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Module 3 Corrosion and Electode System (1)
Module 3 Corrosion and Electode System (1)
,
Associate Professor in Chemistry.
MODULE – 3
SYLLABUS:
Corrosion Chemistry:
Introduction, electrochemical theory of corrosion, types of corrosion-differential metal and
differential aeration. Corrosion control - galvanization, anodization and sacrificial anode method.
Corrosion Penetration Rate (CPR) – Introduction and numerical problem.
Electrode System:
Introduction, types of electrodes. Ion selective electrode – definition, construction, working and
applications of glass electrode. Determination of pH using glass electrode. Reference electrode -
Introduction, calomel electrode – construction, working and applications of calomel electrode.
Concentration cell– Definition, construction and Numerical problems.
Analytical Techniques:
Introduction, principle and instrumentation of Conductometry; its application in the estimation of
weak acid. Potentiometry; its application in the estimation of iron.
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BLOW UP SYLLABUS:
CORROSION:
Corrosion of metals is the oxidation of metals to metal compounds by the surrounding
environment through chemical or electrochemical processes.
CLASSIFICATION:
1. Dry corrosion or chemical corrosion
2. Wet or electrochemical corrosion.
Corrosion Reactions:
Anodic Reaction: The electrons liberated at the anodic region migrate to the cathodic region
constituting the corrosion current.
Cathodic Reactions:
(1) Hydrogen type reaction takes place in absence of oxygen
(a) In acidic medium and in the absence of O2 (b) In neutral medium and in the absence of
2H+ + 2e- H2 O2
2H2O + 2e- 2OH-+ H2
(a) In acidic medium and in the presence of O2 (b) In neutral medium and in the
presence of O2
4H+ + O2 + 4e- 2H2O 2H2O + O2 + 4e- 4OH –
Corrosion of iron produces Fe+2 ions and OH- ions at anode and cathode sites respectively.
These ions diffuse towards each other and combine to give insoluble ferrous hydroxide Fe(OH)2
Fe+2 + 2OH- Fe (OH)2
In the presence of limited oxygen, hydrated magnetic oxide (black rust) is formed.
3Fe(OH)2 + ½ O2 Fe3O4 .3H2O
Fe Cu
Fe2+ 2OH-
Anodic site
Cathodic site
Corrosion in a bimetallic couple.
2) DIFFERENTIAL AERATION CORROSION:
Corrosion of metal arising as a result of the formation of an oxygen concentration cell due
to uneven supply of air on the metal surface is known as differential aeration corrosion.
The part of the metal exposed to higher oxygen concentration acts as a cathodic region and
the part of the metal exposed to lower oxygen concentration acts as anodic region.
(a) WATER LINE CORROSION:
i) Area below the waterline is poorly aerated and acts as anode.
ii) The area above the waterline is well aerated and acts as cathode.
iii) Intense corrosion occurs at the anode and reduction of oxygen occurs near the waterline.
Examples:
Water Storage Steel Tank
Cathode part
Anode part
Pitting Corrosion
Eg.:
Less aerated part of the machinery.
Cracks in metals which are not well aerated
GALVANIZATION is a process of coating a base metal surface with Zinc metal. Galvanization is
carried out by hot dipping method.
The galvanization process involves the following steps.
(1)The metal surface is washed with organic solvents to remove organic matter on the surface
(2) Rust and other deposits are removed by washing with dilute sulphuric acid.
(3) Finally it is washed well with water and air-dried.
(4) The article is then passed through NH4Cl flux to increase the surface activity.
(5)Then article is passed through molten zinc, maintained at 450C and then through the flux of
ammonium chloride to prevent the oxidation of molten zinc.
(6)The excess Zinc on the surface is removed by passing through a pair of hot rollers, which wipes
out excess of Zinc coating and produces a thin coating.
Galvanization
Application: Galvanization is used to protect roofing sheets, water pipes, barbed wire, buckets etc.
Galvanized articles are not used for preparing and storing foodstuffs, since Zinc
dissolves in dilute acids producing toxic Zinc compounds.
ANODIZATION OF ALUMINIUM.
i) Aluminium article after degreasing and polishing is used as the anode and a lead plate is used as
the cathode.
ii) The electrolyte is a mixture of chromic acid and sulphuric acid.
iii)Electrolysis is carried out using d. c. at 350 C maintaining the required current density.
iv) The oxygen liberated at the anode increases the thickness of the oxide film on the surface.
and at cathode hydrogen gas is liberated.
