Electrochemistry & Corrosion Engineering

ChE-311

Dr. SufiyanEngr. Faheem Hassan

CLASS SCHEDULESaturday 13:00 –

13:50

Monday 13:00 – 13:50

Wednesday 13:00 – 13:50

ASSESSMENT METHODAssignments/Attendance:

20%Quiz: 10%Quiz : 10%Mid Term: 20%End Term: 40%

Class Timetable

Course Contents Introduction Basics in corrosion Basics in chemistry Basics in Metallurgy Corrosion reactions Corrosion cells Corrosion rates Electromotive series and Galvanic series Factors affecting corrosion Forms of corrosion Thermodynamics and kinetics of corrosion Corrosion control measures

Textbook

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Definition

Corrosion may be defined as the destruction of a metal or an alloy because of chemical or electrochemical reaction with its surrounding environment or medium

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Envi

ronm

ents

in

Corr

osio

n

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Corrosion: Metallurgy in Reverse

Some Corrosion Failure Examples

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Aloha Incident

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Aloha Incident (Contd..)

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Bhopal Accident

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Carlsbad Pipeline Explosion

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Flow Accelerated Corrosion

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Nuclear Reactor with a Hole in the Head

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Losses due to Corrosion

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Cost of Corrosion

Which cost more? Corrosion Fire Flooding Earthquake

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Cost of Corrosion(2004) in billion US$Country Direct Cost Indirect Cost USA 303.76 200 (approximately)Japan 59.02Former USSR 55.01Germany 49.26UK 8.51Australia 7.32Belgium 6.75India 3.78Poland 3.53Canada 3.38...............Global 510.14 940 (approximately)

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Example of Overdesign An 8" in. dia oil pipeline 225 miles long

with a in. wall thickness was installed with no corrosion protection system

With appropriate protection namely cathodic protection, it would have a thin wall thickness which would save 3,700 tons of steel (worth more than

one million dollar) increase internal capacity of the pipeline

by about 5%.

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So……Why Study Corrosion? Materials are precious resources Engineering design is incomplete without

knowledge of corrosion Applying knowledge of corrosion protection

can minimize disasters Corrosion – contaminate products such as

pharmaceutical, food and dairy products or luxury items like soap

Corrosion products – threat to the environment

Artificial implants for the human body!!!

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Distribution of disciplines in which active corrosion engineers have graduated

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So .. What would be expected from You (a Corrosion Engineer)? Ensuring maximum life of new equipment Preservation of existing equipment Protecting or improving the quality of a product in order

to maintain or improve a competitive position. Avoiding costly interruptions of production. Reducing or eliminating losses of valuable products by

spillage or leaks. Refitting of equipment withdrawn from service because

of corrosion. Reducing hazards to life and property that might be

associated with corrosion: Explosions of pressure vessels or piping systems release of poisonous or explosive gases or vapors are a few examples.

Thanks