchless rehabilitation, could be the best option for future sewer maintenance in China. Instructions and opportunities for applying this technical route are discussed in detail in this study. Finally, additional factors in the development of sewer networks in China are suggested.

Corrosion Control and Mitigation Measures for H2S and Cl2 at the Black Creek Pumping Station

Corrosion Control and Mitigation Measures for H₂S and Cl₂ at the Black Creek Pumping Station

South Australia Water Corporation’s Pro-active Corrosion and Odour Management Strategy Development

This paper describes a process for the selection of sewer corrosion and odour control measures for South Australia Water Corporation (SA Water). SA Water engaged CH2M and the Advanced Water Management Centre (AWMC) to apply the knowledge, tools and practices developed as part of the Sewer Corrosion & Odour Research (SCORe) project to support strategic decisions for cost-effective odour and corrosion management of five catchments in the Adelaide Metro area. This paper provides details of the development of the sewer odour and corrosion management strategy for the Ethelton catchment.

Cyclic Deformation Behavior and Buckling of Pipeline With Local Metal Loss in Response to Axial Seismic Loading

Buried pipelines may be corroded, despite the use of corrosion control measures such as protective coatings and cathodic protection, and buried pipelines may be deformed due to earthquakes. Therefore, it is necessary to ensure the integrity of such corroded pipelines against earthquakes. This study has developed a method to evaluate earthquake resistance of corroded pipelines subjected to seismic motions. Pipes were subjected to artificial local metal loss and axial cyclic loading tests to clarify their cyclic deformation behavior until buckling occurred under seismic motion. As the cyclic loading progressed, displacement shifted to the compression side due to the formation of a bulge. The pipe buckled after several cycles. To evaluate the earthquake resistance of different pipelines with varying degrees of local metal loss, a finite-element analysis method was developed that simulates cyclic deformation behavior. A combination of kinematic and isotropic hardening was used to model the material properties. The associated material parameters were obtained by small specimen tests that consisted of a monotonic tensile test and a low-cycle fatigue test under a specific strain amplitude. This method enabled the successful prediction of cyclic deformation behavior, including the number of cycles required for the buckling of pipes with varying degrees of metal loss.

Metal Corrosion Problems and Countermeasures in High Conductivity of Circulating Water

Objective: Through the test of air conditioning cooling water circulation system and the electrical conductivity of iron corrosion velocity, find out the method of corrosion control measures; Methods: Rotating hanging plate method and conductivity meter and other cooling water test air conditioning system in different conductivity of metal iron corrosion rate; Conductivity results: Air-conditioning cooling water circulation system of more than 1900 μs/cm, metal corrosion rate less than 0.05mm/a, shall meet the relevant standards. Conclusion: Through the addition of corrosion inhibitor, scientific emission and control of circulating cooling water pH, conductivity decreased circulating water cooling, can reduce the corrosion of iron, to ensure the safe and stable operation of cooling water pipe and equipment.

Controlling copper corrosion in new construction by organic matter removal

A new elementary school with persistent elevated copper corrosion by‐product release evaluated pH increase, orthophosphate dosing, and granular activated carbon (GAC) treatment as potential corrosion control measures using bench‐scale experiments. Removal of natural organic matter (NOM) with temporary GAC treatment facilitated the formation of a copper scale with a permanently diminished (&gt; 85%) solubility via an accelerated natural scale‐aging process. Increasing the pH and adding a high dose of orthophosphate were also effective for decreasing copper release but presented significant long‐term drawbacks, and their benefits were reversed if the treatments were discontinued. Temporary GAC treatment may be a holistically attractive option to reduce copper corrosion problems in new construction in certain waters with high levels of NOM.

Investigation of Soil Aggressiveness towards Underground Fuel Storage Tanks and Water Pipelines in Parts of Bayelsa State, Southern Nigeria

Structural failure of buried cast/ductile iron water mains and tanks due to corrosion attacks manifests in leaks and is common in most cities throughout Nigeria. The appropriate corrective action, which aims to restore pipe/tank integrity is usually based on proper understanding of the degree of corrosiveness of the soil. In an attempt to determine the potential corrosiveness of the soil to buried metallic structures in Bayelsa State, surface geoelectrical sounding was carried out. Twenty-five Schlumberger Vertical Electrical Soundings (VES) was carried out in the freshwater and meander belt geomorphic zone and the salt water mangrove swamp and estuary complex of the state using a maximum current electrode separation ranging from 200 - 400 m. The data obtained was interpreted by computer iterative modeling using a 1D inversion technique software (1X1D, Interpex, USA). The results show a high degree of heterogeneity, both laterally and vertically, which is typical of a complex depositional environment. Generally, the sub-soil condition within the expected depth of installation of water mains and storage tanks (0 - 10 m) is slightly or moderately aggressive (effective aggressivity) in the freshwater and meander belt geomorphic zone but is very strongly aggressive in the salt water mangrove swamp and estuary complex. Corrosion cells which may lead to significant corrosion failures may occur in the vicinities of strongly aggressive stations. This poses a significant corrosion risk to metallic water pipes and storage tanks. Current day design should therefore either mandate the use of a non-metallic piping product (water mains) or cathodic protection system. Prediction of potential corrosiveness of a soil and thus the application of proper corrosion control measures will not only protect the environment from spillages but will also avert cost of repair, clean-up and replacement.

