Understanding the behavior of mild steel in sodium hydroxide: a biomass corrosion mitigation approach

doi:10.21203/rs.3.rs-3398773/v1

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Understanding the behavior of mild steel in sodium hydroxide: a biomass corrosion mitigation approach

https://doi.org/10.21203/rs.3.rs-3398773/v1

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Aquatic plant biomasses offer the chance to utilize their undesirable organic matter, which disrupts the environment, as environmentally friendly corrosion inhibitors. The corrosion inhibition of mild steel extracts of water hyacinth (Eichhornia crassipes) was synthesized and evaluated. Electrochemical analysis via potentiodynamic polarization technique and gravimetric methodology was used to study the inhibitive effect, followed by optical micrographic evaluation. The inhibitory efficiency of the plant extract was improved by raising the concentration of the aqueous extracts. The water hyacinth had a linear relationship of increasing concentration with the reduction in corrosion rate. The optical micrographs further support less corrosion pitting at high inhibitor concentrations. Extraction method, temperature, and extract dosage were the three criteria examined. Ambient temperature and plant extract dose concentration were ideal circumstances, mainly when high-temperature digestion for extraction was used. Utilizing the optical microscopy (OM) technique, the efficiency of the examined bio-based inhibitor was also confirmed.

Materials Engineering

Metallurgy

Corrosion

mild steel

water hyacinth

potentiodynamic polarization

One of the biggest problems in most businesses is the corrosion phenomenon because it affects metallic materials, which has a negative impact on the effectiveness of the process and its economics [1]. Due to its low cost and mechanical strength, mild steel is a material that is used extensively in both industries and homes. However, acidic environments are known to cause severe corrosion to mild steel. Although it might result in unfavorable corrosion as a side effect, acid pickling is a typical technique for cleaning metallic surfaces and removing the old scaling layer on a substrate in various industries and applications [2].

Corrosion inhibitors are compounds that can stop or impede metal corrosion and can be inorganic or organic. It is important to note that inorganic inhibitors are no longer employed because of their bio-toxicity and hazardous heavy metal content [3]. As a result, organic corrosion inhibitors are utilized because they are easy to apply and effective at low doses [4]. Due to their heteroatoms of oxygen, sulfur, nitrogen, and aromatic rings, these inhibitors can emit lone electron pairs, which in turn form coordination bonds with the transition metal and lead to chemical adsorption at the metal [5][6]. Given their environmental toxicity, high cost, and carcinogenicity, as well as the rigorous regulations that must be applied in manufacturing plants [7], many chemical-based organic inhibitors are gradually being restricted and dismissed despite their effectiveness.

Acrylic and epoxy are two typical coatings. Due to the ability of epoxy to protect metal surfaces from oxygen and moisture, the shelf life of the metal may be extended. However, pores make it easier for corrosive substances to flow through the covering and cause corrosion [8]. The chemical and solvent resistance of acrylic is subpar. Both polymer coatings deteriorate in UV or sunlight [9]. Including additives in the surface coating constitutes a technique to address these problems. Bio-based corrosion inhibitors are environmentally friendly substitutes made from natural materials like plant extracts. It has been demonstrated that raw materials are preferred as steel corrosion inhibitors in acidic environments in the oil and gas sectors [6]. This can be a result of their affordable preparation costs and straightforward use.

Concern for the environment for reducing the use of chemical-based anti-corrosion inhibitors has increased during the previous few decades. It is strongly recommended that green chemistry concepts be applied in both academic and commercial settings. The use of naturally occurring plant extracts as environmentally friendly corrosion inhibitors for metals in various aqueous media is therefore discussed in many research publications [7][10]. The options for an appropriate solvent that could be used to extract bioactive components from plant biomass are still limited. According to [11] and [12], the type of solvent affects how well it diffuses into plant tissues to dissolve and retrieve the bioactive elements.

