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Chapter
12
Anodic Protection
121 Inroduetion
122 Passity of Metals
123 Equipment Required for Anodle Protection
1231 Cathode
12.22 Reference electrode
12.2. Potential control and power supply
124 Design Concerns
125 Applications
126 Practical Example: Anode Protection Inthe Pulp and
Paper industry
References
88 geese ges
12.1. Introduction
In contrast to cathodic protection, anodic protection is relatively new.
Edeleanu first demonstrated the feasibility of anodic protection in 1954
and tested it on small-scale stainless steel boilers used for sulfuric acid
solutions. This was probably the first industrial application, although
other experimental work had been carried out elsewhere.’ This tech-
nique was developed using electrode kinetics principles and is some-
what difficult to describe without introducing advanced concepts of
electrochemical theory. Simply, anodic protection is based on the for-
mation of a protective film on metals by externally applied anodic cur-
rents. Anodic protection possesses unique advantages. For example,
the applied current is usually equal to the corrosion rate of the pro-
tected system. Thus, anodic protection not only protects but also offers
a direct means for monitoring the corrosion rate of a system. As an922 Chapter Twelve
enthusiast and famous corrosion engineer claimed, “anodic protection
can be classed as one of the most significant advances in the entire his-
tory of corrosion science.”*
Anodic protection can decrease corrosion rate substantially. Table 12.1
lists the corrosion rates of austenitic stainless steel in sulfuric acid solu-
tions containing chloride ions with and without anodic protection.
Examination of the table shows that anodie protection causes a 100,000-
fold decrease in corrosive attack in some systems. The primary advan-
tages of anodic protection are its applicability in extremely corrosive
environments and its low current requirements. Table 12.2 lists several
systems where anodic protection has been applied successfully.
Anodie protection has been most extensively applied to protect equip-
ment used to store and handle sulfuric acid. Sales of anodically pro-
tected heat exchangers used to cool H,SO, manufacturing plants have
represented one of the more successful ventures for this technology.
‘TABLE12.1_Anodie Protection of $30400 Stainless Steel Exposed to
‘an Aerated Sulfuric Acid Environment at 30°C with and without
Protection at 0.500 V ve. SCE
osion Fate
NaClM Unprotected Protected
10 "360 068
10-4 4 11
10" 81 51
10" 49,000 oan
10 29,000, 10
10 2,000 53
TABLE 122 Current Requirements for Anodic Protection
Topasiate, Tomaintan,
180 ‘Temperature, °C mam
1M 2 23
15% 24 oa
06 24 ost
45% 6 180
6% 24 5a.
8% 24 ost
8% 24 Nos020 0.43,
93% 24 Mild steel 0.28
9.9% (oleum) 24 Mild steel 4.7
HPO,
Ta 24 Mild steel 41
115% 82
NaOH
2066 24Anodic Protection 923,
‘These heat exchangers are sold complete with the anodic protection
systems installed and have a commercial advantage in that less costly
materials can be used. Protection of steel in H,SO, (~> 78% concentra-
tion) storage vessels is perhaps the most common application of anodic
protection. There is little activity directed toward developing applica-
tions to protect metals from corrosion by other chemicals.’
Anodic protection is used to a lesser degree than the other corrosion
control techniques, particularly cathodic protection. This is mainly
because of the limitations on metal-chemical systems for which anodic
protection will reduce corrosion. In addition, it is possible to accelerate
corrosion of the equipment if proper controls are not implemented.
However, anodic protection has its place in the corrosion control area,
provided some important basics are respected.