Anode: Oxidation 2Al + 3H2O Al2O3 + 6H+ + 6e-
Cathode: Reduction 6H+ + 6e- 3H2
________________________________________
Net reaction: 2 Al + 3H2O Al2O3 + 3H2
_______________________________________
Anodization
v) The strength and corrosion resistance of the anodized film can be increased by the sealing
process.
2) CATHODIC PROTECTION
Cathodic protection is the technique of making the corrosion prone metal to act as a cathode
instead of as an anode by providing electrons from an external source.
a) SACRIFICIAL ANODE METHOD:
i) More reactive metals like zinc, magnesium and aluminium and their alloys when used as
anodes, provide electrons to the corrosion prone objects and convert the anodic sites on them to
cathodic sites.
ii) The sacrificial anodes get corroded and have to be replaced periodically.
iii) The object acts as cathode and does not corrode.
Application: Buried pipe lines, ship hulls, industrial water tanks, steel rods in RCC are protected
by this method.
Advantages:
(1) The method is simple (2) Low installation cost
(3) Minimum maintenance cost (4) Does not require power supply
Disadvantage: Replacement of consumed anodes.
The Corrosion penetration rate is the speed at which any metal or alloy deteriorates
in a specific corrosive environment through chemical or electrochemical reactions.
Mathematically,
CPR= 𝐾𝑊
𝜌𝑋𝐴𝑋𝑡
The CPR is conveniently expressed in terms of either milli-inch per year (mpy) or
millimeters per year (mm/yr)
Where, 1 mili-inch =0.001 inch
Problems:
1. A sheet of carbon steel one meter wide by three meters long has lost 40g to corrosion over the past six
months. Calculate the penetration rate of the steel in mm/yr units and mpy units. (Carbon steel
density=7.8g/cc)
To calculate CPR in mm/yr
CPR= KW/ ρ A t
= 87.6 x 40 x1000/ 7.8 x 3x 100 x 100 x 6 x30 x 24
= 3.466 x 10-3 mm/yr
CPR= KW/ ρ A t
= 534 x 40 x 1000/7.8 x 3x 1550 x 6 x 30 x 24
= 0.1363 mpy
2. A piece of corroded steel plate was found in a submerged ocean vessel, it was estimated that
the original area was 10in2 that approximately 2.6kg had corroded away during the submersion.
Assuming a corrosion penetration rate of 200mpy for this alloy in sea water, estimate the time in
years, density of steel 7.9g/cc.
CPR= 𝐾𝑊 and t= 𝐾𝑊
𝜌𝑋𝐴𝑋𝑡 𝜌𝑋𝐴𝑋𝑐𝑝𝑟
t=87873.41 = 10.03𝑦𝑟𝑠
365𝑋24
3. Calculate the CPR in both mpy and mm/yr for a thick steel sheet of area 100 in2 which
experiences a weight loss of 485g after one year. (density of steel=7.9g/cm3).
CPR= KW/ ρ A t
CPR= KW/ ρ A t
=0.9518mm/yr
ELECTRODE SYSTEM:
Electrode systems are electrochemical systems which contain two or more electrodes.
TYPES OF ELECTRODES:
1) Metal- Metal ion Electrode: It consists of metal in contact with the solution of its own
ions.
Example: Zinc electrode Zn|Zn2+
2) Amalgam Electrode: It consists of metal amalgam in contact with metal ion solution.
Example: Lead amalgam Electrode Pb-Hg|Pb+2
3) Metal- metal salt ion electrode (Metal- insoluble salt electrode): It consist of metal in
contact with a sparingly soluble salt of the same metal dipped in a solution containing anion
of the salt.
Example: Saturated calomel electrode Pt|Hg|Hg2Cl2|KCl(sat)
4) Gas Electrode: It consists of a gas bubbling about an inert metal wire or foil immersed in
a solution containing ions to which the gas is reversible.
Example: Standard hydrogen electrode Pt| H+ (1M) | H2 (1 atm)
6) Ion selective electrodes: Ion selective electrode is the electrode which develops potential due
to the presence of specific ion in a solution containing a mixture of ions.
Ion selective membranes are used in ion selective electrodes. Hence, ISE are also known as
membrane electrodes.
REFERENCE ELECTRODES:
These are the electrodes of constant potential and are used to measure the electrode potential of other
electrodes.
Representation: Pt|Hg|Hg2Cl2|KCl(sat)
Working:
Reduction
The reaction involved is, Hg2Cl2 + 2e- 2Hg + 2Cl-
Oxidation
ION SELECTIVE ELECTRODES: Ion selective electrode is the electrode which develops
potential due to the presence of specific ion in a solution containing a mixture of ions.
