Pitting corrosion of copper in waters with high pH and low alkalinity

The acceleration of localized copper corrosion by extracellular polymeric substances of sulfate-reducing bacteria

Microbial-induced corrosion (MIC) of copper pipelines, especially in sulfate-reducing bacteria (SRB)-rich environments, poses a significant challenge. Despite its importance, the role of SRB-secreted extracellular polymeric substances (EPS) in copper corrosion particularly their time-dependent interactions remains unclear. This knowledge gap limits the development of effective corrosion mitigation strategies. In this study, we investigate the impact of EPS on copper corrosion using electrochemical and surface characterization techniques. Our findings reveal that EPS exhibits a dual role in copper corrosion. During the initial immersion phase (1-3 days), EPS adsorption forms a protective layer, temporarily inhibiting corrosion. In the middle stage (4-8 days), EPS accelerates corrosion by degrading the copper oxide film, as evidenced by a negative shift in the breakdown potential (Eb). In the final stage (9-14 days), uneven EPS coverage exacerbates localized corrosion. Thus, SRB-secreted EPS initially acts as a corrosion inhibitor but later promotes localized corrosion through oxide film disruption and non-uniform coverage. We systematically investigated the mechanisms of EPS-mediated corrosion inhibition across different immersion periods, identifying the critical transition threshold between the inhibition and promotion phases.

Decoupling CO2 effects from electrochemistry: A mechanistic study of copper catalyst degradation

Copper-based nanoparticles are key electrocatalysts for CO2 electrochemical reduction (CO2 ER) to liquid fuels and other value-added products. However, the copper catalyst can undergo rapid electrochemical corrosion, leading to a loss of catalyst material, fluctuations in the reaction conditions and increasing operational costs. We establish a mechanistic understanding of this detrimental process using in situ electrochemical electron microscopy and density functional theory (DFT). We find that copper corrosion can occur in the presence of CO2 in electroless conditions and before the onset potentials required for CO2 ER. The effects are isolated from pH changes resulting from dissolved CO2. Particles of corroded copper have oxidized surfaces, in contrast to copper surfaces exposed to CO2-free electrolytes. DFT calculations identify multiple routes by which CO2 can behave as a dissolution agent for copper and copper-oxide surfaces and suggest that formate-intermediates are a key driver of corrosion. This study highlights microenvironment-based factors that affect copper performance and degradation, facilitating strategies to inhibit and reverse copper degradation during CO2 ER.

Free Chlorine Can Inhibit Lead Solder Corrosion via Electrochemical Reversal

Galvanic corrosion of lead-tin solder in copper plumbing can be a major contributor to water lead contamination. Here, we report the electrochemical reversal of the copper-solder galvanic couple, in which the normally anodic solder becomes cathodic to copper via a reaction with free chlorine. This reversal occurred after a few months of exposure to continuously circulating water with relatively low pH and low alkalinity, causing dramatically decreased lead release and the formation of a Pb(IV) scale. Chloramine did not similarly inhibit solder corrosion over the 4-9 month test duration, resulting in up to 100 times more lead contamination of the water relative to free chlorine. These findings have major implications for corrosion control and public health and can help explain anomalously low levels of lead contamination in some waters with free chlorine that are normally considered corrosive to solder.

Effect of benzotriazole on the existing pits of copper tube in fire sprinkler system

In this paper, two leaking tubes were investigated among copper tubes injected with 200 and 400 ppm benzotriazole after 8 years of usage. The electrochemical tests were conducted in simulated pit-out and pit-in environments (i.e., regions outside and inside of the pit) to determine the effect of benzotriazole on the propagation of an existing pit. The electrochemical analysis results showed that 200 and 400 ppm benzotriazole exhibit relatively lower inhibition efficiency in an acidic simulated pit-in environment because of the difficulty of forming a protective film and the benzotriazole cationization.

