Eee Module 3
Eee Module 3
MODULE-3
CORROSION SCIENCE AND E-WASTE
MANAGEMENT
INTRODUCTION
Metals and alloys are used as fabrication or construction materials in engineering. If the metals or alloy structures are not properly
maintained, they deteriorate slowly by the action of atmospheric gases, moisture and other chemicals. This phenomenon of
destruction of metals and alloys is known as corrosion.
Corrosion
Ill effects of Corrosion:
1. It is estimated that 20% of iron produced annually is used replace damaged iron
objects which indicates a huge loss of metal due to corrosion.
2. Corrosion causes poor appearance of the object.
3. Increase of maintenance and operating cost of the metallic structure.
4. Severe corrosion of the machinery and tools leads to shutdown of production
plants.
5. Loss of valuable of products due to leakage.
6. Effects on safety and reliability in handling hazardous materials.
Electrochemical theory of corrosion taking iron as an example
O2
Fe2+Fe2+ OHOH H2O
Iron Metal
Liberation of hydrogen (in the absence of Absorption of oxygen (in the presence of
oxygen) oxygen)
In acidic medium the reaction is In acidic medium, the reaction is
2H+ + 2e H2 4H+ + O2 + 4e 2H2O
In neutral or alkaline medium, the In neutral or alkaline medium, the
reaction is reaction is
2H2O + 2e 2OH + H2 2H2O + O2 + 4e 4OH
Medium
Iron Highly Copper,
reactive e- noble,
Anode Cathode
Corrosion product
Factors affecting rate of galvanic
corrosion:
Metal with low electrode potential---- Anode( Iron)
Higher the potential difference
Metal with high electrode potential----Cathode( Copper)
between the anodic and cathodic
The anodic metal undergoes oxidation and gets corroded as
metals, higher is the rate of corrosion.
shown in fig. A reduction reaction occurs at the cathodic
Smaller anodic area and larger
metal. The cathodic metal does not undergo corrosion.
cathodic area increases the rate of
The reactions may be represented as follows:
galvanic corrosion.
At anode: M Mn+ + ne
At cathode: 2H2O + O2 + 4e 4OH
Differential aeration corrosion
This type of corrosion occurs when two different parts of the same metal are exposed to
different oxygen concentrations. (e.g. An iron rod partially dipped in water.) The part of
the metal which is exposed to less oxygen concentration acts as anode as shown in Fig:.
The part which is exposed to more oxygen concentration acts as cathode. The anodic
region undergoes corrosion and the cathodic region is unaffected.
Metal in contact with less oxygen- Anode
Iron
Metal in contact with more oxygen- Cathode
Anode- Oxidation Cathode- Reduction
More O2, (Cathode)
Water
(a) Water line corrosion
When a steel tank is partially filled with water for a long time, the inner
portion of the tank below the water line is exposed only to DO, whereas,
the portion above the water line is exposed to more oxygen. Thus the
portion below the water line acts as anode and undergoes corrosion. The
upper portion acts as cathode and is unaffected. A distinct brown line is
formed just below the water line due to the deposition of rust as shown in
Fig 3.6.
Conditions
Anode Aluminium
Cathode Steel or Copper
Electrolyte 5-10% Chromic acid
Temperature 35 0C
Applied potential 0-50V
The aluminum structure is cleaned, polished and connected to the anode and steel or copper is
made as cathode. The electrodes are immersed in an electrolyte consisting of 5-10% Chromic acid.
The temperature of the plating bath is maintained at 35oC. Potential is applied and gradually
increased from 0-40V during first 30 minutes; under this condition anodizing starts and slowly the
surface of Al oxidizes to form Al2O3. After 30 minutes the potential is increased to 50V and held at
this potential for five minutes, results opaque oxide layer of thickness 2-8µm thickness is formed
on the surface of aluminum article. Finally, the aluminum structure is treated with nickel acetate
solution followed by boiling water.
(i) Anodization is used for aluminium pressure cookers and cooking pots.
(ii) Aluminium window frames are anodized.
(iii) Sliding doors of office cabins.
(iv) Commercial and residential building products.
(v) Furniture.
Cathodic protection
The metal to be protected is completely converted into a cathode by supplying electrons
from external source.
