LAB REPORT SETG 4711

GAS FLOW SYSTEM LABORATORY

2024/2025 – 02

EXPERIMENT SACRIFICIAL ANODE AND IMPRESSED CURRENT CATHODIC

PROTECTION SYSTEM

LECTURER’S NAME DR. NORHANA BINTI MOHAMED RASHID

SECTION 02

GROUP NO. 01

GROUP MEMBERS NO. NAME MATRICS NO.

1. NUREEN DAYANA BINTI MOHD A21ET0194

IZMANIZAN

2. IRDINA BINTI EZMIL ARIFF A21ET0066

3. DANISYAH HANI NASRIN BINTI A21ET0040

MOHAMAD NAZALI

4. MUHAMMAD ABDULLAH BIN MUKRAM A22ET0340

DATE OF :30 MAY 2024

SUBMISSION

DATE OF : 1 APRIL 2024

EXPERIMENT
1.0 Introduction

When dissimilar metals are in electrical or physical contact through an electrolyte,

galvanic corrosion can take place. The process is akin to a simple DC cell in which the more
active metal becomes the anode and corrodes, whereas the less active metal becomes the
cathode and is protected. (CUs)

Cathodic Protection is an electrochemical means of corrosion control in which the

oxidation reaction in a galvanic cell is concentrated at the anode and suppresses corrosion of
the cathode in the same cell. (CUs)

In a Galvanic Series for a particular medium, metals which have more positive electrode
potentials act as cathodes while those which have less positive or more negative potential will
become anodes. Table 6.1 shows a Galvanic Series of metals and alloys in seawater.

To protect a metal from corrosion, it should be coupled with another of more negative
electrode potential. The metal which acts as an anode will corrode or in other words sacrifice
itself. This method is called corrosion protection by sacrificial anode. A metal might also be
protected from corrosion by forcing its electrode potential to be more positive or in other words
to force the metal to be a cathode. It is achieved by supplying current to the metal. This method
is known as cathodic protection by impressed current.

Sacrificial anode systems are simpler. They require only a material anodic to the
protected steel in the environment of interest. Unlike sacrificial anodes, impressed-current
anodes need not be naturally anodic to steel, and in fact, they seldom are. Most impressed-
current anodes are made from non-consumable electrode materials that are naturally cathodic
to steel. If these electrodes were wired directly to a structure, they would act as cathodes and
would cause accelerated corrosion of the structure they are intended to protect. The direct
current source reverses the natural polarity and allows the materials to act like anodes. Instead
of corrosion of the anodes, some other oxidation reaction, that is, oxygen or chlorine evolution,
occurs at the anodes, and the anodes are not consumed. (CUs)This report focuses on examining
the natural electrode potentials of various metals in a sacrificial anode system and calculating
the cathodic protection current density required for a steel pipe in an impressed current system.
2.0 Objectives

• To study the natural electrode potential of several metal anodes for a steel pipe
sacrificial anode system.

• To calculate the cathodic protection current density required for a steel pipe impressed
current cathodic protection system.

3.0 Apparatus and Material

• Cathodic protection trainer

• Reference electrode (Cu/CuSO4)

• Various metal electrodes (Zinc, Magnesium, Copper, Platinized Titanium, Aluminum)

• Wet sieved sand

• Sandpaper

• Measurement tools

4.0 Methods

4.1 Sacrificial Anode System

i. Polish a steel electrode using sandpaper and connect it to the specimen point.

ii. Connect the reference electrode (Cu/CuSO4) to the reference point.

iii. Submerge the reference electrode and steel electrode into wet sieved sand.

iv. Record the natural electrode potential of the steel.

v. Connect an anode electrode to the anode point and submerge it into wet sand.

vi. Record the natural electrode potential with and without the steel connected to the
specimen point.

vii. Repeat steps 5-6 for different metal electrodes.