12.2. Passivity of Metals
‘The passivation behavior of a metal is typically studied with a basic
electrochemical testing setup (App. D, Basic Electrochemical
Instrumentation). When the potential of a metallic component is con-
trolled and shifted in the more anodic (positive) direction, the current
required to cause that shift will vary. If the current required for the
shift has the general polarization behavior illustrated in Fig. 12.1, the
metal is active-passive and can be anodically protected. Only a few
systems exhibit this behavior in an appreciable and usable way. The
corrosion rate of an active-passive metal can be significantly reduced
by shifting the potential of the metal so that it is at a value in the pas-
sive range shown in Fig. 12.1. The current required to shift the poten-
tial in the anodie direction from the corrosion potential E.,,. can be
several orders of magnitude greater than the current necessary to
maintain the potential at a passive value. The current will peak at the
passivation potential value shown as E,, (Fig. 12.1)
‘To produce passivation the critical current density (i,.) must be
exceeded. The anodic potential must then be maintained in the passive
region without allowing it to fall back in the active region or getting into
the transpassive region, where the protective anodic film can be dam-
aged and even break down completely. It follows that although a high
current density may be required to cause passivation (> i,), only a small
current density is required to maintain it, and that in the passive region
the corrosion rate corresponds to the passive current density (i,).
‘The relative tendency for passivation is strongly dependent on the
interactions between a metal and its environment. The passivation
behavior can vary extensively with changes in either. Figure 12.2 illus-
trates how the sensitization of a $30400 stainless steel, for example,
can affect its passivation behavior when exposed to sulfuric acid.*924 Chapter Twelve
‘passive current)
|
Oxygen evolution
‘tans passive
passive
‘ge (ctiteal current)
Potential
—.,
(passivation
Potential)
cot
(corrosion potentia)
Log (Current density)
Figure 12.1 Hypothetical polarization diagram for a passivable system with active, pas-
sive, and trangpansive regions.
Among the parameters that are particularly affected by sensitization
are i, and i, as defined in Fig. 12.1. In this example, the ability to sus-
tain passivity increases as the current density to maintain passivity
((,) decreases and as the total film resistance increases, as indicated
from measurements obtained with different metals exposed to 67%
sulfuric acid (Table 12.3). The lower or more reducing the potential at
which a passive metal becomes active, the greater the stability of pas-
sivity. The depassivation potential corresponding to the passive-active
transition, called the Flade potential, can differ appreciably from Ey,
measured by going through the active-passive process of the same sys-
tem. This technical distinction is important for the control aspect of
anodic protection where Ey, is the potential to traverse to obtain pas-
sivation, and the Flade potential is the potential to avoid traversing
back into active corrosion.
Passivity can also be readily produced in the absence of an externally
applied passivating potential by using oxidants to control the redox
potential of the environment. Very few metals will passivate in nonoxi-
dizing acids or environments, when the redox potential is more cathodic
than the potential at which hydrogen can be produced. A good example
of that behavior is titanium and some of its alloys, which can be readily
passivated by most acids, whereas mild steel requires a strong oxidizingAnodic Protection 925,
5
No senstizaton
\
8
oan
8
Potertial (mY vs. SHE)
8
8
Log Current density (uA em*)
Figue 12, Anodic polarization curves of $9040 tel in 1M H,SO, at 99°C aor sen
agent, such as fuming HNO, for its passivation. Alloying with a more
easily passivated metal normally increases the ease of passivation and
lowers the passivation potential, as in the alloying of iron and chromium
in 10% sulfuric acid (Table 12.4). Small additions of copper in carbon
steels have been found to reduce ip in sulfuric acid. Each alloy system has
to be evaluated for its own passivating behavior, as illustrated by the
case Ni-Cr alloys where both the additions of nickel to chromium and
chromium to nickel decrease the critical current density in a mixture
of sulfuric acid and 0.25 M K,SO, (Table 12.5).!
‘The parameters defining and controlling the passivation domain of
a system are thus directly related to the composition, concentration,
purity, temperature, and agitation of the environment. ‘This is illus-
trated with the current densities required to obtain passivity (j,.), and
to maintain passivity (i,), for a 30400 steel in different electrolytes,
as presented in Table 12.6. From the data in this table, it can be seen
that it is approximately 100,000 times easier to passivate large areas
of this steel in contact with 115% phosphoric acid than in 20% sodium
hydroxide. The concentration of the electrolyte is also important, and
for a 31600 steel in sulfuric acid, although there is a maximum cor-
rosion rate at about 55%, the critical current density decreases pro-
gressively as the concentration of acid increases (Table 12.7).926 Chapter Twelve
TABLE 123 Current Density to Maintain Passivity and Film
Resistance of Some Metals in 67% Sulfurie Acid
Siealorally Ip phen? Filmresistance Mivem
‘Mild steel 150 0.026
S20400 steel 22 050
S21000 steel 05 21
21600 steel 0.1 175.
