Charging a sacrificial anode with ions of the sacrificial material

• US 8,961,746 B2
• Filed: 07/19/2012
• Issued: 02/24/2015
• Est. Priority Date: 07/19/2012
• Status: Active Grant

• Current Assignee: Vector Corrosion Technologies Incorporated (Vector Corrosion Technologies)
• Original Assignee: Vector Corrosion Technologies Incorporated (Vector Corrosion Technologies)
• Inventors: Sergi, George, Seneviratne, Attanayake Mudiyanselage Gamini, Whitmore, David
• Primary Examiner(s): Van, Luan
• Assistant Examiner(s): Keeling, Alexander W
• Application Number:
  US13/553,498
• Publication Number:
  US 20140021062A1
• Time in Patent Office: 950 Days
• Field of Search: 205/724, 205/734, 205/735, 204/196.01, 204/196.02, 204/196.04
• US Class Current: 204/196.04
• CPC Class Codes: C04B 2111/265 Cathodic protection of reinforced concrete structures
• CPC Class Codes: C23F 13/04 Controlling or regulating desired parameters
• CPC Class Codes: C23F 13/06 Constructional parts, or assemblies of cathodic-protection apparatus
• CPC Class Codes: C23F 13/08 Electrodes specially adapted for inhibiting corrosion by cathodic protection; Manufacture thereof; Conducting electric current thereto
• CPC Class Codes: C23F 13/14 Material for sacrificial anodes
• CPC Class Codes: C23F 13/20 Conducting electric current to electrodes
• CPC Class Codes: C23F 2201/02 Concrete, e.g. reinforced
• CPC Class Codes: C23F 2213/22 characterized by the ionic conductor, e.g. humectant, hydratant or backfill
• CPC Class Codes: E04C 5/015 Anti-corrosion coatings or treating compositions, e.g. containing waterglass or based on another metal coating of discrete reinforcing elements C04B20/10

Abstract

Cathodic protection of steel in concrete is provided by locating an anode assembly including both a sacrificial anode and an impressed current anode in contact with the concrete and providing an impressed current from a power supply to the anode. The impressed current anode forms a perforated sleeve surrounding a rod of the sacrificial anode material with an activated ionically-conductive filler material between. The system can be used without the power supply in sacrificial mode or when the power supply is connected, the impressed current anode can be powered to provide an impressed current system and/or to recharge the sacrificial anode from sacrificial anode corrosion products.

Claims

1. A method for use in corrosion protection of a metal section in an ionically conductive material comprising:

locating a sacrificial anode of a sacrificial material in ionic contact with the ionically conductive material;

causing the sacrificial anode to corrode preferentially in relation to the metal section while the sacrificial anode is connected to the metal section to provide corrosion protection of the metal section by the corrosion of the sacrificial anode such that ions of the sacrificial material are depleted from the sacrificial anode as the sacrificial anode corrodes;

and recharging the sacrificial anode using a current supplied by a DC power supply which causes ions of sacrificial anode material to be re-deposited on the sacrificial anode.

2. The method according to claim 1 wherein the sacrificial anode is re-charged by locating an impressed current anode in ionic contact with the ionically conductive material and connecting a first terminal of a DC power supply to the impressed current anode so as to cause ionic current to flow through material to cause sacrificial anode ions to be deposited on the sacrificial anode.

3. The method according to claim 1 wherein sacrificial anode ions are present in the ionically conductive material.

4. The method according to claim 1 wherein the re-charging causes hydroxyl ions to be generated at the surface of the sacrificial anode.

5. The method according to claim 1 wherein the re-charging causes an alkali environment to be re-generated around the sacrificial anode.

6. The method according to claim 1 wherein the sacrificial anode is recharged repeatedly using a current supplied by the DC power supply which causes ions of sacrificial anode material to be re-deposited on the sacrificial anode.

7. The method according to claim 1 wherein the DC power supply is applied temporarily.

8. The method according to claim 1 wherein the DC power supply is applied by a battery.

9. The method according to claim 1 wherein the ions of the sacrificial material are soluble.

10. The method according to claim 1 wherein the ions of the sacrificial material are electrochemically mobile.

11. The method according to claim 1 wherein the metal section is steel and the ionically conductive material is concrete or mortar.

12. The method according to claim 1 wherein the DC power supply is applied by a solar cell.

13. The method according to claim 1 wherein the DC power supply is applied by a rectifier.

14. The method according to claim 1 wherein there is provided an ionically conductive filler material adjacent the sacrificial anode and wherein the method includes incorporating ions of the sacrificial material in the ionically conductive filler material for deposit of the incorporated ions of the sacrificial material on the sacrificial anode.

15. A method for use in corrosion protection of a metal section in an ionically conductive material comprising:

locating an impressed current anode in ionic contact with the ionically conductive material;

locating a sacrificial anode in ionic contact with the ionically conductive material;

providing a DC power supply;

connecting a first terminal of a DC power supply to the impressed current anode;

connecting a second terminal of the DC power supply to the sacrificial anode so as to cause ions of sacrificial anode material to be deposited on the sacrificial anode.