The influence of calcium on copper corrosion and its by-product release in drinking water

Copper is a high-quality material commonly used in drinking water supply pipes. Calcium is a prevalent cation found in drinking water. However, the effects of calcium on copper corrosion and its by-product release remain unclear. This study discusses the influences of Ca²⁺ on copper corrosion and its by-product release in drinking water under different conditions of Cl^-, SO₄^2-, and Cl^-/SO₄^2-, using electrochemical and scanning electron microscopy techniques. The results indicate that Ca²⁺ slows down the corrosion reaction of copper to some extent in comparison with Cl^-, and the E_corr shifts positively by 0.022 V, while I_corr decreases by 0.235 μA cm^-2. However, the by-product release rate increases by 0.5 μg cm^-2. The addition of Ca²⁺ causes the anodic process to become the controlling factor for corrosion, with an increase in resistance observed in both the inner and outer layers of the corrosion product film through SEM analysis. The corrosion product film becomes denser due to the reaction between Ca²⁺ and Cl^-, forming a product that inhibits the entry of Cl^- into the passive film on the copper surface. Adding Ca²⁺ promotes copper corrosion with the help of SO₄^2- and the release of corrosion by-products. The anodic reaction resistance decreases while the cathodic reaction resistance increases, resulting in a small potential difference of only 10 mV between the anode and cathode. The resistance of the inner layer film decreases, while that of the outer layer film increases. SEM analysis shows that the surface becomes rougher with the addition of Ca²⁺, and 1-4 mm granular corrosion products are formed. This is due to the fact that Cu₄(OH)₆SO₄ has low solubility and forms a relatively dense passive film that inhibits the corrosion reaction. The added Ca²⁺ also reacts with SO₄^2- to form CaSO₄, which reduces the amount of Cu₄(OH)₆SO₄ generated at the interface, thus damaging the integrity of the passive film. Adding Ca²⁺ promotes the corrosion of copper by Cl^- and SO₄^2- and enhances the release of corrosion by-products, with the highest corrosion rate observed under the Cl^-/SO₄^2-/Ca²⁺ conditions. The resistance of the inner layer membrane decreases, while the mass transfer resistance of the outer layer membrane increases. Under the Cl^-/SO₄^2- conditions, the SEM surface of the Cu₂O particles is uniform in size, arranged in an orderly and compact manner. After adding Ca²⁺, the size of the particles becomes uneven, and the surface becomes rough and uneven. This is because Ca²⁺ firstly combines with SO₄^2-, thus promoting corrosion. And then the remaining Ca²⁺ combines with Cl^-, which inhibits corrosion. Despite the amount of remaining Ca²⁺ being small, it still promotes corrosion. The amount of released corrosion by-products is mainly controlled by the redeposition reaction that occurs in the outer layer membrane, determining the amount of Cu₂O to which the copper ions are converted. The increase in resistance of the outer layer membrane means that the charge transfer resistance of the redeposition reaction increases, and the reaction rate slows down. Consequently, the amount of Cu(ii) converted to Cu₂O decreases, leading to an increase in Cu(ii) in the solution. Therefore, adding Ca²⁺ in all three conditions results in an increase in the release of corrosion by-products.

Optimized purification methods for metallic contaminant removal from directly recycled Li-ion battery cathodes

Metallic contaminants pose a significant challenge to the viability of directly recycling Li-ion batteries. To date, few strategies exist to selectively remove metallic impurities from mixtures of shredded end-of-life material (black mass; BM) without concurrently damaging the structure and electrochemical performance of the target active material. We herein present tailored methods to selectively ionize two major contaminants-Al and Cu-while retaining a representative cathode (LiNi_0.33Mn_0.33Co_0.33O₂; NMC-111) intact. This BM purification process is conducted at moderate temperatures in a KOH-based solution matrix. We rationally evaluate approaches to increase both the kinetic corrosion rate and the thermodynamic solubility of Al⁰ and Cu⁰, and evaluate the impact of these treatment conditions on the structure, chemistry, and electrochemical performance of NMC. Specifically, we explore the impacts of chloride-based salts, a strong chelating agent, elevated temperature, and sonication on the rate and extent of contaminant corrosion, while concurrently evaluating the effects on NMC. The reported BM purification process is then demonstrated on samples of "simulated BM" containing a practically relevant 1 wt% concentration of Al or Cu. Increasing the kinetic energy of the purifying solution matrix through elevated temperature and sonication accelerates the corrosion of metallic Al and Cu, such that ∼100% corrosion of 75 μm Al and Cu particles is achieved within 2.5 hr. Further, we determine that effective mass transport of ionized species critically impacts the efficacy of Cu corrosion, and that saturated Cl^- hinders rather than accelerates Cu corrosion by increasing solution viscosity and introducing competitive pathways for Cu surface passivation. The purification conditions do not induce bulk structural damage to NMC, and electrochemical capacity is maintained in half-cell format. Testing in full cells suggests that a limited quantity of residual surface species are present after treatment, which initially disrupt electrochemical behavior at the graphite anode but are subsequently consumed. Process demonstration on simulated BM suggests that contaminated samples-which prior to treatment show catastrophic electrochemical performance-can be recovered to pristine electrochemical capacity. The reported BM purification method offers a compelling and commercially viable solution to address contamination, particularly in the "fine" fraction of BM where contaminant sizes are on the same order of magnitude as NMC and where traditional separation approaches are unfeasible. Thus, this optimized BM purification technique offers a pathway towards viable direct recycling of BM feedstocks that would otherwise be unusable.