CPR the amount of weight loss per year in the thickness of metal or alloy due to corrosion.
87.6 𝑋 40 𝑋 1000𝑚𝑔
CPR= g = 3.466 X10-3 mm/yr
7.8 𝑋3x100X100 𝑐𝑚 2 𝑋 6x30X24 hrs
cc
CPR= 0.003466mm/yr
To calculate CPR in mpy
Given CPR in mpy
K 534
W (wt loss) 40 g 40 x1000 mg
Ρ 7.8g/cm3 7.8g/cm3
A 1m x3m = 3m2 3 x1550 inch2
T 6 months 6 x30x24 hrs
𝐾𝑊 534 𝑋 40 𝑋 1000𝑚𝑔
CPR= CPR= g =
𝜌𝑋𝐴𝑋𝑡 7.8 𝑋3x1550 𝑖𝑛 2 𝑋 6x30X24 hrs
cc
0.1363mpy
2. A piece of corroded steel plate was found in a submerged ocean vessel, it was
estimated that the original area was 10inch2 that approximately 2.6kg had corroded away
during the submersion. Assuming a corrosion penetration rate of 200mpy for this alloy
in sea water, estimate the time in years, density of steel 7.9g/cc.
𝐾𝑊
Given CPR in mpy CPR=
𝜌𝑋𝐴𝑋𝑡
K 534
W 2.6kg 2.6 x 1000 x1000 mg
ρ 7.9g/cc 7.9 g/cc 𝐾𝑊
t=
A 10 inch2 10 inch2 𝜌𝑋𝐴𝑋𝑐𝑝𝑟
t X X hrs
534𝑋2.6𝑋106 𝑚𝑔
t= t= 87873.41hrs
7.9 𝑔/𝑐𝑐𝑋10𝑖𝑛2𝑋200𝑚𝑝𝑦
87873.41
t= = 10.03𝑦𝑟𝑠
365𝑋24
the CPR in both mpy and mm/yr for a thick steel sheet of area 100 in2 which
3. Calculate
experiences a weight loss of 485g after one year. (density of steel=7.9g/cm3).
T 1 yr 365 x 24 hrs
a) Consumer electronics include Toasters, Coffee machines, Clocks, Watches, Hair dryer, Sharvers.
Constituents of e-waste
COMPONENTS CONSTITUENTS
Printed circuit boards Lead & cadmium
Cathode ray tubes (CRTs) Lead oxide & Cadmium
Switches & flat screen monitors Mercury
Computer batteries Cadmium
Capacitors and transformers Poly Chlorinated Bi-phenyls
(PCB)
Printed circuit boards, plastic Brominated Flame Retardant
casings cable
Cable insulation/coating Poly Vinyl Chloride (PVC)
Sl No Substance Occurance in e-waste
Halogenated Compounds
1 PCB( Poly Chlorinated Biphenyls) Condensers, Transformers
2 PBB(Poly Brominated Biphenyls) Fire retardants for Plastics, cable insulation), Printed wiring boards
and casings
3 CFCs Cooling units and insulation foam
Heavy Metals and other metals
4 Arsenic LEDs
5 Barioum CRT
6 Beryllium Power Supply boxes
7 Cadmium Ni-Cd batteries, CRTs, Printer inks and toners, Photo copying
machines (toner drum)
8 Chromium VI Data tapes, Floppy disc, Corrosion protectors
11 Lead CRT Screen, Printed Writing board, batteries, Solder
12 Mercury Fluorescent lamp to provide back lighting in LCDs, alkaline
batteries, mercury wetted switches, PCB, Switches, Relays
13 Nickel Ni-Cd, NiMH batteries, electron gun in CRT
Printed circuit boards -Lead & cadmium
Cathode ray tubes (CRTs) Lead oxide & Cadmium
Switches & flat screen monitors Mercury
Computer batteries Cadmium
Characteristics of e-waste
E-waste contains both hazardous and non-hazardous substances in their components.
a) Partly hazardous: e-waste contains different substances, some of which can pose serious risk
due to wrong handling. Substances like plastic, lead, cadmium, bismuth and arsenic pose health
hazards on humankind. The people engaged in the recycling and recovery from the e-waste is
severely affected with chronic and acute diseases like cancer etc.