Corrosion inhibitors made from plant extracts have been effectively used for steel in a variety of media. For instance, the leaves and seeds of the date palm have been investigated as an anti-corrosion agent for carbon steel corrosion in an acidic medium [13]. In a 1 M solution of hydrochloric acid (HCl) medium, coffee grounds were used as a corrosion inhibitor for the corrosion mitigation of C38 steel [14]. A citrous aurantium leaf extract was used to prevent mild steel from corroding in 1 M sulfuric acid (H₂SO4). They discovered that at 40°C, the inhibition efficacy was 89% [15]. Using apricot juice [16], it was determined whether or not mild steel was inhibited in 1 M phosphoric acid (H₃PO₄). Liquid betel leaf extract was previously utilized to prevent corrosion in Q235 steel, and at a dosage of 400 mg/l, it was practical to a degree of 94% [17]. It goes without saying that there are several pickling liquids to investigate as an acidic medium. Here, we settled on 0.5 M H₂SO₄ as the pickling agent. Because it is less volatile than HCl and HNO3, it has superior stability than the other acids. Additionally, the metal-corroding properties of HCl are very severe, and rising temperatures make HNO₃ rapidly decomposable [18]. Most of these studies had a single factor under investigation at any given moment. In a particular work [19], the authors investigated the aqueous kokum (Garcinia Indica) fruit extract as a mild steel inhibitor in an acidic media; they discovered that it was 93% and 87% effective for 0.5 and 1 M HCl, accordingly. Moreover, the boiling point temperature route for bi-inhibitor extraction has not, however, been widely employed to assess the variables that influence the inhibitory efficiency of plant extracts on metal corrosion in an alkaline medium [20].

Since it is a widespread aquatic weed, water hyacinth (Eichhornia crassipes) was selected as a potential green corrosion inhibitor for this study. Alkaloids, phenolics, terpenoids, and flavonoids are just a few of the phytochemicals that have reportedly been found in plant extract [21]. To investigate the application of the biomass of water hyacinth plant extracts as an eco-friendly inhibitor of the corrosion of mild steel in an alkaline medium and to demonstrate how to extract dose influences corrosion inhibition and surface morphologies of test samples, this study will look at their utilization.

2.1. Experimentation

The metallurgical foundry of the Federal University of Technology Metallurgical and Materials Engineering Department is located in the Ondo State part of Nigeria, and the test samples for this work were acquired from this location. The results from the chemical compositions of the test mild steel specimen are presented in Table 1. This type of steel for structural application is reactive in alkaline working environments if there is no provision for a surface barrier and or introduction of corrosion inhibitors [22]. This current work used the bio-based inhibitor, digested powder extract (DPE) from the leaves of the water hyacinth plant, to investigate its corrosion protective properties on the prevalence of the test specimens in an alkaline media. According to [21], the phytochemical constituents of the extract are given in Table 2.

Table 1

Components of the as-received test metal sample
Element	Mn	Mo	Cr	S	P	Cu	Si	C
Weight (g)	0.52	0.011	0.17	0.031	0.035	0.15	0.20	0.29
Element	Co	Fe	Ca	Ti	Al	B	Zn	V
Weight (g)	0.007	98.3	0.003	0.002	0.007	0.0002	> 0.027	0.003
Element	Pb	Sb	As	Sn	N	Sb
Weight (g)	0.007	0.018	0.006	0.026	0.023	0.018

Table 2

Plant extract from water hyacinth with its phytochemical makeup [21].
Compositions	Anthraquinones	Anthocyanin	Saponin	Flavonoids	Tannins

2.2. Samples for testing and producing a hot water digestion-based water hyacinth plant extract

The measurement of the mild steel working specimens was carried out via the digital vernier caliper and separated into multiple sets according to the design of the experiment. Each sample set was polished using SiC emery papers of various grit sizes to create a sparkling and smooth surface appropriate for the electrochemical polarization analysis and weight loss experiment. The weight loss measurements after exposure to the test solution, 0.5 M NaOH, were conducted in three days intervals for a total of thirty days.

The biomass of the water hyacinth plant was taken from a famous river known as Igbokoda in Nigeria, where the plant is a serious menace and problematic to water transportation to the community. The plant's petals were separated and washed followed by oven-drying at a controlled temperature of 70°C for not more than five hours to prevent denaturing of the plant. After the oven-drying process, the dried leaves were crushed mechanically into extremely fine powder, denoted in this work as digested powdered extract (DPE). The purpose of grinding is to increase the surface area required for maximum extraction of the phytochemical elements for corrosion protection characteristics. The solutions in each beaker were decanted and placed through filtering to produce the requisite powdered filtrate. The term (DPE), which is similar to our recent article [23], is related to the same procedure. For the test, different weights of the DPE concentration were studied, ranging from 0.05 to 0.25 g/l with an increasing step size of 0.05 g/l followed by the control sample in five different laboratory beakers with 100 ml of the test alkaline solution, 0.5 M NaOH, at room temperature.