Titanium 0.08 175
Nos020 0.03 46
‘TABLE124 Effect on Critical Current Density
‘and Passivation Potential of Chromium Content
{or ron-Chromium Alloys in 10% Sulfuric Acid
Thommen > Ay, Ven SHE
° 1000 ross
28 360 0.58
a7 340 10.35
95 7 Fos
uo 19 0.03
TABLE 125. Effect on Critical Current Density and
Passivation Potential on Alloying Nickel with Chromium
nO Mand 5 MH-S0, Containing 0.25 Ml K:SO,
Nis _igymAcm™? Epp, V VS. SHE
05M osm
io 100 v0.36
a 0.95 $0.06
a on 082 4007
49 0020 020 40.03
27 oo12 0041 +002
10 0.0013 oon }0.04
1 1050-032
° 1580-030
‘The presence in the environment of impurities that retard the for-
mation of a passive film or accelerate its degradation is often detri-
mental. In this context, chloride ions can be quite aggressive for
many alloys and particularly for steels and stainless steels. As an
example, the addition of 3% HCI hydrochloric acid to 67% sulfuric
acid raises the critical current density for the passivation of a $31600
stainless steel from 0.7 to 40 mA-cm~ and the current density to
maintain passivity from 0.1 to 60 pA-cm *. Therefore, the use of the
calomel electrode in anodic-protection systems is not recommended
because of the possible leakage of chloride ions into the electrolyte,Anodic Protection 927
‘ABLE126 Critical Current Density and Current
Density to Maintain Passivity of §30400 Stainless
TamAca? ip hem
20% NaOH 465 99)
67% H,S0,24°0) 0.51 0.093
LiOH (pH ~ 9.5) 008 0.022
80% HNO; (24°C) 0.0025 0031
T15%HPO,(24°C) 0.000015 0.00015
and metal/metal oxide and other electrodes are often preferred.
Because of this chloride effect the storage of hydrochloric acid
requires a more passive metal than mild steel, and titanium anodi-
cally protected by an external source of current or galvanic coupling
has been reported to be satisfactory although even this oxide film has
sometimes been found to be unstable."
‘An increase in the temperature of an electrolyte may have several
effects. An increase in temperature may make passivation more diffi
cult, reduce the potential range in which a metal is passive, and
increase the current density or corrosion rate during passivity as indi-
cated in Fig. 12.3 for mild steel in 10% H.SO,.! Note the magnitude of
the critical current density that is slightly higher than 10 mA‘em
Such a high current density requirement creates a problem in practical
anodic protection systems where the surfaces to be protected can be
quite large.
12.3 Equipment Required for Anodic
Protection
Figure 12.4 shows a schematic of an anodic protection system for a
storage vessel. Some of the basic properties required of the compo-
nents of an anodic system are described here.2000
1600
Potential (mV vs. SHE)
8
500
1000
200 150 100 050 00 os 100 150 200 280
Log Current density (mA om*)
Figure 123. Forward and backward potentiostatie anodic polarization curves for mild
Steelin 106 sulfarie acid at 22 and 60°C.