Ion selective membranes are used in ion selective electrodes. Hence, ISE are also known as
membrane electrodes.
GLASS ELECTRODE: Glass electrode develops potential due to the presence of H+ ion in a
solution containing a mixture of ions.
Construction:
Glass Electrode consists of a glass bulb of pH sensitive glass membrane sealed onto one end of
glass tube. It contains Ag-AgCl electrode as internal reference electrode. The glass electrode is filled
with 0.1 M HCl solution.
Working:
The reaction involved is, H+(Analyte) + Na+ Gl-(Glass) Na+(Analyte) + H+ Gl-(Glass)
ii) The Eref is the potential developed by Ag- AgCl electrode in contact with 0.1M HCl solution.
iii) E asym is the potential developed due asymmetry of outer surface of glass membrane.
Applications
1) Used to measure pH of the given solution.
2) Specialized glass electrode is used to measure the concentration of sodium.
Working:
Ecell = Ecathode – E anode
E cell= E SCE – Eg
Ecell = ESCE – [E0 g – 0.0591pH]
E cell= 0.2422- E0g + 0.0591 pH
Evaluation of E0g
The above cell assembly is placed in a solution of known pH and emf of the cell is measured
using a potentiometer
E0g = 0.0591 pH + 0.2422 – E cell
Evaluation of Eog is essential since it varies with glass electrode and the reference electrode.
CONCENTRATION CELLS: Two like electrodes immersed in electrolytes containing its own
ions of varying concentrations or two like electrodes at different concentrations dipped in the same
solution of electrolyte constitutes a concentration cell.
Electrolyte concentration cells:
Two like electrodes immersed in electrolytes containing its own ions of varying concentrations
constitutes a concentration cell.
1. The driving force for the cell reaction is the tendency for the solution concentrations to
become equalized.
2. There is transfer of material from a higher concentration to a lower concentration, with
decrease in free energy and electrical energy is derived.
3. Concentration cell is represented as
Ecell= log
Numerical problems:
1. A Concentration cell was constructed by immersing two silver electrodes in 0.05M
and 1M AgNO3 solution. Write the cell representation , cell reactions and calculate
the emf of the cell.
At anode; Ag Ag + (0.05M) + e-
At cathode; Ag + (1M)+ e- Ag
----------------------------------------------------------------------
Net cell reaction , Ag + (1M) Ag + (0.05M)
2. The Spontaneous Galvanic cell Tin | Tin ion (0.024M) ‖ Tin ion (0.064M) | Tin
develops an emf of 0.0126 V at 250C, Calculate the Valency of Tin.
n~ 2 , Valency of Tin is 2
3. The emf of cell Cd |CdSO4(0.0093M) || CdSO4(xM)| Cd is 0.086V at 250C. Find the value of
X.
Solution: n= 2, C2 = x M, C1=0.0093 M
Ecell = 0.086 V
4. Calculate the emf of Copper concentration cell at 25 0 C, where the copper ions ratio
in the cell is 10.
Solution: n= 2, = 10
Ecell = log ,
ANALYTICAL TECHNIQUES:
Eg: Conductometry
Potentiometry
The electrode potential of the indicator electrode, for a redox reaction is given by Nernst’s
equation.
at 25 oC
Where Eo is the standard electrode potential and ‘n’ is the valency of the ions. During
titration, concentration of ions changes. Hence potential of the electrode changes. There is a
sudden change in potential at the equivalence point, when emf is plotted against volume of
the titrant.
The analyte is taken in the beaker and titrant is added from micro burette. Magnetic stirrer
is used to stir the solution.
Micro burette
beaker
Application:
Potentiometric estimation of Mohr’s salt solution using standard potassium dichromate
solution.
Indicator electrode: Platinized platinum foil
Reference electrode: Calomel electrode.
Analyte Solution: Acidified Mohr’s salt solution.
Titrant Solution: Standard potassium dichromate solution.
When a small volume of the oxidant dichromate is added to Mohr’s salt solution, a redox
electrode is set up at the indicator electrode.
Redox electrode: Pt / Fe3+, Fe2+.
Electrode reaction:
2 2 + +
C r2O7 + 14 H+ + 6Fe (aq) 2Cr 3+ + 6Fe3 + 7H2O
(aq) (aq) (aq) (aq)
(Oxidation
numbers) 2(+ 6 ) 6(+2 ) 2(+3 ) 6(+3 )
Electrode potential:
Observations:
1. The e.m.f. is plotted against the volume of the titrant added. The central portion of the S –
shaped curve can be taken as the end point.
e.m.f.
