Corrosion reaction kinetics

Passive corrosion caused by chemically inert substances is the same whether the substance is living or dead. The substance acts as an occluding medium, changes heat conduction, and/or influences flow. Concentration cell corrosion, increased corrosion reaction kinetics, and erosion-corrosion can he caused by biological masses whose metabolic processes do not materially influence corrosion processes. Among these masses are slime layers. 

The Avrami equation is crucial in the description of crystallisation and other processes. The equation has been applied to areas as diverse as corrosion, reaction kinetics and the growth of micro-organisms. If applied correctly, it can give information on the type of nucleation (homogeneous or heterogeneous) as well as the geometry of crystallisation, for... 

Many reaction schemes have been proposed (161,162). All reaction schemes ate designed such that reaction steps having positive A. " values are operated at high (625—725°C) temperatures, whereas reaction steps having negative AA values are operated at low (about 225°C) temperatures. The purpose is to lower the free energy change, ie, the work requirement, and increase the thermal requirement, for improved efficiency. Other considerations, such as reaction kinetics, corrosion, cost of materials, and side reactions must also be taken into account. 

The two dashed lines in the upper left hand corner of the Evans diagram represent the electrochemical potential vs electrochemical reaction rate (expressed as current density) for the oxidation and the reduction form of the hydrogen reaction. At point A the two are equal, ie, at equiUbrium, and the potential is therefore the equiUbrium potential, for the specific conditions involved. Note that the reaction kinetics are linear on these axes. The change in potential for each decade of log current density is referred to as the Tafel slope (12). Electrochemical reactions often exhibit this behavior and a common Tafel slope for the analysis of corrosion problems is 100 millivolts per decade of log current (1). A more detailed treatment of Tafel slopes can be found elsewhere (4,13,14). 

Multiinformational Prohes Corrosion probes can provide more information than just corrosion rate. The next three types of probes yield information about the type of corrosion, the kinetics of the corrosion reaction, as well as the local corrosion rate. 

Macroscopic heterogeneities, e.g. crevices, discontinuities in surface films, bimetallic contacts etc. will have a pronounced effect on the location and the kinetics of the corrosion reaction and are considered in various sections throughout this work. Practical environments are shown schematically in Fig. 1.3, which also serves to emphasise the relationship between the detailed structure of the metal, the environment, and external factors such as stress, fatigue, velocity, impingement, etc. 

The study of corrosion is essentially the study of the nature of the metal reaction products (corrosion products) and of their influence on the reaction rate. It is evident that the behaviour of metals and alloys in most practical environments is highly dependent on the solubility, structure, thickness, adhesion, etc. of the solid metal compounds that form during a corrosion reaction. These may be formed naturally by reaction with their environment (during processing of the metal and/or during subsequent exposure) or as a result of some deliberate pretreatment process that is used to produce thicker films or to modify the nature of existing films. The importance of these solid reaction products is due to the fact that they frequently form a kinetic barrier that isolates the metal from its environment and thus controls the rate of the reaction the protection afforded to the metal will, of course, depend on the physical and chemical properties outlined above. 

The rate (or kinetics) and form of a corrosion reaction will be affected by a variety of factors associated with the metal and the metal surface (which can range from a planar outer surface to the surface within pits or fine cracks), and the environment. Thus heterogeneities in a metal (see Section 1.3) may have a marked effect on the kinetics of a reaction without affecting the thermodynamics of the system there is no reason to believe that a perfect single crystal of pure zinc completely free from lattic defects (a hypothetical concept) would not corrode when immersed in hydrochloric acid, but it would probably corrode at a significantly slower rate than polycrystalline pure zinc, although there is no thermodynamic difference between these two forms of zinc. Furthermore, although heavy metal impurities in zinc will affect the rate of reaction they cannot alter the final position of equilibrium. 

The above considerations show that the rate of a corrosion reaction is dependent on both the thermodynamic parameter and the kinetic parameters rjj and rjj. It is also apparent that (q) the potential actually measured when corrosion reaction occurs on a metal surface is mixed, compromise or corrosion potential whose magnitude depends on E, and on the Ej, -I and Ej, -I relationships, and (b) direct measurement of 7 is not possible when the electrodes are inseparable. 