Hastetoy
cathode
vighigsoa—
reference electrode Power
‘supply
/
Sulfuric acid
N
Figure 124 Schematic of an anodie protection system for a sulfuric aid storage vesselAnodic Protection 929
12.3.1 Cathode
‘The cathode should be a permanent-type electrode that is not dis-
solved by the solution or the currents impressed between the vessel
wall and electrode. The cathodes used in most of the first applications
of anodic protection were made of platinum-clad brass. These elec-
trodes were excellent electrochemically but were costly, and the active
area contacting the solution was limited by this cost. Because the over-
all resistance is a direct function of current density, itis advantageous
to use large surface area electrodes. Many other, less costly metals
have been used for cathodes instead of these costly materials. Some of
these metals are listed in Table 12.8 with the chemical environments
in which they were used.*® The electrode size is chosen to conform to
the geometry of the vessel and to provide as large a surface area as
possible. The location of the cathode is not a critical factor in simple
geometry, such as storage vessels, but in heat exchangers, it is neces-
sary to extend the electrode around the surface to be protected.
Multiple cathodes can be used in parallel to distribute the current and
to decrease circuit resistance.
12.32 Reference electrode
Reference electrodes must be used in anodic protection systems
because the potential of the vessel to be protected has to be carefully
controlled. The reference electrode must have an electrochemical
potential that is constant with respect to time and that is minimally
affected by changes in temperature and solution composition. Several
reference electrodes have been used for anodic protection, including
those listed in Table 12.9." The reference electrode has been a source
of many problems in anodic protection installations because of its
fragile nature.
Platinum-clad brass Sulfuric acd of various concentrations
Steel Kraft pulping liquor
Chromium nickel steel Hy8O, 78-105%)
Silicon east iron 80, (89-105)
Copper Hydroxplamine sulfate
20100, Liquid fertilizers (nitrate solutions)
Sulfurie acid
Nickel-plated steel Chemical nickel plating solutions
Hastelloy © Liquid fertilizers (nitrate solutions)
Sulfur acid of various concentrations
Kraft digester liquid990 Chapter Twelve
‘TABLE129_ Reference Electrodes Used for Anodic
Protectir
[actos
Calomel __Sulfurie aid of various concentrations
Kraft digester
Ag/AgCl Sulfur acd, fresh or spent
Kraft solutions
Fertilizer solutions
Sulfonation plant
HygHgSO, HsS0,
Hydroxylamine sulfate
PuPLo H,S0,
‘AvlAud Alcohol solution
Mo‘Mo0; Sodium earbonate solutions
Kraft digester
Green of black liquors
Platinum = H,SO,
Bismuth NH,OH.
531600 steel Fertilizer solutions
H,S0,
Nickel Fertilizer solutions
Nickel plating solutions
Silicon Fertilizer solutions
12.3.3 Potential control and power supply
‘The de power supplies used in anodic protection systems have similar
design and requirements as the rectifiers for cathodic protection, with
one exception. Because of the nature of the active-passive behavior of
the vessel, the currents required to maintain the potential of the ves-
sel wall in the passive range can become very small. Some designs of
de power supplies must be specially modified to reduce the minimum
amount of current put out of the power supply.*
‘The potential control in anodic protection installations has two func-
tions. First, the potential must be measured and compared to a desired
preset value. Second, a control signal must then be sent to the power sup-
ply to force the de current between the cathode and vessel wall. In early
systems, this control function was done in an ON-oFF method because of
the high costs of electronic circuitry. The recent progress in power elec-
tronics has resulted in all systems having a continuous proportional-type
control.’ Packaging these electronic components occasionally involves
special requirements because most of the installations are made in
chemical plants. Explosion-proof enclosures are sometimes required, and
chemically resistant enclosures are necessary in other installations.
12.4. Design Concerns
Designing an anodic protection system requires knowledge of the basic
electrochemical behavior of the system and of the geometry of the‘Anodic Protection 931
equipment to be protected, considering any special operational condi-
tions. As described earlier, the electrochemical parameters of concern
are the potential at which the vessel must be maintained for corrosion
protection, the current required to establish passivity, and the current
required to maintain passivity. The electrode potential can be deter-
mined directly from polarization curves, and the required currents can
be estimated from the polarization data. However, because the current
is so strongly time dependent, its variations with respect to time must
be carefully estimated. Empirical data available from field installations
are the best source for this type of information.