A New Type of Silica-induced “Moundless” Pitting Corrosion in Copper Observed in Japan

A new type of pitting corrosion in copper, namely “moundless” corrosion, has recently been reported in Japan. This type of pitting corrosion has some unique morphological features that differ from ordinary types of pitting corrosion, such as type I or type II. Firstly, this type of pitting corrosion has no mound of corrosion products that cover the mouth of the pit. In addition, a glassy verdigris exists around the pit. Furthermore, the pit measures <1 mm in diameter, but is extremely deep. In our study, we reproduced moundless pits by field testing in an area where moundless pits have often occurred. Moundless pits were also generated in synthetic freshwater through the dissolution of some selected components in a laboratory test. This synthetic freshwater contained 40 ppm SiO₂, 50 ppm SO₄²⁻, 10 ppm Cl⁻, and 10 ppm HCO₃⁻. Surface analysis of the moundless pit revealed that the mouths of the pits were covered with thin films that were mainly composed of silica.

Multivariate experimental design provides insights for the optimisation of rechloramination conditions and water age to control disinfectant decay and disinfection by-product formation in treated drinking water

The stability of drinking water disinfectant residuals is known to be influenced by multiple variables. To evaluate the effects of various influencing variables on disinfectant stability, a multivariate analysis of chloramine decay and associated disinfection by-products (DBPs) formation was investigated in a series of bench-scale experiments. Of nine water quality variables previously identified, monochloramine dose, pH, and bromide concentration were selected as key water quality variables based on previous investigations and modelling. Co-effects of these key variables on monochloramine decay and formation of 33 halogenated and nitrogen-containing DBPs were investigated using response surface experimental design. Rechloramination conditions, including monochloramine dose, pH and bromide concentration, were optimised via a 3-factorial multivariate analysis of monochloramine stability in post-treatment drinking water. Effects of influencing variables on disinfectant decay and DBP formation were assessed and graphically presented as response surfaces with minimal experiments using Doehlert matrix experimental design compared to other multivariate experimental designs. Concentrations of trihalomethanes (THMs), haloacetic acids (HAAs), and N-nitrosamines were found to increase with water age, whereas opposite phenomenon was observed in the net production of haloacetonitriles (HANs). Increasing pH was found to stabilise monochloramine but it could cause DBP speciation to shift. Furthermore, increasing bromide concentration elevated Br-DBP formation. In bromide-containing water, pH = 7.8-8.0 should be considered as higher pH increases Br-THMs formations and lower pH increases formations of Br-HAAs and Br-HANs. However, water age or pH has insignificant impacts on DBP formation after significant monochloramine decay or at low initial monochloramine dose. These findings indicate that effective combined control measures to maintain monochloramine stability should include the application of high monochloramine dose (>1.5 mg-Cl₂.L^-1) under conditions of moderate to high pH (pH = 7.8-8.0) and minimal bromide concentration. This study provides relevant insights to water utilities aiming to design effective disinfectant residual management strategies for controlling monochloramine decay and DBP formation.

Quartz Crystal Microbalance with Dissipation: A New Approach of Examining Corrosion of New Copper Surfaces in Drinking Water

Corrosion of copper material in drinking water systems causes public health concerns and plumbing failures. This study investigated the early corrosion of new copper surfaces in situ using a novel technique: quartz crystal microbalance with dissipation (QCMD). The QCMD results showed that increasing the water pH from 6.5 to 9.0 and the addition of 6 mg/L orthophosphate at pH 6.5 and 9.0 slowed down the copper surface mass changes as indicated by the reduced changes in frequency (Δf5) at 51-89% and total copper release at 29-72%. The water pH 9.0 without orthophosphate was the most likely to induce localized corrosion relative to other conditions at pH 6.5 and pH 9.0 with orthophosphate. Based on the changes in dissipation values (ΔD5) from QCMD and the morphology, microstructure, and composition of the deposited copper corrosion byproducts, digital microscopy, field-emission scanning electron microscopy with energy dispersive spectroscopy, and X-ray photoelectron spectrometry analyses confirmed that the pH and orthophosphate inhibited copper corrosion with different mechanisms. QCMD provided sensitive, rapid, and continuous responses to mass and surface changes and can be useful for evaluating early water corrosivity to new copper.

