EP2836624A1 - Kathodisches schutzsystem - Google Patents

Kathodisches schutzsystem

Info

Publication number
EP2836624A1
EP2836624A1 EP13775873.6A EP13775873A EP2836624A1 EP 2836624 A1 EP2836624 A1 EP 2836624A1 EP 13775873 A EP13775873 A EP 13775873A EP 2836624 A1 EP2836624 A1 EP 2836624A1
Authority
EP
European Patent Office
Prior art keywords
cathodic protection
protection system
impressed current
current cathodic
anode
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP13775873.6A
Other languages
English (en)
French (fr)
Other versions
EP2836624A4 (de
Inventor
Wayne Alan Robert BURNS
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Anode Engineering Pty Ltd
Original Assignee
Anode Engineering Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2012901419A external-priority patent/AU2012901419A0/en
Application filed by Anode Engineering Pty Ltd filed Critical Anode Engineering Pty Ltd
Publication of EP2836624A1 publication Critical patent/EP2836624A1/de
Publication of EP2836624A4 publication Critical patent/EP2836624A4/de
Withdrawn legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F13/00—Inhibiting corrosion of metals by anodic or cathodic protection
    • C23F13/02—Inhibiting corrosion of metals by anodic or cathodic protection cathodic; Selection of conditions, parameters or procedures for cathodic protection, e.g. of electrical conditions
    • C23F13/06—Constructional parts, or assemblies of cathodic-protection apparatus
    • C23F13/08—Electrodes specially adapted for inhibiting corrosion by cathodic protection; Manufacture thereof; Conducting electric current thereto
    • C23F13/12—Electrodes characterised by the material
    • C23F13/14—Material for sacrificial anodes
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F13/00—Inhibiting corrosion of metals by anodic or cathodic protection
    • C23F13/02—Inhibiting corrosion of metals by anodic or cathodic protection cathodic; Selection of conditions, parameters or procedures for cathodic protection, e.g. of electrical conditions
    • C23F13/06—Constructional parts, or assemblies of cathodic-protection apparatus
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F13/00—Inhibiting corrosion of metals by anodic or cathodic protection
    • C23F13/02—Inhibiting corrosion of metals by anodic or cathodic protection cathodic; Selection of conditions, parameters or procedures for cathodic protection, e.g. of electrical conditions
    • C23F13/06—Constructional parts, or assemblies of cathodic-protection apparatus
    • C23F13/08—Electrodes specially adapted for inhibiting corrosion by cathodic protection; Manufacture thereof; Conducting electric current thereto
    • C23F13/12—Electrodes characterised by the material
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F13/00—Inhibiting corrosion of metals by anodic or cathodic protection
    • C23F13/02—Inhibiting corrosion of metals by anodic or cathodic protection cathodic; Selection of conditions, parameters or procedures for cathodic protection, e.g. of electrical conditions
    • C23F13/06—Constructional parts, or assemblies of cathodic-protection apparatus
    • C23F13/08—Electrodes specially adapted for inhibiting corrosion by cathodic protection; Manufacture thereof; Conducting electric current thereto
    • C23F13/16—Electrodes characterised by the combination of the structure and the material
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F13/00—Inhibiting corrosion of metals by anodic or cathodic protection
    • C23F13/02—Inhibiting corrosion of metals by anodic or cathodic protection cathodic; Selection of conditions, parameters or procedures for cathodic protection, e.g. of electrical conditions
    • C23F13/06—Constructional parts, or assemblies of cathodic-protection apparatus
    • C23F13/08—Electrodes specially adapted for inhibiting corrosion by cathodic protection; Manufacture thereof; Conducting electric current thereto
    • C23F13/22—Monitoring arrangements therefor
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F2213/00—Aspects of inhibiting corrosion of metals by anodic or cathodic protection
    • C23F2213/20—Constructional parts or assemblies of the anodic or cathodic protection apparatus
    • C23F2213/22—Constructional parts or assemblies of the anodic or cathodic protection apparatus characterized by the ionic conductor, e.g. humectant, hydratant or backfill
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23F—NON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F2213/00—Aspects of inhibiting corrosion of metals by anodic or cathodic protection
    • C23F2213/30—Anodic or cathodic protection specially adapted for a specific object
    • C23F2213/32—Pipes