Special care and attention should also be focused on estimating the
solution resistivity of a system because it is important in determining
the overall circuit resistance. The power requirements for the de power
supply should be as low as possible to reduce operating costs. The
solution resistivity should usually be sufficiently low so that the cir-
cuit resistance is controlled by the cathode surface area. It is essen-
tial for a system to have good throwing power or good ability for the
applied current to reach the required value over complex geometry
and variable distances. In general, a uniform distribution of potential
over a regular-shaped passivated surface can be readily obtained by
anodic protection. It is much more difficult to protect surface irregu-
larities, such as the recessions around sharp slots, grooves, or crevices
because the required current density will not be obtained in these
areas. This incomplete passivation can have catastrophic conse-
quences. This difficulty can be overcome by designing the surface to
avoid these irregularities or by using a metal or alloy that is easily
passivated with as low a critical current density as possible. In the
rayon industry, crevice corrosion in titanium has been overcome by
alloying it with 0.1% palladium.
‘The actual passivation of a surface is very rapid if the applied cur-
rent density is greater than the critical value. However, because of the
high current requirements, it has been found to be neither technically
nor economically practical to passivate the whole surface of a large
vessel in the same initial period. For a storage vessel with an area of
1000 m®, for example, a current of 5000 A could be necessary. It is
therefore essential to avoid these very high currents by using one of a
few techniques. It may be possible and practical, for example, to lower
the temperature of the electrolyte, thereby reducing the critical cur-
rent density before passivating the metal. Ifa vessel has a very small
floor area, it may be treated in a stepwise manner by passivating the
base, then the lower areas of the walls, and finally the upper areas of
the walls, but this technique is not practical for very large storage
tanks with a considerable floor area.t
Another method that has been successful is to passivate the metal by
using a solution with a low critical current density (such as phosphoric992 Chapter Twelve
acid), which is then replaced with the more aggressive acid (such as sul-
furic acid) that has to be contained in the vessel (cf. Table 12.6). The crit-
ical current density can also be minimized by pretreating the metal
surface with a passivating inhibitor.
12.5 Applications
Anodie protection has been used for storage vessels, process reactors,
heat exchangers, and transportation vessels that contain various cor-
rosive solutions. The majority of the applications of anodic protection
involve the manufacture, storage, and transport of sulfuric acid, more
of which is produced worldwide than any other chemicals. Storage of
93% H,SO, and above in low-carbon steel vessels has met with some
success in terms of vessel life. Anodie protection has been successful in
reducing the amount of iron picked up during storage. Field studies
have shown that the iron content of H,SO, in concentrations of 93%
and above increases at rates of 5 to 20 ppm per day of storage, depend-
ing on acid concentrations vessel size, acid residence time, and storage
temperature. Several anodic protection systems have been successful
in reducing the rates of iron pickup to 1 ppm per day or less. The level
of purity of the acid has been sufficient to meet market demands for
low iron content acid. Sulfuric acid will continue to pick up iron dur-
ing transportation in trucks, railroad cars, and barges. Portable anodic
protection has been used for such vessels to maintain the purity of the
acid and to extend storage time.*
lange market has developed for anodically protected heat exchang-
ers as replacements for cast iron coolers. Shell and tube, spiral, and
plate-type exchangers have been sold complete with anodie protection
as an integral part of the equipment. Sulfuric acid of 96 to 98% con-
centration at temperatures up to 110°C has been handled in S31600
stainless steel heat exchangers by the use of anodic protection.
Corrosion rates have been reduced from unprotected rates of more
than 5 mm-y-* to less than 0.025 mm-y-, and cost savings have been
substantial because of extended equipment life and the higher-purity
acid that was produced by using these protected heat exchangers.
Several other corrosive systems have also been handled in anodically
protected heat exchangers.’