The presence of heavy metals in e-waste made it indifferent to the municipal biodegradable
waste as they not only hamper the bio-degradation process but harms the human health and
environment also. These, heavy metals enters in to food chain and causes Bio-magnification.
b) Partly valuable: Mother boards, PCB’s and connectors which are coated with gold and other
noble metals are valuable, which can be recycled.
Need for e-waste management
Following are the challenges for E-waste management:
Electrical and electronic equipment contain different hazardous materials which are harmful to
human health and the environment if not disposed off carefully.
E-waste is a serious issue for our environment because it releases harmful toxic chemicals
from the metals due to chemical reactions and these toxic chemicals harm our environment,
therefore they must be handled with care when no longer wanted or needed.
Electronic scrap components, such as CPUs, contain potentially harmful materials such as
lead, cadmium, beryllium, or brominated flame retardants. Improper disposal of e-waste is
highly dangerous to the global environment involving significant risk to the health of
workers and their communities
The consequences of improper e-waste disposal in landfills or other non-dumping
sites pose serious threats to current public health and can pollute ecosystems for
generations to come. When electronics are improperly disposed of and end up in
landfills, toxic chemicals are released, impacting the earth’s air, soil, water, and
ultimately, human health.
1. The Negative effect onhuman health
E-waste contains hazardous metals such as cadmium, mercury, lead, chromium, polyvinyl chlorides
(PVC), brominated flame retardants, beryllium, antimony. Long term exposure to these chemicals
damages internal organs of human.
To prevent the human being and environment from contamination of these pollutants, it is desirable to
manage e-waste scientifically and to follow reuse and recycle methodologies.
Health hazards of e-waste
Solder: Solder contains lead that damages the nervous system, blood system, and kidney and also
affect the development of brain in children.
Relays, Switches and Printed Circuit Boards
Mercury present in these elements leads to brain damage, disorders in the respiratory system and
skin diseases.
Corrosion Protectors
Asthmatic bronchitis and DNA damage are caused due to the Hexavalent Chromium present.
Cabling and Computer Housing
When burn these produce dioxin, which causes problems of reproduction, destruction of the
immune system, and regulatory hormones are damaged too.
Brominated Flame Retardants: BFRs increases contamination of the environment, wildlife, and
people. These do not decompose easily in the environment, and long term exposure can cause
impaired memory function and learning. Pregnant women exposed to brominated flame retardants
have been shown to give birth to babies with behavioral problems as it interferes with estrogen
and thyroid functioning.
Arsenic: Arsenic is a poisonous metallic element which is present in dust and soluble substances.
Chronic exposure to arsenic can lead to various diseases of skin and decrease nerve conduction
velocity. Chronic exposure to arsenic can also cause lung cancer and can often be fatal.
Barium: Barium forms toxic oxides when reacted with air. Short term exposure to barium could
lead to brain swelling, damage to heart, liver and spleen.
Beryllium: Exposure to Beryllium causes lung cancer. People working in beryllium atmosphere
will suffer from Beryllicosis, a disease primarily affects lungs.
Cadmium: Cadmium can easily be accumulated in human body. Acute exposure to cadmium
fumes causes flu-like symptoms of weakness, fever, headache, chills, sweating and muscular
pain. Long exposure to Cadmium causes lung cancer and kidney damage. It also causes
pulmonary emphysema and one disease(osteomalacia and osteoporosis)
Methods of disposal of E-waste:
To avoid the toxic effects of e-waste, it is crucial to dispose them in proper manner, so
that items can be recycled, resold, or reused.
hydrochloric, nitric acid solutions that remove the metal from the e-waste. The
recovered metal is further reused to create other products. This method also has
drawbacks, like the acid solutions sometimes dumped into the water resources
The electronic waste also contains fair percentage of precious metals like Cu, Ag, Au, Pd,
Rh etc.
a) Recovery of Gold: Stage II leachate was treated with 0.1M organic amide in toluene, stirred for 2hrs at 20˚C.
Organic and acid layers are physically separated and Organic layer was stripped in 1.0M Sodium Hydroxide.
Further, purification is done by electrolysis using 100% Gold as cathode.