Volume of titrant
V eq
Volume of Titrant
The point of inflection in the curve gives a peak at the equivalence point.
Theory: The resistance (R) of a conductor is directly proportional to the length (L) of
the conductor and inversely proportional to its area of cross section (A).
R = L Where is the resistivity or specific resistance of the material of the
conductor.
A
= AR
L
Reciprocal of resistivity () is called specific conductance or conductivity (K).
K = LC Where conductance, C = 1/R
A
Conductivity (specific conductance) of an electrolyte solution (K) is the electrical conductance of the
electrolyte solution placed between two parallel platinum plates coated with platinum black of area of
Instrumentation:
It consists of a conductivity cell made up of two platinum electrodes and a
conductivity meter. The two electrodes have unit area of cross section and are placed unit
distance apart. The analyte is taken in the beaker and titrant is added from micro burette.
Magnetic stirrer is used to stir the solution.
Micro burette
beaker
QUESTION BANK
BTL L 1 Questions
1. Define the term corrosion.
2. Define metallic corrosion.
3. Define differential aeration corrosion.
4. What is anodic metal coating?
5. What is anodizing?
6. What is cathodic protection?
7. What are reference electrodes?
8. What are Ion selective electrodes?
9. What are Concentration cells ?
BTL L2 Questions
10. Discuss the corrosion of iron based on electrochemical theory.
11. Explain the differential metal or galvanic corrosion with examples.
12. Explain differential aeration corrosion with suitable example.
13. Write a note on galvanization.
14. Explain anodizing of aluminium.
15. Explain sacrificial anode techniques for prevention of corrosion.
16. Discuss the construction, working and applications of calomel electrode.
17. Discuss the different types of electrodes with example.
18. Discuss the Construction and working of glass electrode.
19. Discuss the determination of pH using glass electrode.
20. Write a note on Electrolyte concentration cells.
21. Discuss the theory, instrumentation and application for the estimation of iron using
potentiometry.
22. Discuss the theory, instrumentation and application for the estimation of weak acid
using conductometry.
BTL L3 Questions
23. Explain what type of corrosion occurs when
i) Steel pipe is connected to copper plumbing or Copper nut is in contact with iron
bolt [Differential metal (Galvanic) Corrosion.]
ii) Presence of small dust particles on iron surface for a long time [Differential
aeration.]
(Greater the difference in their positions in galvanic series, faster is the rate of
corrosion at anode. There greater difference in position between Zn and Ag
compared to Zn and Cu in galvanic series.)
ii) The hull of a ship suffers from severe corrosion, when partially dipped in sea
water.( differential aeration corrosion - water line corrosion).
25. Explain why pinholes on tin coated iron are more prone to corrosion than pinholes
on zinc coated iron.
(Galvanization is a anodic (sacrificial) coating where as tinning is a cathodic
coating.)
26. Explain why Galvanized iron sheets are more preferable than tin coated iron sheets.
(Galvanization is an anodic (sacrificial) coating where as tinning is a cathodic
coating.)
27. A sheet of carbon steel one meter wide by three meters long has lost 40g to corrosion
over the past six months. Calculate the penetration rate of the steel in mm/yr units
and mpy units. (Carbon steel density=7.8g/cc)
28. A piece of corroded steel plate was found in a submerged ocean vessel, it was
estimated that the original area was 10in2 that approximately 2.6kg had corroded away
during the submersion. Assuming a corrosion penetration rate of 200mpy for this
alloy in sea water, estimate the time in years, density of steel 7.9g/cc.
29. Calculate the CPR in both mpy and mm/yr for a thick steel sheet of area 100 in2
which experiences a weight loss of 485g after one year. (density of
steel=7.9g/cm3).
30. A Concentration cell was constructed by immersing two silver electrodes in 0.05M
and 1M AgNO3 solution. Write the cell representation , cell reactions and calculate
the emf of the cell.
31. The Spontaneous Galvanic cell Tin | Tin ion (0.024M) ‖ Tin ion (0.064M) | Tin
develops an emf of 0.0126 V at 250C, Calculate the Valency of Tin.
32. The emf of cell Cd |CdSO4(0.0093M) || CdSO4(xM)| Cd is 0.086V at 250C. Find the
value of X.
33. Calculate the emf of copper concentration cell at 250 C, where the copper ions ratio in
the cell is 10.