‘One consequence of reducing the rate of corrosion of steel in an acid
is also to reduce the production of hydrogen, which has been reported
as the cause of explosions in phosphoric acid systems. ‘The presence of
hydrogen may also induce the formation of blisters at inclusions in the
metal and can also produce grooving on vertical surfaces. Anodic pro-
tection has been found to significantly stifle the formation of hydrogen,
therefore minimizing such problems.Anodic Protection 933,
12.6. Practical Example: Anodic Protection
in the Pulp and Paper Industry
Anodic protection is a powerful technique used to mitigate corrosion of
liquor tankage. However, the electrochemistry of Kraft liquors is com-
plex due to the multiple oxidation states of sulfur compounds, the
number of possible Fe-S-H.O reactions, and the existence of active-
passive behavior. The electrochemical behavior may be further com-
plicated because some Fe-S compounds are semiconductors.* ‘The
major sulfur species in Kraft liquors are listed in Table 12.10.
Anodic protection of a Kraft liquor tank was first successfully real-
ized at the end of 1984, and the success of this system resulted in
many commercial installations. Unfortunately, unexpectedly high cor-
rosion rates were reported at localized areas in several of the tanks
even though the remainder of the surfaces corroded at rates less than
0.13 mm-y-! Most of the problems experienced have been attributed
to incomplete understanding of the electrochemistry of carbon steel! in
these liquors and the coexistence of active and passive areas, which
had not been addressed properly in earlier control strategies.
‘Tromans deduced an elegant yet simple model of passivation in
caustic sulfide that explains the role of sulfide in the process.”
According to Tromans, after the initial nucleation of Fe;O,, sulfide is
incorporated as substitutional ions into the Fe,0, spinel lattice, form-
ing a nonprotective compound Fe,O-x8x. At the peak of the active-pas-
sive transition, Tromans predicted x to be approximately 0.19. Because
passivation cannot occur until the sulfide in the film is completely
removed by oxidation, high current densities are required to force this
reaction. However, once devoid of sulfide, the film can remain stable if
the potential is kept more positive than the Flade potential corre-
sponding to the reduction reaction of oxidized sulfur species such as
S,0,"" and $=
Figure 12.5 depicts one anodic and four cathodic idealized polariza-
tion curves, including the possible intersection points. The number and
location of the intersection points creates four types of behavior,
namely, monostable (active), bistable, astable, and monostable (pas-
‘TABLE12.10 Major Sulfur Species in Kraft Liquors
Species Symbol Sulfur valence
Sulfate (SOF)
(80;)
‘Thinsulate (8,0,?-)
Sulfur S.
ide $2
s994 Chapter Twelve
200
200
Monastabi ate
200
200
a as 2 is 4 vs OBC
Log current density (mA em")
Figure 125 Possible combinations of anodiclcathodie intersections in the mixed poten-
fial representation of earbon steel exposed to Kraft liquors,
sive). A potentiodynamic curve of each of these types of behavior is
shown, respectively, in Figs. 12.6 through 12.9. Astable behavior occurs
infrequently because it requires a single anodic-cathodic intersection
on the negative resistance portion of the anodic curve. This is an unsta-
ble operating condition that results in continuous oscillations between
active and passive potentials. Various alloys in elevated temperature
sulfuric acid are known to exhibit such behavior:®
‘The four types of mixed potential models presented in Figs. 12.6 to
129 are simplistic and do not necessarily reflect the complete behav-
ior of carbon steel in Kraft liquors because the models all assume some
sort of steady states. Figure 12.10 depicts typical curves from an in
situ test in a white liquor clarifier at different scan rates. The passive
state does not exist until after the active-passive transition is tra-
versed. Therefore, unless sufficient anodic current density is dis-
charged from carbon steel by a naturally occurring cathodic reaction or
an applied anodic protection current, the carbon steel liquor interface
remains monostable (active) because the passive film and its low cur-
rent density properties do not exist.
Under normal operating chemistries in white and green Kraft
liquors, carbon steel exhibits a monostable (active) behavior, and the
bistable behavior occurs only after the passivation process has reached
some degree of completion, as predicted by romans and verified byAnodic Protection 995,
300
200
Potential (V vs. SSE)
200
00
a 1
Log current density (mA em")
Figure 12.6 ‘Theoretical polarization curve illustrating the monostable (active) behavior
of mild steel exposed to Kraft liquors
300.