4.2 Impressed Current Cathodic Protection System

i. Polish a steel electrode using sandpaper. Measure the dimensions of the steel electrode
and calculate the total surface area.

ii. Connect the reference electrode (Cu/CuSO4) to the reference point.

iii. Connect an anode electrode to the anode point.

iv. Submerge the electrodes into wet sieved sand and record the natural electrode potential.

v. Set base current and potential current to zero and set voltage and current to maximum
value.

vi. Adjust the potential current to 1.00V.

vii. Immediately record the current and electrode potential value.

viii. When readings are constant, start a polarization test at intervals of 12 seconds until a
stable potential is achieved. Record the current and electrode potential value.
5.0 Raw Data/Expected Results

5.1 Sacrificial Anode System

Figure 1: Sacrificial anode system raw data.

Natural electrode potential (mV)

Specimen
Without steel connected With steel connected to the
to the specimen point specimen point

Steel 0.52

Zinc 0.80 0.59

Magnesium 1.22 0.83

Copper 0.05 0.54

Platinized titanium -0.1 0.55

Aluminum 0.51 0.56

Table 1: Sacrificial anode system data.
5.2 Impressed Current Cathodic Protection System

Figure 2: Impressed current cathodic protection system raw data.

• Diameter of steel: 20 mm
• Length of steel: 14.2 mm
• Total surface area: 89221.2 mm² = 0.0892 m²
• Initial current: 0.01 A
• Current after polarization: 0.001 A
• Natural electrode potential: 0.55 mV
• Electrode potential after polarization: 1.00 mV
• Initial voltage: 30.1 mV
• Voltage after polarization: 3.0 mV
6.0 Discussions

6.1 Comparison of Natural Electrode Potentials

To determine suitable anode electrodes for cathodic protection (CP) of steel, we

compare the natural electrode potentials of various materials listed in the table. The steel
electrode has a potential of 0.52 mV. For an anode to be effective, it must have a more negative
potential than the steel to ensure it corrodes preferentially, protecting the steel. Magnesium,
with potentials of 1.22 mV (without steel connected) and 0.83 mV (with steel connected), is
more positive than steel, making it unsuitable. Zinc also shows more positive potential (0.80
mV without and 0.59 mV with steel), rendering it ineffective. Copper, with a potential of 0.05
mV (without steel) and 0.54 mV (with steel), is slightly more negative and could be considered.
Platinized titanium, at -0.1 mV (without steel) and 0.55 mV (with steel), is more negative
without connection, making it a viable choice. Aluminum’s potential (0.51 mV without and
0.56 mV with steel) are very close to steel, providing marginal protection. Thus, the best
candidates for CP of steel are platinized titanium and copper, with platinized titanium being
the superior option due to its more negative potential, ensuring better protection of the steel
electrode.

Summary of suitable anodes;

Based on the criteria that the anode must have a more negative potential than steel;

• Platinized Titanium (without steel connected) with a potential of -0.1 mV is suitable.

• Copper (without steel connected) with a potential of 0.05 mV is also suitable, but
slightly less negative than Platinized Titanium.

• Aluminium (without steel connected) with a potential of 0.51 mV is only marginally

more negative than steel, making it a less optimal choice.

For the CP system to protect a steel electrode, (without steel connected) is the most suitable
anode due to its more negative potential relative to steel. Copper can also be used but is less
optimal compared to Platinized Titanium. Aluminum is a marginal choice and may not provide
the best protection due to its close potential to steel.
6.2 Cathodic Protection Current Density Calculation

𝐼
𝑗=
𝐴

Where;

• I is the current in amperes (A)

• A is the total surface area in square meters (m²)

Given the data;

• Total surface area 𝐴 = 0.0892𝑚2

• Initial current 𝐼𝑖𝑛𝑖𝑡𝑖𝑎𝑙 = 0.05𝐴

• Current after polarization 𝐼𝑎𝑓𝑡𝑒𝑟 = 0.001𝐴

We can calculate the initial current density and the current density after polarization;

Initial Current Density

𝐼𝑖𝑛𝑖𝑡𝑖𝑎𝑙 0.01𝐴
𝑗𝑖𝑛𝑖𝑡𝑖𝑎𝑙 = =
𝐴 0.0892𝑚2

= 0.112𝐴𝑚−2
Current Density After Polarization

𝐼𝑓𝑖𝑛𝑎𝑙 0.001𝐴
𝑗𝑓𝑖𝑛𝑎𝑙 = =
𝐴 0.0892𝑚2

= 0.011𝐴𝑚−2

These values indicate that the current density required for cathodic protection significantly
decreases after polarization.

