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Electrochemistry, Corrosion & Its Prevention

Electrochemistry — electrolytes and conductance, electrochemical (galvanic) and electrolytic cells, electrode potential and standard hydrogen electrode, EMF of cells, electrochemical series, Nernst equation, reference electrodes, pH measurement; batteries (primary, secondary, lithium-ion) and fuel cells; Faraday's laws of electrolysis and electroplating; corrosion — dry (chemical) and wet (electrochemical) mechanisms, rusting of iron, Pilling–Bedworth rule, galvanic series; types — galvanic, differential aeration, pitting, crevice, stress corrosion, intergranular, erosion and microbiological corrosion; factors affecting corrosion; corrosion of steel in concrete — passivation, carbonation and chloride attack; prevention — design, material selection, coatings (galvanising, tinning, paints, epoxy), cathodic protection, inhibitors and concrete durability measures — with fully worked numericals.

📑 Contents (11 sections)

Last reviewed 16 Sept 2026 · 11 min read

Electrochemistry basics

  • Electrolytes conduct electricity by movement of ions (in solution or molten state) — strong (NaCl, HCl) and weak (CH₃COOH, NH₄OH).
  • Conductance ; specific conductance (conductivity) κ; molar conductivity increases with dilution.
  • Electrochemical cell (galvanic/voltaic) — converts chemical energy → electrical energy spontaneously (batteries).
  • Electrolytic cell — uses electrical energy to drive non-spontaneous reactions (electroplating, electrolysis).

Electrodes

  • Anode — oxidation (loss of electrons).
  • Cathode — reduction (gain of electrons).
  • In a galvanic cell, anode is negative, cathode positive; in an electrolytic cell, anode is positive.
  • Mnemonic: "An Ox, Red Cat" (anode oxidation, reduction cathode).

Daniell cell: Zn | Zn²⁺ || Cu²⁺ | Cu — zinc anode (Zn → Zn²⁺ + 2e⁻), copper cathode (Cu²⁺ + 2e⁻ → Cu); salt bridge completes the circuit and maintains neutrality.

Electrode potential and EMF

  • Standard electrode potential E° — measured against the standard hydrogen electrode (SHE), assigned 0.00 V, at 25 °C, 1 M ion concentration, 1 atm.
  • Standard reduction potentials (examples):
Half reaction E° (V)
Li⁺ + e⁻ → Li −3.04
Mg²⁺ + 2e⁻ → Mg −2.37
Al³⁺ + 3e⁻ → Al −1.66
Zn²⁺ + 2e⁻ → Zn −0.76
Fe²⁺ + 2e⁻ → Fe −0.44
2H⁺ + 2e⁻ → H₂ 0.00
Cu²⁺ + 2e⁻ → Cu +0.34
O₂ + 2H₂O + 4e⁻ → 4OH⁻ +0.40
Ag⁺ + e⁻ → Ag +0.80
Au³⁺ + 3e⁻ → Au ≈ +1.5
  • Electrochemical series — metals with more negative E° are more active (stronger reducing agents, more easily oxidised/corroded) and displace metals below them from solution.
FormulaCell EMF and Nernst equation

Nernst equation (25 °C):

= electrons transferred; = reaction quotient. For an electrode : .

Spontaneity: — reaction is spontaneous when .

Reference electrodes and pH

  • Calomel electrode (Hg/Hg₂Cl₂/KCl), silver–silver chloride electrode — stable secondary references.
  • Copper–copper sulphate electrode (CSE) — used in half-cell potential surveys of reinforced concrete.
  • Glass electrode — pH measurement; pH .

Batteries and fuel cells

Type Examples Features
Primary (non-rechargeable) Dry cell (Leclanché, zinc–carbon), alkaline cell Single use
Secondary (rechargeable) Lead–acid (Pb anode, PbO₂ cathode, H₂SO₄; ~2 V per cell), nickel–cadmium, nickel–metal hydride, lithium-ion Rechargeable; Li-ion — high energy density (vehicles, electronics, grid storage for solar)
Fuel cells Hydrogen–oxygen fuel cell (H₂ + ½O₂ → H₂O) Continuous supply of fuel; high efficiency; only water as product (hydrogen fuel cells)

Electrolysis — Faraday's laws

FormulaFaraday's laws

First law: mass deposited ∝ charge passed

= electrochemical equivalent; = molar mass; = valency (electrons per ion); = Faraday constant ≈ 96 485 C/mol.

Second law: for the same charge, masses deposited are proportional to chemical equivalent weights ().

Applications: electroplating (chromium, nickel, zinc), electrorefining of copper, electrometallurgy of aluminium, electrochemical chloride extraction and re-alkalisation of concrete (rehabilitation techniques).

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