2.3. Corrosion rate of test specimens utilizing the gravimetric (weight-loss) method

Test samples were immersed in 100 ml of the test alkaline solution and a part for the control experiment with no inhibitor exposure. In the 0.5 M NaOH solution, the additional test samples were examined to learn more about the inhibition of DPE at increasing concentrations. The initial weights of the test samples before immersion were estimated using a laboratory weighing balance, and the reduction or loss in weights was computed throughout 30 days at 3-day intervals. After observing the loss in weight, the corrosion rate was calculated using Eq. 1 in accordance with ASTM G1 standard using the weight loss for respective test samples [23].

$$CR=\frac{ 3.45{\times 10}^{6} \times W}{A\times T\times D} \dots \dots \dots \dots \dots \dots \dots \dots \dots \dots \dots \dots \dots \dots \dots \dots . \dots \dots \dots \dots \dots \dots \dots \dots \dots \dots \dots \dots \dots \left(1\right)$$

The following values are given: T for exposure duration (in hrs), A stands for the area of exposure (in cm²), W for loss in weight (in g), CR for the rate of corrosion (in mpy), and D for the density of the test specimen (in gcm^− 3).

2.4. Electrochemical polarization of the test samples

The 0.5M sodium hydroxide solution employed in this work served as the working exposure solution and contained various extract concentrations from 0.05 to 0.25 g/l with a step size of 0.05 g/l alongside the control sample with no extract. Figure 1 depicts the sample setup with copper wire in an insulating conduit attached to the test surface of the test specimens for electrochemical testing, followed by epoxy coating to reveal only the test surface area required. The test surface area exposed was further surface-prepared via polishing by SiC emery papers before exposure.

In the current study, Ag/AgCl served as the reference electrode, platinum rod served as a counter electrode, and the prepared test specimens as the working electrodes. The electrochemical tests were conducted at room temperature using the three-electrode cell configuration, as indicated in Fig. 2, and an AUTOLAB PGSTAT 204N instrument was used. The corrosion current density (Icorr) and corrosion potential (Ecorr), two electrochemical parameters, were obtained by fitting the polarization curves via Tafel fitting using the multifunctional electrochemical program. Potentiodynamic polarisation analysis was used to calculate the current density and corrosion rate [24].

2.5. Optical micrograph analysis of the test samples

The metallic surface attributes were investigated to discover how they had altered employing corroded and control sample surface study via optical microscope with model number 702907. The samples were meticulously ground using SiC emery papers. The specimens subjected at the best inhibitor concentrations and those with the lowest inhibitor concentrations and highest corrosion after 30 days in the alkaline medium regulated laboratory circumstances were taken into account for optical microstructural examination.

3.1. Optical surface features of test samples

Figure 3 gives the optical examination profiles of the corrosion for the test samples with and without DPE and the as-received sample. When compared to the surface profile of the micrograph of the control sample (Fig. 3B), which was taken as soon as it was received (Fig. 3A), the test samples show surface deterioration upon exposure to the alkaline solution. Additionally, Fig. 3B shows the surface characteristics of a 0.5M NaOH solution, which depicts localized corrosion [25]. The surface characteristics of test the sample submerged in the test solution containing 0.25 g/L of DPE is shown in Fig. 3C. Localized corrosion outside the M_{0.25 g/L} sample did not experience severe localized corrosion compared to the control sample (Fig. 3C). In addition, it was found that the corrosion product on the surface of the M_{0.25 g/L} samples was disseminated over the surface in a targeted manner (3C), which may be the reason for the diminished corrosion attack [25]. The electrochemical and gravimetric analyses are presented in the next section to further study the corrosion characteristics of the test samples.