Figures 1.27a to d show how the Evans diagram can be used to illustrate how the rate may be controlled by either the polarisation of one or both of the partial reactions (cathodic, anodic or mixed control) constituting corrosion reaction, or by the resistivity of the solution or films on the metal surface (resistance control). Figures 1. lie and/illustrate how kinetic factors may be more significant than the thermodynamic tendency ( , u) and how provides no information on the corrosion rate.

Over the years the original Evans diagrams have been modified by various workers who have replaced the linear E-I curves by curves that provide a more fundamental representation of the electrode kinetics of the anodic and cathodic processes constituting a corrosion reaction (see Fig. 1.26). This has been possible partly by the application of electrochemical theory and partly by the development of newer experimental techniques. Thus the cathodic curve is plotted so that it shows whether activation-controlled charge transfer (equation 1.70) or mass transfer (equation 1.74) is rate determining. In addition, the potentiostat (see Section 20.2) has provided... 

Equations 1.83 and 1.84, or the equations derived from them (1.85 to 1.89), may be used to calculate and E an., providing the various parameters involved are known. The equations also serve to illustrate how and corr, depend upon a thermodynamic factor ( r,ceii. °r r.c and E, ) and the kinetic factors a and / o for each of the half reactions that constitute the corrosion reaction. 

It should be noted that since the rust is formed at a position in between the anodic and cathodic sites it will not influence the kinetics of the corrosion reaction. 

Metals are more frequently exposed to the atmosphere than to any other corrosive environment. Atmospheric corrosion is also the oldest corrosion problem known to mankind, yet even today it is not fully understood. The principal reason for this paradox lies in the complexity of the variables which determine the kinetics of the corrosion reactions. Thus, corrosion rates vary from place to place, from hour to hour and from season to season. Equally important, this complexity makes meaningful results from laboratory experiments very difficult to obtain. 

Although Table 2.16 shows which metal of a couple will be the anode and will thus corrode more rapidly, little information regarding the corrosion current, and hence the corrosion rate, can be obtained from the e.m.f. of the cell. The kinetics of the corrosion reaction will be determined by the rates of the electrode processes and the corrosion rates of the anode of the couple will depend on the rate of reduction of hydrogen ions or dissolved oxygen at the cathode metal (Section 1.4). 

It was indicated earlier that the cathodic current was a poor indicator of adequate protection. Whilst, to a first approximation the protection potential is a function of the metal, the current required for protection is a function of the environment and, more particularly, of the cathodic kinetics it entails. From Fig. 10.4 it is apparent that any circumstance that causes the cathodic kinetics to increase will cause both the corrosion rate and the current required for full (/") or partial (1/ — /, ) protection to rise. For example, an increase in the limiting current in Fig. 10.5 produced by an increase in environmental oxygen concentration or in fluid flow rate will increase the corrosion rate and the cathodic protection current. Similarly, if the environment is made more acid the hydrogen evolution reaction is more likely to be involved in the corrosion reaction and it also becomes easier and faster this too produces an increased corrosion rate and cathodic current demand. 

Reaction kinetics, catalyst handling, mass and heat transfer, corrosion and many other practical industrial chemistry and engineering considerations impact the success of scaleup from lab to commercial for batch processing. Since the starting point for scaleup studies is the ultimate intended commercial unit, the professional should scaledown from the design parameters and constraints of the proposed commercial unit. 

Eqnation (3.29) allows ns to determine the kinetics of most corrosion reactions from only three parameters /S, io, and ii-... 

The introduction of 0 in the equations for current density need by no means refer only to the adsorbed intermediates in the electrode reaction. What of other entities that may he adsorbed on the surface For example, suppose one adds to the solution an oiganic substance (e.g., aniline) and this becomes adsorbed on the electrode surface. Then, the 0 for the adsorbed organic substance must also be allowed for in the electrode kinetic equations. So, in Eq. (7.149), the value of 0 would really have to become a 0, where the summation is over all the entities that remain upon the surface and block off sites for the discharging entities. Many practical aspects of electrodics arise from this aspect of the Butler-Volmer equation. For example, the action of organic corrosion inhibitors partly arises in this way (adsorption and blocking of the surface of the electrode and hence reduction of the rate of the corrosion reaction per apparent unit area).67... 

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