Effect of Benzotriazole on the Localized Corrosion of Copper Covered with Carbonaceous Residue

Carbonaceous residues on copper pipes during the manufacturing process are known to be one of the main causes of pitting corrosion on copper pipes. This study examined the corrosion-inhibiting effect of benzotriazole (BTA) on C12200 copper pipes with carbonaceous film in synthetic tap water. In the absence of BTA, localized corrosion mechanisms due to galvanic corrosion, crevice corrosion, and oxygen-concentration cell were proposed in the boundary part of the carbonaceous film on the copper through X-ray photoelectron spectroscopy (XPS), scanning electron microscopy (SEM) with energy dispersive spectrometer (EDS) analyses. Electrochemical tests showed that BTA inhibits corrosion by forming Cu−BTA complexes on all over the copper surface where carbonaceous film is present. BTA mitigates galvanic corrosion and crevice corrosion at the boundary of the carbonaceous film and suppresses the formation of oxygen-concentration cells through the formation of a Cu−BTA complex.

Causes, Factors, and Control Measures of Opportunistic Premise Plumbing Pathogens—A Critical Review

This review critically analyses the chemical and physical parameters that influence the occurrence of opportunistic pathogens in the drinking water distribution system, specifically in premise plumbing. A comprehensive literature review reveals significant impacts of water age, disinfectant residual (type and concentration), temperature, pH, and pipe materials. Evidence suggests that there is substantial interplay between these parameters; however, the dynamics of such relationships is yet to be elucidated. There is a correlation between premise plumbing system characteristics, including those featuring water and energy conservation measures, and increased water quality issues and public health concerns. Other interconnected issues exacerbated by high water age, such as disinfectant decay and reduced corrosion control efficiency, deserve closer attention. Some common features and trends in the occurrence of opportunistic pathogens have been identified through a thorough analysis of the available literature. It is proposed that the efforts to reduce or eliminate their incidence might best focus on these common features.

Legionellosis and Recent Advances in Technologies for Legionella Control in Premise Plumbing Systems: A Review

This review discusses Legionella, among the most prolific and publicly well-known waterborne pathogens, and advances in potential treatment technologies. The number of cases associated with Legionella continues to rise, as does its public awareness. Currently, cases associated with premise plumbing account for the largest number of legionellosis cases in the United States. So, while it is important to understand Legionella as such, it is also important to investigate how to treat drinking water in premise plumbing for Legionella and other waterborne pathogens. While there are currently several methods recognized as potential means of inactivating waterborne pathogens, several shortcomings continue to plague its implementation. These methods are generally of two types. Firstly, there are chemical treatments such as chlorine, chlorine dioxide, monochloramine, ozone, and copper-silver ionization. Secondly, there are physical treatments such as thermal inactivation and media filtration. Their shortcomings range from being labor-intensive and costly to having negative health effects if not properly operated. Recently developed technologies including ultraviolet (UV) irradiation using light emitting diodes (LEDs) and innovative carbon nanotube (CNT) filters can better control waterborne pathogens by allowing for the simultaneous use of different treatment measures in plumbing systems.

Georgeite: A Rare Copper Mineral with Important Drinking Water Implications

Significant research has been conducted on copper corrosion and solubility in drinking water, including the establishment of the "cupric hydroxide model". The model describes the temporal aging and associated solubility changes of copper minerals beginning with the most soluble solid, cupric hydroxide. Although the model explains copper levels in field observations well, there are aspects of the model that are not well understood, including a lack of evidence of the presence of cupric hydroxide in drinking water distribution systems. This study aimed to understand the effect of water chemistry on the solubility and properties of newly precipitated cupric solids, including mineral identification. Bench-scale copper precipitation tests were performed in water under a matrix of pH and dissolved inorganic carbon conditions. Copper solids were analyzed using a combination of materials analysis tools including XRD, FT-IR, TGA, and inorganic carbon analyses. Copper solids were X-ray amorphous, isotropic, and were light blue to blue. Based on repeated analysis, georgeite (Cu₂(CO₃)(OH)₂·6H₂O) was conclusively identified as the solid at all test conditions. Georgeite is an extremely rare, amorphous malachite analog, and because of its rarity, very little has been reported on its presence in any environment.

