Steels continued anodes

Execution. In the execution phase, the CP system is applied to the structure following the design. During the work, the complete concrete surface is checked for cracking, delaminations, cover depth, steel continuity and the presence of metal objects that might cause short circuits. If necessary, continuity is provided and metal objects are connected to the reinforcement. Subsequently the cracked and spalled areas are removed and repaired. The reference electrodes and other monitoring probes are embedded. Then the anode is applied, with overlay or top coat as designed. All electrical coimections are made and the power source is installed. 

Rebar continuity is essential to avoid stray currents that can accelerate corrosion. Figure 7.19 shows how an isolated rebar between the anode and the cathode will be cathodic where the current enters the steel and anodic where it exits. This will accelerate corrosion at the anodic site. Although there are few serious cases identified in cathodic protection systems, this is a greater concern for realkalization and desalination systems where the charge density is higher. 

United States, LaSalle, IH. 1918 continuous Hquid-phase oxidation (since ca 1961) K MnO separation from Hquid phase is without prior dilution continuous electrolysis of filtered electrolyte in bipolar ceUs Monel anodes, mild steel cathodes, vacuum crystallization 14,000 ... 

The reaction mixture is filtered. The soHds containing K MnO are leached, filtered, and the filtrate composition adjusted for electrolysis. The soHds are gangue. The Cams Chemical Co. electrolyzes a solution containing 120—150 g/L KOH and 50—60 g/L K MnO. The cells are bipolar (68). The anode side is monel and the cathode mild steel. The cathode consists of small protmsions from the bipolar unit. The base of the cathode is coated with a corrosion-resistant plastic such that the ratio of active cathode area to anode area is about 1 to 140. Cells operate at 1.2—1.4 kA. Anode and cathode current densities are about 85—100 A/m and 13—15 kA/m, respectively. The small cathode areas and large anode areas are used to minimize the reduction of permanganate at the cathode (69). Potassium permanganate is continuously crystallized from cell Hquors. The caustic mother Hquors are evaporated and returned to the cell feed preparation system. 

Although iron pipes suffer from the same corrosion risk as steel pipelines, associated with the generation of a galvanic cell with a small anode and a large cathode, the risk is mitigated for iron pipelines because the electrical continuity is broken at every pipe joint. For this reason long-line currents are uncommon in iron lines and cathodic protection is rarely necessary. It also accounts for the ability to protect iron lines by the application of nonadherent polyethylene sleeving . 

Tin is anodic to steel in alkaline solutions, the corrosion rate for a continuous coating being similar to that of pure tin, and tinned articles that are washed in aerated alkaline detergents slowly lose their coating. 

The primary function of a coating is to act as a barrier which isolates the underlying metal from the environment, and in certain circumstances such as an impervious continuous vitreous enamel on steel, this could be regarded as thermodynamic control. However, whereas a thick bituminous coating will act in the same way as n vitreous enamel, paint coatings are normally permeable to oxygen and water and in the case of an inhibitive primer (red lead, zinc chromate) anodic control will be significant, whilst the converse applies to a zinc-rich primer that will provide cathodic control to the substrate. 

Alkaline batteries were introduced in the early 1960s they last two to five times longer than Zn-carbon cells on continuous discharge and command two or three times the price in the USA (far more in Europe and the East). Alkaline cells became a necessary invention and they succeeded as a result of the requirements of the electronic devices. The essential improvement was the change from ammonium chloride and/or zinc chloride electrolyte to alkaline (KOH) electrolyte, the steel can construction, the outside cathode, and the zinc powder (large surface) anode. A main low-cost feature is that they use pressed cathodes and do not need to follow "jellyroll"... 

Often, however, steel is subject to pitting attack by sea water. The deepest attack on steel is reported to be about 10 to 15 mils per year. The presence of mill scale on the steel—especially when it covers a large portion of the exposed area—significantly increases the rate of pitting, and penetrations of about 20 mils per year can be expected. This is a result of the mill scale serving as large cathodes to the small, bare anodic areas. Pitting attack often tapers off with continued exposure. 

---