200.
3
Potential (Vs. SSE)
Bo
200.
00.
: 25 2 ie 4 os, 0 05 1
Log current density (mA em")
Figure 12.7. ‘Theoretical polarization curve illustrating the bistable behavior of mild steel
exposed to Kraft liquors996 Chapter Twolve
300
200
100
(vve. se)
2
200
00
3 as 2 1s a 05 0 05
Log current density (mA em")
Figure 128 ‘Theoretical polarization curve illustrating the monostable (passive) behav-
Tor of mild steel exposed to Kraft iquars
300
200
10.
8
2
Potent
100
200.
200
a9 a a. 484 os oS 1
Log current density (mA.cm*)
Figure 12.9.‘Theoretical polarization curve illustrating the astable behavior of mild steel
exposed to Kraft liquors.Anodic Protection 997
300
2m o02mvs"
N\ ume
Potential (Vvs, SSE)
200
200
9 25 a 48 a 05 0 05 1
Log current density (mA om")
Figure 12.10. ‘Typical in situ polarization curves of carbon steel immersed in white liquor
typical curves. However, once created, the passive state is not perma-
nently stable. When the direction of the curve is reversed, a second
stable equilibrium potential is established. During traverse of the
active-passive transition, the corrosion rate has been measured to be
only 10 percent of the total Faradaic equivalent; hence 90 percent of
the current is consumed in sulfide oxidation. Design of the protection
and control systems now incorporates all of the features required to
passivate the tank, maintain passivation, detect active areas, and
repassivate if required.* Some of these features are
1. The location of cathodes. Design is based on primary current
distribution with the ratio of the minimum to maximum current den-
sity around the circumference of the tank greater than 0.9.
2. Fluctuating liquor level. ‘This requires higher initial current
density and more frequent repassivation cycles to form a tenacious
passive layer. When immersed, the wet/dry zone of a tank exhibits a
more positive potential than the remainder of tank, which may
account for the higher corrosion rates there. However, it has been
observed that the wet/dry zone does not get covered with surface
buildup or deposits. The constantly immersed zone builds a thick sur-
face deposit on these protected surfaces.
8. Control scheme. Conventional control schemes rely on a simple
proportional, integral algorithm (PI). ‘This technique is not optimal
when active and passive areas exist simultaneously. ‘The use of this998 Chapter Twelve
type of control will, in fact, result in accelerated corrosion of active
areas. When a surface is entirely passive, the measured potential is
uniform to within a few millivolts around the circumference of the
tank. An active area of any size significantly distorts this uniformity.
‘The impact is so acute and precise that active areas can be located by
triangulation. Once this distortion is detected, the control system ini-
tiates an automatic repassivation using high currents for a program-
mable period of time. Implementation of this scheme has revealed
when and where active areas are formed on the vessel. Several repas-
sivations are common during the first month of operation. Activation
seldom occurs after this stabilization period.
References
1, Walker, R., Anodie Protection, in Shreir, L. L., Jarman, R. A., and Burstein, G. 7.
(eds.}, Corrosion Control, Oxford, U.K. Butterworths Heinemann, 1994, pp.
10:158-10.170,
Fontana, M. G., Corrosion Engineering, New York, McGraw Hi
Locke, C. E., Anodie Protection, in Metals Handbook: Corn
Ohio, ASM International, 1987, pp. 462-465.
4, Sedriks,A. J, Corrosion of Stainless Steels, New York, John Wiley, 1979.
5. Riggs, O. Land Locke, C. &., Anodie Protection, New York, Plenum Press, 1981
& Munro, J. i, Anodie Protection of White and Green-Liquor Tankage With and
Without’ the Use of Protective Organic Linings, in Proceedings of the 7th
International Symposium on Corrosion in the Pulp and Paper Industry, Atlanta, Ga.
‘TAPPI, 1992, 117-130.
7. Tromans, D., Anodic Polarization Behavior of Mild Stee! in Hot Alkaline Sulfide
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