MM 713 Aqueous Corrosion and Its Control V.S. RAJA Institute Chair - - PowerPoint PPT Presentation

MM 713 Aqueous Corrosion and Its Control

V.S. RAJA Institute Chair Professor Department of Metallurgical Engineering and Materials Science Indian Institute of Technology Bombay

Areas of Research Interest

Corrosion Science and Engineering: Electrochemistry & Corrosion, Mechanisms: Atomic, microscopic levels Materials Coatings Stress Corrosion Cracking

VS Raja, Aqueous Corrosion Lab, IITB

Introduction of Students

VS Raja, Aqueous Corrosion Lab, IITB

What is Corrosion? Why Corrosion Occurs?

VS Raja, Aqueous Corrosion Lab, IITB

Corrosion Basics

VS Raja, Aqueous Corrosion Lab, IITB

Corrosion Material Environment Design

Corrosion: Deterioration of materials in

presence of a chemical environment leading to loss in their function.

VS Raja, Aqueous Corrosion Lab, IITB

Corrosion Tendency

VS Raja, Aqueous Corrosion Lab, IITB

Energy level State/time Ore Metal

Metal Electrolyte without oxidising species

Fe Fe Fe Fe Fe2+ Fe2+ Fe2+ Fe2+

e- e- e- e- e- e- e- e- e- e-

Fe Fe2+ Fe

VS Raja, Aqueous Corrosion Lab, IITB

Environment / Electrolyte with H+ ions

Fe Fe2+

H+ H+ H+ H+

e- e-

H

2

H H H

Fe Fe2+

e- e-

H

H

2

Metal

VS Raja, Aqueous Corrosion Lab, IITB

Oxidation and Reduction reactions

VS Raja, Aqueous Corrosion Lab, IITB

Environment

M+ e M+ e Metal Ox  Electron acceptor (H+, M+, O2 ) R  Reduced species (H2,OH-,M ) R Ox Ox R

Corrosion Control

VS Raja, Aqueous Corrosion Lab, IITB

Energy level State/time Metal

Passive film formation

VS Raja, Aqueous Corrosion Lab, IITB

Environment

Metal M+ R Ox M

passive film impedance

Electrochemical Corrosion Kinetics: 10-15 lectures

Industrial Corrosion

HP Heater Failure in a Co-Gen!

Failed Pressure vessel of a catalytic Reformer Unit

Pipeline Nozzle Failure in a Refinery: Stress concentration led to cracking

Blades Failure in a Agitator of a Speciality Chemical Manufacturing Company

Loss of Productivity: Misunderstanding is the cause Martensitic steel Vs martensitic stainless steel Location of the Problem: Process Condensate

VS Raja, Aqueous Corrosion Lab, IITB

VS Raja.Aqueous Corrosion Lab,IIT B

Failure Investigation of Condenser Tubes of a Refinery, if fails company losses 10 million Rs./day

Erosion Corrosion

But the flow velocity was <1m/s Alloy 90Cu-10Ni

Appearance

VS Raja, Aqueous Corrosion Lab, IITB

External Corrosion of a Pipeline (Soil)

VS Raja, Aqueous Corrosion Lab, IITB

Internal Corrosion of a Pipeline (Microbes)

Compelling Reasons for Corrosion Mitigation?

• Environmental impact-

regulations

• Sustainability and Cost

Effective

• Depleting Resources
• Spoke in the wheel to develop

Lighter & Smarter technologies and Efficient-Process

• Loss of Profit

23 Crude oil leaking from an Company’s pipeline destroying agricultural land:

• Saturday. June 17, 2017 9:53 pm, express news service

Gas Pipeline Leak, June 28, 2014, 18 people were reportedly killed and over 40 injured in the accident

Metals/Materials are subjected to

• Fabrication
• Pressure &

Temperature

• Process Conditions

VS Raja, Aqueous Corrosion Lab, IITB

HIC SCC

b

100 m

IGC

Microbe induced corrosion

Pitting

Cavitation

Crevice Corrosion

VS Raja, Aqueous Corrosion Lab, IITB

Why is Corrosion More Often a Problem? Functional requirements of materials

• Mechanical

– Strength – Ductility – Toughness – Wear

• Dimensional Stability
• Wear
• Machinability
• Physical

– Thermal Conductivity – Electrical Resistance – Magnetic – Optical – acoustic

• Chemical

– Catalytic

VS Raja, Aqueous Corrosion Lab, IITB

What is the Impact of Corrosion?

VS Raja, Aqueous Corrosion Lab, IITB

Where does the problem occur? All industries using Metals/Materials

Corrosion Impact-3.4 % GDP for Global and 4.2 % GDP for India!

http://impact.nace.org/documents/Nace-International- Report.pdf NACE International USA , March 01, 2016

28

Services: Include infrastructures, transport sectors, basic facilities, defense

25 Lectures: Application to Industrial Corrosion

• Mechanisms (Forms of Corrosion)
• Parameters Affecting Corrosion
• Corrosion Control Measures
• Test Methods
• Illustrations

VS Raja, Aqueous Corrosion Lab, IITB

Books

• Mars. G. Fontana, Corrosion Engineering, 3rd Edition,

McGraw Hill, Singapore, 1987

• R.W. Revie, H.H. Uhlig, Corrosion and its Control, 4th

Edition, Wiley, Singapore, 2008

• E.E. Stansbury, R.A. Buchanan, Fundamentals of

Electrochemical Corrosion, ASM International, OH, USA , 2000

• Stress Corrosion Cracking – Theory and Practice, edited by

V S Raja and T Shoji, Woodhead Publishing Ltd., Oxford , 2011

• Corrosion Failures: Theory, Case Studies and Solutions,

K.E. Perumal and V.S. Raja, John Wiley & Sons, NJ, USA, 2015

• ASM handbook, Vol. 13 (a-c), 10th Edition, OH, USA

VS Raja, Aqueous Corrosion Lab, IITB

No Attendance required for Appearing for the End-Sem Exams

• However, attendance will be taken for grading

purpose

• It will be taken at the beginning of the each

class and there after no attendance will be given

VS Raja, Aqueous Corrosion Lab, IITB

Marks for Attendance

• 5 marks for 95% Attendance
• 4 marks for 85% Attendance
• 3 marks for 80% Attendance
• 2 marks for 70% Attendance
• 1 mark for 60% Attendance
• None for less than 60% Attendance

VS Raja, Aqueous Corrosion Lab, IITB

Evaluation

• 1st Quiz

20 (Aug. third week)

• 2nd Quiz

20 (Oct. 3rd week)

• End-sem

45

• Attendance

05

• Two Assignments

10 (5+5) marks

VS Raja, Aqueous Corrosion Lab, IITB

Exams Nature

• Problems
• Concepts
• Some description of phenomena

VS Raja, Aqueous Corrosion Lab, IITB

TAs

• Ms. Dorothi Bairagi; Email: 173110033@iitb.ac.in

Rakshit Verma; Email: 173110030@iitb.ac.in

VS Raja, Aqueous Corrosion Lab, IITB

VS Raja, Aqueous Corrosion Lab, IITB

http://www.corrosioncost.com/home.html

VS Raja, Aqueous Corrosion Lab, IITB