Definitions

  • This invention relates to a cathodic protection system for steel structures (or cast iron) structures.
  • This invention has particular application for cathodic protection of buried and submerged structures (on land and in marine off-shore applications). However, it is also be relevant for other types of structures in which steel (or iron) is a significant structural component.
  • the current output capacity of a magnesium sacrificial anode system attached to a pipeline or similar structure is normally 50 mA or less.
  • anode systems as high as 1500 mA or greater can be required.
  • Magnesium anodes are very inefficient. In order to generate 100 mA of current, one kilogram of magnesium alloy is consumed per year. 55% of consumption produces the DC current. The remaining 45% of the corrosion is consumed by self corrosion of the magnesium metal. Accordingly, the electrical efficiency of the anode is only around 55%. If the anode were disconnected from the steel structure, it would still naturally waste away due to self corrosion.
  • anode beds are typically installed at two to four kilometre intervals at a distance of not more than two metres from the pipeline easement.
  • a typical anode bed is comprised of 5 or more anodes in order to generate the requisite current at the installation location.
  • the primary cost for five sacrificial anodes will be in the order of AUD$2,000.00.
  • the installation and commissioning costs of the anode bed including civil works and commissioning will typically be in the order of AUD$5, 000.00.
  • a typical magnesium sacrificial anode system has a life expectancy of ten years. Because many sacrificial anode systems are installed on pipelines often in congested city streets and have to be installed close to the pipelines. With urban development, the cost to excavate and install new anode beds on a ten year cycle is significantly higher. Replacement costs plus extensive excavation costs in congested urban areas can be in the order of at least AUD$10,000 per site. For installations along a pipeline route, being installed every two to four kilometers, the accumulated replacement costs over a fifty year lifecycle of a pipeline can be in the hundreds of thousands of dollars. The cost to the environment in producing 1 kg of magnesium is approximately 40kJ of power. So, apart from being a very inefficient anode material, the carbon footprint to the environment is grossly unacceptable. The environmental efficiency of a material is largely determined by the C0 2 footprint.
  • C0 2 footprint The production of 1 kg of magnesium generates a C0 2 footprint of 42 kg of C0 2 .
  • the annual average magnesium tonnage consumed by the cathodic protection industry per annum in Australia and New Zealand alone is in excess of 400 tonnes. This equates to an annual C0 2 footprint of 16,800 tonnes of C0 2 .
  • Assuming a cost of AUD$23.00 per tonne for C0 2 this equates to an annual cost to industry before materials of $386,400. Over a fifty year design life, this equates to a CO 2 cost of AUD$19,320,000.00 (being close to AUD$20,000,000.
  • the environmental efficiency of a material substitution is largely determined by the CO 2 footprint. Summary of the Invention
  • an impressed current cathodic protection system for a target structure susceptible to corrosion which comprises an inert mixed metal oxide (hereinafter referred to as "MMO") anode surrounded by a tightly packed conductive zone connected to a power supply source and having an input/output regulator to control the flow of current to the target structure.
  • MMO inert mixed metal oxide
  • the tightly packed conductive zone is in the form of a powder.
  • the tightly packed conductive zone is comprised of calcined petroleum coke (semi graphitized carbon particles).
  • the system is driven by a DC power supply stored in a sealed battery cell. A number of conventional anode materials were considered for this application and rejected.
  • An MMO electrode is one in which the surface contains two or more kinds of metal oxides.
  • One of the metals usually one or more earth derivatives (such as RuO 2 , lrO 2 , or PtOo.12 conducts electricity and catalyzes the reaction.
  • the amount of this (more expensive) metal is up to 10-12g per square metre.
  • the other metal is typically in the form of TiO 2 which does not conduct or catalyze the reaction, but prevents corrosion of the interior (and is cheaper).
  • the interior of the MMO electrode is typically made of titanium. The MMO coating is applied to the surface of the titanium substrate to activate the surface.
  • the anode is surrounded by a zone of calcined petroleum coke, being a highly conductive material.
  • This is in the form of a tightly packed powder with a low moisture content. This provides a tightly packed conductive zone around the anode and effectively increases the active zone of the anode.
  • the specification for the calcined petroleum coke is as follows:
  • This material was selected as it exhibited the best electrical properties and reliability under the conditions tested.
  • the anode and surrounding zone of calcined petroleum coke is contained within a tubular sleeve which is sealed at both ends.
  • the sleeve may be of a permeable synthetic or linen cloth, or other suitable material, which is non-degradable in the environment in which the anode is to be used.
  • the MMO wire is located along the centre of the sleeve which is sealed at one end.
  • the calcined petroleum coke backfill is air blown into the sleeve through the other end and then sealed.
  • the sleeve which by way of example may be typically (approx 50mm Diameter x 2000mm and approximately 2kg in weight) is of a compact design and allows for ease of installation. This is particularly important in congested urban areas where a more compact system is required.
  • the system is designed to be able to produce 50 to 150 mA of current subject to suitable conditions (such as soil resistivity).
  • suitable conditions such as soil resistivity.
  • the number of anodes required to achieve the desired life expectancy will vary from one to a number of anodes depending upon the soil resistivity.
