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

Material Environment Corrosion Design Corrosion Basics VS Raja, Aqueous Corrosion Lab, IITB

Corrosion: Deterioration of materials in presence of a chemical environment leading to loss in their function. VS Raja, Aqueous Corrosion Lab, IITB

VS Raja, Aqueous Corrosion Lab, IITB Corrosion Tendency State/time Metal Ore Energy level

e - Fe 2+ Fe e - e - Fe 2+ Fe e - e - Fe 2+ Fe e - e - Fe 2+ Fe e - e - Fe 2+ Fe Fe e - Metal Electrolyte without oxidising species VS Raja, Aqueous Corrosion Lab, IITB

VS Raja, Aqueous Corrosion Lab, IITB Environment / Electrolyte with H + ions H + H + H + H + Fe 2+ Fe 2+ H 2 H 2 H H H H Fe Fe e - e - e - Metal e -

Oxidation and Reduction reactions R O x M + e e M + Metal Environment R O x O x  Electron acceptor (H + , M + , O 2 ) VS Raja, Aqueous Corrosion Lab, IITB R  Reduced species (H 2 ,OH - ,M )

VS Raja, Aqueous Corrosion Lab, IITB Corrosion Control State/time Metal Energy level

Passive film formation M M + Metal Environment O x R VS Raja, Aqueous Corrosion Lab, IITB 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

Failure Investigation of Condenser Tubes of a Refinery, if fails company losses 10 million Rs./day Erosion Corrosion Alloy 90Cu-10Ni But the flow velocity was <1m/s VS Raja.Aqueous Corrosion Lab,IIT B

VS Raja, Aqueous Corrosion Lab, IITB Appearance

External Corrosion of a Pipeline (Soil) Internal Corrosion of a Pipeline (Microbes) VS Raja, Aqueous Corrosion Lab, IITB

Compelling Reasons for Corrosion Mitigation? • Environmental impact- regulations • Sustainability and Cost Effective Gas Pipeline Leak, June 28, 2014, 18 people were reportedly killed and over 40 injured in the accident • Depleting Resources • Spoke in the wheel to develop Lighter & Smarter technologies and Efficient-Process • Loss of Profit Crude oil leaking from an Company’s pipeline destroying agricultural land: 23 Saturday. June 17, 2017 9:53 pm, express news service

Metals/Materials are subjected to • Fabrication • Pressure & Temperature • Process Conditions VS Raja, Aqueous Corrosion Lab, IITB

b IGC HIC 100  m SCC Cavitation Microbe induced corrosion Crevice Corrosion VS Raja, Aqueous Corrosion Lab, IITB Pitting

Why is Corrosion More Often a Problem? Functional requirements of materials • Mechanical • Physical – Strength – Thermal Conductivity – Ductility – Electrical Resistance – Toughness – Magnetic – Wear – Optical – acoustic • Dimensional Stability • Wear • Chemical • Machinability – Catalytic VS Raja, Aqueous Corrosion Lab, IITB

What is the Impact of Corrosion? Where does the problem occur? All industries using Metals/Materials VS Raja, Aqueous Corrosion Lab, IITB

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 Services: Include infrastructures, transport sectors, basic facilities, defense 28

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, 3 rd Edition, McGraw Hill, Singapore, 1987 • R.W. Revie, H.H. Uhlig, Corrosion and its Control, 4 th 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), 10 th 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 • 1 st Quiz 20 (Aug. third week ) • 2 nd Quiz 20 (Oct. 3 rd 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