16. The method according to claim 15 wherein there is provided a connection between the sacrificial anode and the metal section so that the sacrificial anode provides cathodic protection.

17. The method according to claim 15 wherein there is provided a connection between the sacrificial anode and the metal section when the DC power supply is causing ionic current to flow through the ionically conductive material.

18. The method according to claim 15 wherein the ions of the sacrificial material deposited on the sacrificial anode are present in the ionically conductive material.

19. The method according to claim 15 wherein the ionic current acts to generate hydroxyl ions at the surface of the sacrificial anode.

20. The method according to claim 15 wherein the ionic current acts to regenerate an alkali environment around the sacrificial anode.

21. The method according to claim 15 wherein, in a first step, the sacrificial anode is connected to the metal section to provide corrosion protection of the metal section by corrosion of the sacrificial anode which results in the formation of corrosion products of the sacrificial anode and wherein, in a second step after corrosion of the sacrificial anode has occurred, the current supplied by the DC power supply causes the ions of the sacrificial material, from the corrosion products of the sacrificial anode, to be re-deposited on the sacrificial anode.

22. The method according to claim 15 wherein the step of causing ions of the sacrificial anode material to be deposited on the sacrificial anode acts to cause fabrication of at least a portion of the sacrificial anode.

23. The method according to claim 15 wherein, the second terminal of the DC power supply is connected to the sacrificial anode and to the metal section.

24. The method according to claim 23 wherein the connection of the DC power supply across the impressed current anode and the metal section creates a current between the metal section and the impressed current anode which is used to passivate the metal section.

25. The method according to claim 23 wherein the connection of the DC power supply across the impressed current anode and the metal section creates a current between the metal section and the impressed current anode which is used to provide corrosion protection to the metal section while the ions of the sacrificial material are being deposited on the sacrificial anode.

26. The method according to claim 15 wherein the sacrificial anode and the impressed current anode comprise common components of a common anode assembly.

27. The method according to claim 26 wherein the impressed current anode and the sacrificial anode are electrically separated to prevent electrical communication therebetween.

28. The method according to claim 26 wherein the impressed current anode is perforated so to allow passage of ionic current through the impressed current anode.

29. The method according to claim 15 wherein the sacrificial anode forms a rod and the impressed current anode forms a sleeve surrounding the rod.

30. The method according to claim 15 wherein the impressed current anode and the sacrificial anode comprise side by side plates.

31. The method according to claim 15 wherein there is provided an ionically conductive filler material adjacent the sacrificial anode.

32. The method according to claim 31 wherein the ionically conductive filler material is different from said ionically conductive material.

33. The method according to claim 31 including the step of adding ions of sacrificial anode material to the ionically conductive filler material.

34. The method according to claim 31 wherein the ionically conductive filler material is porous.

35. The method according to claim 31 wherein the ionically conductive filler material is deformable.

36. The method according to claim 31 wherein the ionically conductive filler material contains at least one activator to ensure continued corrosion of the sacrificial anode.

37. The method according to claim 31 wherein the ionically conductive filler material is hydroscopic.

38. The method according to claim 31 wherein the ionically conductive filler material has a pH sufficiently high for corrosion of the sacrificial anode to occur and for passive film formation on the sacrificial anode to be avoided.

39. The method according to claim 15 wherein there is provided a plurality of sacrificial anodes and wherein the impressed current anode is separate from said sacrificial anodes.

40. The method according to claim 15 wherein there is provided a plurality of impressed current anodes and wherein the sacrificial anode is separate from said impressed current anodes.

41. The method according to claim 15 wherein the impressed current anode is arranged to be mounted temporarily to provide current through a surface of the ionically conductive material.

42. The method according to claim 15 wherein the ions of sacrificial anode material are soluble.

43. The method according to claim 15 wherein the ions of sacrificial anode material are electrochemically mobile.

44. The method according to claim 15 wherein the metal section is steel and the ionically conductive material is concrete or mortar.

45. The method according to claim 15 wherein a portion of the ionically conductive material or the sacrificial anode is wetted.

46. The method according to claim 15 wherein the impressed current anode is mounted temporarily for the purpose of causing the ions of the sacrificial material to be deposited.

47. The method according to claim 15 wherein the DC power supply is applied by a solar cell.

48. The method according to claim 15 wherein the DC power supply is applied by a rectifier.

49. A method for use in corrosion protection of a metal section in an ionically conductive material comprising:

locating a sacrificial anode in ionic contact with the ionically conductive material to provide corrosion protection of the of the metal section;

and temporarily placing an impressed current anode in ionic contact with a surface of the ionically conductive material and applying a voltage from a DC power supply to the impressed current anode so as to cause ions of sacrificial anode material to be deposited on the sacrificial anode.