Mineralogical Evidence of Galvanic Corrosion in Drinking Water Lead Pipe Joints

Galvanic corrosion as a mechanism of toxic lead release into drinking water has been under scientific debate in the U.S. for over 30 years. Visual and mineralogical analysis of 28 lead pipe joints, excavated after 60+ years from eight U.S. water utilities, provided the first direct view of three distinct galvanic corrosion patterns in practice: (1) no evidence of galvanic corrosion; (2) galvanic corrosion with lead cathode; (3) galvanic corrosion with lead anode. Pattern 3 is consistent with empirical galvanic series (lead → brass → copper in order of increasing nobility) and poses the greatest risk of Pb exposure. Pattern 2 is consistent with galvanic battery reversion. The identification of copper-sulfate minerals (Pattern 2), and lead-sulfate and lead-chloride minerals (Pattern 3) in galvanic zones illustrated the migration of chloride and sulfate toward the anode. Geochemical modeling confirmed the required pH drop from the bulk water level to at least pH 3.0-4.0 (Pattern 2) and pH < 5.5 (Pattern 3) in order to form these minerals. Despite joints being over 60 years old, galvanic zones in Pattern 3 were active and possibly posed an important source of lead to drinking water. Importantly, Pattern 3 was not observed in samples from systems representing water qualities favoring PbO2 formation.

Increasing chloride in rivers of the conterminous U.S. and linkages to potential corrosivity and lead action level exceedances in drinking water

Corrosion in water-distribution systems is a costly problem and controlling corrosion is a primary focus of efforts to reduce lead (Pb) and copper (Cu) in tap water. High chloride concentrations can increase the tendency of water to cause corrosion in distribution systems. The effects of chloride are also expressed in several indices commonly used to describe the potential corrosivity of water, the chloride-sulfate mass ratio (CSMR) and the Larson Ratio (LR). Elevated CSMR has been linked to the galvanic corrosion of Pb whereas LR is indicative of the corrosivity of water to iron and steel. Despite the known importance of chloride, CSMR, and LR to the potential corrosivity of water, monitoring of seasonal and interannual changes in these parameters is not common among water purveyors. We analyzed long-term trends (1992-2012) and the current status (2010-2015) of chloride, CSMR, and LR in order to investigate the short and long-term temporal variability in potential corrosivity of US streams and rivers. Among all sites in the trend analyses, chloride, CSMR, and LR increased slightly, with median changes of 0.9mgL^-1, 0.08, and 0.01, respectively. However, urban-dominated sites had much larger increases, 46.9mgL^-1, 2.50, and 0.53, respectively. Median CSMR and LR in urban streams (4.01 and 1.34, respectively) greatly exceeded thresholds found to cause corrosion in water distribution systems (0.5 and 0.3, respectively). Urbanization was strongly correlated with elevated chloride, CSMR, and LR, especially in the most snow-affected areas in the study, which are most likely to use road salt. The probability of Pb action-level exceedances (ALEs) in drinking water facilities increased along with raw surface water CSMR, indicating a statistical connection between surface water chemistry and corrosion in drinking water facilities. Optimal corrosion control will require monitoring of critical constituents reflecting the potential corrosivity in surface waters.

Inhibition of Copper Pitting Corrosion in Aggressive Potable Waters

Copper pitting corrosion can lead to premature plumbing failures, and can be caused by aggressive potable waters characterized by high pH, free chlorine residual and low alkalinity. In such waters and under continuous flow, certain inhibitors including phosphate, silica or natural organic matter may greatly reduce pitting occurrence. In the current work, 1 mg/L phosphate (as P) completely prevented initiation of pits, and 5 mg/L silica (as Si) significantly decelerated pitting. However, much lower doses of these inhibitors had little benefit and actually accelerated the rate of attack in some cases. Effects of organic matter were dependent on both the type (e.g., natural versus ozonated humic substances) and dosage. Dose-response effects of free chlorine and alkalinity were also investigated. Based on electrochemical data, pits initiated more rapidly with increased free chlorine, but even moderate levels of chlorine (~0.4 mg/L) eventually caused severe pitting. High alkalinity decreased pit propagation rates but did not prevent pit formation.