3.2. Weight loss corrosion behavior of test specimens

The loss in weight upon exposure to the test solution for each experimental sample was assessed following each three-day testing period to determine the pace during which the media brought on corrosion. Figure 4 displays the corrosion rate by weight loss technique and micrographs for the most minor and control samples. Eq. 1 was used to compute the distinctive corrosion rate of every specimen tested utilizing the weight loss data of that sample. The results demonstrate wide variation in the corrosion response of the test samples for the first ten days of the test in the alkaline medium, with the control sample showing a higher corrosion trend and suggesting a less protective corrosion profile. The test samples with an overlay of the corroded surface feature further support the M_{0.25 g/L} sample showing a decreased propensity for corrosion rate with exposure (Fig. 4). It should be noted that the corrosion rate of each test specimen was affected by the amount of DPE present and the duration of exposure [27].

3.3. Electrochemical potentiodynamic polarization characteristics of test samples

The effects of DPE on the polarisation curves of mild steel in 0.5 M NaOH solution are shown in Fig. 5. It is demonstrated that the corrosion current density (i_corr) values shifted more strongly towards decreasing values as the extract concentration rose. Similar results were achieved in a recent report [28], where the authors used the extract of Cratevaadansonii as a biomass-based inhibitor for mild steel in an acidic media.

As the dosage levels of DPE rose compared to the reference sample, Fig. 5 demonstrates that the polarisation curves of the samples with DPE went towards decreasing values of the current density regime and a more positive regime of the corrosion potential. This demonstrates that when DPE content increases, the corrosion rate reduces, further supporting the gravimetric conclusion shown in Fig. 4 and our earlier research [20]. These results indicate that in alkaline-prone environments, synthetic DPE bio-inhibitor can effectively limit mild steel corrosion rates [29]. Particularly for the DPE samples, a decreased corrosion rate was found according to the polarisation curve (Fig. 5). According to the gravimetric results, which also show that corrosion rates decrease with increasing dosage of extract concentration, the M_{0.25 g/L} specimen had the lowest corrosion rate, and the control sample had the highest corrosion rate. As evidence of the decreased corrosion rate due to the DPE, the specimen M_{0.25 g/L} exhibits a higher corrosion potential than the reference sample (Fig. 5). Likewise, the phytochemical elements of the water hyacinth plant (Table 2) may be the result for inhibiting the chemical reaction of the alkaline solution with the tested samples, which resulted in lower corrosion rate characteristics. It should be noted that both the cathodic and anodic Tafel lines are shown to be affected by the presence of the aqueous extract showing that the synthesized bio-based extract function as a mixed-type inhibitor. As a result, both cathodic and anodic locations are more prone to experience the adsorption of inhibitors, and this phenomenon is also reflected in a recent research article [30].

The findings of this investigation demonstrated that the characteristics of the corrosion of mild steel in an alkaline medium responded differently concerning the DPE content in an alkaline solution. The weight loss, surface morphology, and electrochemical polarization results were evaluated to analyze the behavior of the test samples in the experimental setting. The weight and the electrochemical data showed that the test samples' corrosion rate decreased linearly with the concentration of the DPE. The electrochemical polarization results for corrosion reduction showed increased corrosion potential with increasing inhibitor dosage. It, therefore, implies the possibility of employing mild steel as components in design in an alkaline-based environment with DPE as the coating on the surface due to the decrease in corrosion rate caused by the DPE medium, highlighting its potential applicability. For the future, it is essential to look at the interface electrical properties via electrochemical impedance spectroscopy, surface chemistry via x-ray photoelectron spectroscopy, and other state-of-the-art interface study techniques to establish a thorough interface relationship of the synthesized DPE on mild steel in an alkaline medium.

Competing interest

There are no competing interests to declare.

Funding

This research work did not receive any funding.

Acknowledgment

The Metallurgical and Materials Engineering Department, Corrosion Laboratory, Federal University of Technology Akure, Nigeria.

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Understanding the behavior of mild steel in sodium hydroxide: a biomass corrosion mitigation approach

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Abstract

Figures

1. Introduction

2. Materials and method

2.1. Experimentation

2.2. Samples for testing and producing a hot water digestion-based water hyacinth plant extract

2.3. Corrosion rate of test specimens utilizing the gravimetric (weight-loss) method

2.4. Electrochemical polarization of the test samples

2.5. Optical micrograph analysis of the test samples

3. Results and discussion

3.1. Optical surface features of test samples

3.2. Weight loss corrosion behavior of test specimens

3.3. Electrochemical potentiodynamic polarization characteristics of test samples

4. Conclusion

Declarations

Competing interest

Funding

Acknowledgment

References

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