A thermodynamic rationalisation for the oxidising behaviour of concentrated H2SO4

AbstractAn attempt is made to extend the principle of equilibrium electrochemical potential–pH diagrams for sulfur compounds in dilute aqueous solutions of sulfuric acid (H2SO4) to more concentrated aqueous solutions up to 100 wt.%. Published Hammett acidity data is used to account for the medium effect (undissociated H2SO4) on the proton activity. The calculated electrochemical potential‐Hammett acidity diagrams predict a thermodynamic stability domain for all three of the reduction products experimentally observed during cathodic electrolysis, which included sulfur dioxide (SO2), sulfur (S), and hydrogen sulfide (H2S). The implications of the relative stability domains on corrosion control measures are discussed.

Corrosion Control Inside Water-filled Steel Fire Sprinkler Piping

This article is a guide for sprinkler contractors, facilities managers, and their technical advisors who sometimes have to deal with the consequences of iron-water corrosion inside pressurized, low-carbon steel fire protection systems that contain water. The consequences include: (1) pinhole leaks and (2) build-up of insoluble corrosion residues on the interior pipe wall that increases pipe friction losses. A reference is made to sections of the National Fire Codes/NFPA 13 that address pipe materials, protection of steel piping against corrosion, and pipe friction losses. Electrochemical metal-water corrosion processes that can occur inside pressurized, low-carbon steel fire protection systems that contain water are discussed, as is microbiologically influenced corrosion. Corrosion control measures arising from the electrochemical science underlying both metal-water corrosion and microbiologically influenced corrosion are suggested.

Evaluation of Deoxygenation as a Corrosion Control Measure for Ballast Tanks

Abstract Field experiments designed to evaluate deoxygenation of natural seawater as a corrosion control measure for unprotected carbon steel seawater ballast tanks demonstrated decreased corrosion in hypoxic (<0.2 ppm O2) seawater using linear polarization measurements. They also demonstrated the difficulty of maintaining hypoxic seawater. Using a gas mixture it was possible to displace dissolved oxygen. However, aerobic respiration and corrosion reactions consumed oxygen and produced totally anaerobic conditions within the first days of hypoxia. When gaskets and seals failed, oxygen was inadvertently introduced. The impact of oxygen ingress on corrosion depends on the amount of oxygen in the system at the time oxygen is introduced. Carbon steel exposed to cycles of hypoxic seawater and oxygenated atmosphere had higher corrosion rates than coupons exposed to cycles of either consistently aerobic or deoxygenated conditions.

Assessing the impact of corrosion control measures on tap drinking water of the Greater Vancouver Regional District

A study on the quality of water distributed within the Greater Vancouver Regional District (GVRD) was carried out to evaluate the effectiveness of previously implemented corrosion controls. In addition, the effect of temperature fluctuations was investigated to determine if it influenced the efficacy of the control measures. The GVRD was divided into four distribution areas. The Capilano water had no corrosion control treatment. Seymour, Coquitlam, and Newton waters were treated with soda ash, resulting in a pH of 6.8, 6.9, and 8.1, respectively. Standing cold water and running hot and cold water samples were collected from the four zones and analyzed for lead, copper, and zinc concentrations. The source water did not influence the amount of lead at the tap. The source water did influence the amount of copper and zinc at the tap. The highest copper and zinc concentrations were found in the water with the lowest pH (Capilano) and the lowest concentrations in the water with the highest pH (Newton). Seasonal temperature fluctuations of distributed GVRD water did not affect the metal concentrations in the water.Key words: corrosion control, GVRD drinking water, copper, lead, zinc, pH adjustment.

A review of differing approaches used to estimate the cost of corrosion (and their relevance in the development of modern corrosion prevention and control strategies)

PurposeTo analyze the different approaches used to estimate the cost of corrosion and understand the limitations so as to have proper appropriation in future appraisals.Design/methodology/approachFour well‐known approaches to analysis of cost of corrosion viz., the Uhlig method, the Hoar method, NBS‐BCL input/output method and net present value method have been considered in great detail and the impact of these approaches on corrosion economy in different countries has been highlighted.FindingsUhlig method of estimating corrosion cost always gives a conservative estimate of the direct cost of corrosion. The direct cost of corrosion, as estimated by the Hoar method, is found to be somewhat higher than is the estimate made using the Uhlig method, as shown by Shibata of Japan. The NBS‐BCL method of input/output analysis, though apparently more scientific, is subject ultimately to uncertainties in quantifying the capital cost and intermediate output. The net present value method appears to be more realistic than do other approaches as it enables a life cycle costing of each structure/facility to be made and arrives at the most cost‐effective corrosion control method. Even though all the above four approaches enable an estimation of direct cost of corrosion, there is no standard approach to assess the indirect cost of corrosion.Originality/valueIn a developing economy, each and every industry has to go for systematic corrosion auditing in order to identify and adopt the most appropriate corrosion control measures and effect considerable savings. This paper would be of immense use in that regard.

New polish for Institute of Corrosion

The UK's Institute of Corrosion is (IC) launching a ”new look” in a bid to encourage new members. The IC will be seeking to promote sound corrosion management practice, the advancement of cost-effective corrosion control measures, and a sustained effort to raise awareness at all stages of design and manufacture. It estimates that corrosion costs the UK 4 per cent of GNP every year. This is a short news story only. Visit www.metal-powder.net for the latest powder metallurgy industry news.