  • a number of anodes are placed into a bed. The placement of the anode bed will be determined by a range of factors such as safe burial offset or below pipe distances and soil resistivity.
  • the system is provided with solar input power generation and battery storage.
  • the batteries are charged by solar powered cells or panels. These may be mounted by various means. These may be mounted on the structure itself or in the case of a pipeline on a column designed for this purpose which may also conveniently house the hardware and service access.
  • the output power to the structure is controlled by a DC input/output regulator.
  • the system will be capable of operating at a number of output capacity ranges. Typically, these would be 50, 150, 500 and 1000 mA. However, these figures are by way of example only. The range may vary depending upon the application. Preferably, this would also be provided with lightning and surge protection.
  • the output regulator is approximately 30mm x 80mm.
  • the output regulator and control circuitry are designed to fit within a small control box which may be fitted on the structure or support column or, where applicable, on a structure within close proximity such as a suburban lamppost.
  • the system design can also accommodate a range of optional monitoring systems.
  • the system can accommodate the inclusion of a permanently installed reference cell to allow monitoring of the protection system by conventional manual methods or via an electronic interface or SCADA system.
  • the system can accommodate remote electronic surveillance and monitoring systems to provide continuous electronic monitoring and reporting via satellite or a GSM communications system. Accordingly, the system is capable of reducing the need to travel to sites for inspection and testing.
  • the system can also accommodate an automatically controlled output regulated system that incorporates the above reference cells. This may be set during commissioning to allow for a set protection level and also regulates output in automatic control mode.
  • the above system utilizes inert anodes that do not galvanically corrode and increases the active zone of the anode, thus greatly increasing the life expectancy of the system over those systems currently known and in use. It is anticipated that the system of the present invention will have a life of at least 50 years. To accord with the anticipated life expectancy, the anode bed,
  • electronics and related electrical components are also all designed to a specification of at least a 50 year life expectancy.
  • the advantage of the above invention over current systems is that it provides a compact system with a 50 year life expectancy which is easy to install even in difficult conditions. It is also able to be modified so as to provide a level of flexibility.
  • Figure 1 is a cross-sectional view of a preferred embodiment of the impressed current cathodic protection system.
  • Figure 2 is a cross-sectional elevational view of a further preferred embodiment of the system of the present invention showing a solar powered impressed current cathodic protection system and reference cell installation.
  • Figure 3 is a cross-sectional side view of the embodiment in Figure 2.
  • Figure 4 is a detailed front elevational view of the solar panel and supporting column, foundation for the solar powered installation in Figures 2 and 3 and of the housing for the regulator and control circuitry.
  • FIG 5 is a further detailed front elevational view of the solar panel, supporting column, foundation and baseplate for the solar powered installation in Figures 2 and 3.
  • an impressed current cathodic protection system for steel (& cast iron?) structures (1 ) which comprises an inert mixed metal oxide (MMO) anode wire (2) surrounded by a zone of calcined petroleum coke (3) contained within a tubular sleeve (4) sealed at both ends (5) and connected via a cable tail (6) to a power supply.
  • MMO mixed metal oxide
  • the system is driven by a DC power supply, which in this embodiment is a sealed battery cell (not shown).
  • the system also has an output regulator (not shown) to control the flow of current to the target structure.
  • an output regulator not shown to control the flow of current to the target structure.
  • Particle Sizing Dust free with a maximum particle size of 1 mm.
  • This material was selected as it exhibited the best electrical properties and reliability under the conditions tested.
  • FIG. 2 & 3 there is shown an elevational and side view respectively of a further preferred embodiment of the cathodic protection system (which may be comprised of one or a bed of anodes) of the present invention.
  • Figures 2 and 3 show the placement of the cathodic protection system (1 ) and a reference cell (7) relative to pipeline (8), being the target structure in this case.
  • the cathodic protection system (1 ) and reference cell (7) are embedded in sand (9) at a safe burial distance from the pipeline (8). This is covered by a layer of rock/free backfill (10) and generally topped with a finished grade (1 1 ).
  • the system is provided with solar input power generation.
  • the cathodic protection system is connected by cables (12) to one or more batteries.
  • the batteries are charged by solar cells on one or more solar panels (13). These are mounted on a supporting column (14) with baseplate (15) in concrete foundation (15).
  • the output regulator, control circuitry and service access are located in housing (17) at the base of the column (14) with access door (18) for ease of access.
  • a detailed view of the column (14), foundation (16), housing (17) and baseplate (15) are provided in Figure 4. Structural components and related equipment are manufactured to applicable local building and safety standards.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Prevention Of Electric Corrosion (AREA)
EP13775873.6A 2012-04-11 2013-04-11 Kathodisches schutzsystem Withdrawn EP2836624A4 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2012901419A AU2012901419A0 (en) 2012-04-11 Cathodic protection system
PCT/AU2013/000376 WO2013152398A1 (en) 2012-04-11 2013-04-11 Cathodic protection system