6.3 Resistance of the Medium

Resistance of the medium can be calculated using Ohm’s law;

𝑉
𝑅=
𝐼

Where;

• V is the voltage (Volts)

• I is the current (Ampere)

We have the following data;

• 𝑉𝑖𝑛𝑖𝑡𝑖𝑎𝑙 = 0.0301𝑉
• 𝐼𝑖𝑛𝑖𝑡𝑖𝑎𝑙 = 0.01𝐴
• 𝑉𝑓𝑖𝑛𝑎𝑙 = 0.003𝑉
• 𝐼𝑓𝑖𝑛𝑎𝑙 = 0.001𝐴
Calculating the resistance;

Initial Resistance

𝑉𝑖𝑛𝑖𝑡𝑖𝑎𝑙 0.0301𝑉
𝑅𝑖𝑛𝑖𝑡𝑖𝑎𝑙 = =
𝐼𝑖𝑛𝑖𝑡𝑖𝑎𝑙 0.01𝐴

= 3.01Ω

Resistance after Polarization

𝑉𝑓𝑖𝑛𝑎𝑙 0.003𝑉
𝑅𝑓𝑖𝑛𝑎𝑙 = =
𝐼𝑓𝑖𝑛𝑎𝑙 0.01𝐴

= 3.00Ω

These calculations show that the resistance of the medium is slightly higher initially but
stabilizes to a slightly lower value after polarization.

6.4 Importance of Current Density and Resistance

Determining the cathodic current density and the resistance in a cathodic protection
(CP) system is crucial for several reasons. The cathodic current density, defined as the current
per unit area of the protected structure, is a key parameter that ensures sufficient current is
supplied to mitigate corrosion. If the current density is too low, the structure may not be
adequately protected, leading to potential corrosion damage. Conversely, excessive current
density can cause hydrogen embrittlement and increased operational costs. Resistance in the
CP system impacts the efficiency of current delivery. High resistance in the medium can lead
to significant voltage drops, requiring higher voltages to achieve the desired current density.
This not only increases energy consumption but also affects the overall reliability and
performance of the CP system. Accurately calculating resistance helps in designing the CP
system to ensure optimal performance, energy efficiency, and longevity of both the protected
structure and the anodes used in the system. Understanding these parameters helps in fine-
tuning the system to provide effective and economical corrosion protection.

7.0 Conclusion

In conclusion, the experiment successfully demonstrated the principles of cathodic

protection using both sacrificial anode and impressed current systems. The data gathered will
allow for selecting suitable anode materials and calculating necessary current densities to
protect steel pipelines effectively.

Cathodic protection is a highly adaptable and effective means of preventing corrosion

on a variety of underground or underwater structures. There are basically two types of systems
namely, sacrificial anode and impressed current. Each has characteristics which make it more
adaptable under given circumstances. Cathodic protection designs can differ considerably
depending upon the coating, the configuration of the structure, the environment and the
presence of neighbouring structures. When a system is designed, installed and maintained
properly, cathodic protection is one of the most effective and economical methods of
preventing corrosion.
8.0 References

Integrated Publishing. (n.d.). Table 11-1: Advantages and disadvantages of sacrificial anodes.
Electronics Technician Volume 2—Stray Current Corrosion. Retrieved May 30, 2024,
from https://electronicstechnician.tpub.com/14344/Table-11-1-Advantages-And-
Disadvantages-Of-Sacrificial-Anodes-430.html

Integrated Publishing. (n.d.). Table 11-1: Advantages and disadvantages of sacrificial anodes.
Electronics Technician Volume 2—Stray Current Corrosion. Retrieved May 30, 2024,
from https://electronicstechnician.tpub.com/14344/Table-11-1-Advantages-And-
Disadvantages-Of-Sacrificial-Anodes-430.html