Publications (2)

Publication Number Publication Date
EP2836624A1 true EP2836624A1 (de) 2015-02-18
EP2836624A4 EP2836624A4 (de) 2015-12-30

Family

ID=49326953

Family Applications (1)

Application Number Title Priority Date Filing Date
EP13775873.6A Withdrawn EP2836624A4 (de) 2012-04-11 2013-04-11 Kathodisches schutzsystem

Country Status (4)

Country Link
US (1) US20150068919A1 (de)
EP (1) EP2836624A4 (de)
AU (1) AU2013247398A1 (de)
WO (1) WO2013152398A1 (de)

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105154888A (zh) * 2015-08-06 2015-12-16 北京市燃气集团有限责任公司 一种适用于城镇燃气管网的交流缓解方法
JP2019501277A (ja) * 2015-11-03 2019-01-17 ベクター コロージョン テクノロジーズ エルティーディー． 陰極防食
US10570523B2 (en) * 2017-08-25 2020-02-25 David William Whitmore Manufacture of sacrificial anodes
US11346009B2 (en) * 2017-08-25 2022-05-31 David William Whitmore Manufacture of sacrificial anodes
CN110158096A (zh) * 2019-06-10 2019-08-23 上海电力学院 利用太阳能发电实现海水设备防腐蚀的装置

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ITMI20051738A1 (it) * 2005-09-20 2007-03-21 De Nora Elettrodi S P A Anodo discreto per la protezione catodica del calcestruzzo armato
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Also Published As

Publication number Publication date
AU2013247398A1 (en) 2014-11-27
WO2013152398A1 (en) 2013-10-17
EP2836624A4 (de) 2015-12-30
US20150068919A1 (en) 2015-03-12

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