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For a zinc electrode, there are several distinct types, each suited for particular electrolysis environments and required performance properties. Their characteristics, benefits, and principal uses are discussed in detail in the sections that follow.
Due to their corrosion-resistant coating, zinc anodes are increasingly used in marine applications with a high threat of corrosion, such as on boats, ships, and offshore structures. The coating, often made of other alloys such as zinc-aluminium, improves operation by forming a protective layer over the electrode. Coated zinc electrodes are utilized for cathodic safety in pipelines, storage tanks, and other underground or submerged infrastructure in addition to their use in maritime environments.
Graphite composite electrodes have been added for solid, long-lasting, and low-resistance zinc electrodes. These materials balance electrical conductivity and resistance to corrosion and wear. Also, they are less likely to suffer from passivation, a process in which the metal surface develops a non-conductive layer over time and inhibits further reactions.
Zinc is mainly used as a sacrificial anode in cathodic protection systems. In such cases, zinc anodes are hung or positioned away from the protected structure to prevent the marine environment from ingressing. This method is frequently used in systems protecting pipelines, docks, and underwater structures. In addition to being hung in underwater systems, hanging zinc electrodes can also be used in electroplating baths to maintain even metal deposition across the object being plated.
A cylindrical design is used for tubular zinc electrodes to enhance their surface area and electrical contact. These are most widely used in contexts where there is a large volume of electrolytic solution for current propagation. Tube electrodes are widely used in laboratory experiments involving electrochemical cells because of their high efficiency and simple replacement process.
A zinc electrode is a versatile electrochemical component used in various industries because of its unique chemical and physical characteristics. Common industry applications include the following:
To protect marine vessels, offshore structures, and underwater construction from corrosion, cathodic protection systems must be installed. This is done by zinc electrodes, also known as sacrificial anodes, which corrode preferentially to the metal structure they protect. For instance, on ships, zinc anodes are placed at various points to prolong the life of the hull and internal machinery by minimizing corrosion.
Zinc electrodes are conceptualized and used in batteries, mainly in alkaline and zinc-air varieties. In Zn-air batteries, for instance, zinc is used as the anode in batteries that power hearing aids and other small electronic devices. It also has potential use in large-scale energy storage systems, which are needed to balance the fluctuations in renewable energy sources, such as solar and wind power. These applications require the electrodes to be reversible.
The zinc electrode is used in the electroplating process to deposit a layer of zinc onto metal surfaces to increase their resistance to rust and corrosion. The automotive industry, where parts are coated to extend their shelf life and maintain aesthetics, and the construction industry, where steel elements frequently suffer from weather-related corrosion, use electroplating.
In the chemical industry, occupied by electrodes made from or based on zinc, electrochemical processes are employed to manufacture or transform chemical substances. Zinc electrodes can be used to produce chlorine, caustic soda, and other key industry chemicals through the electrolysis of brine (salt water). Moreover, zinc electrodes catalytically enable various reactions essential for producing chemicals, such as lubricants, polymers, and acids.
In electrochemical wastewater treatment systems, the zinc electrode can be used to help remove contaminants from effluents. The zinc anode creates an electric current that facilitates the precipitation or transformation of harmful substances in wastewater, such as heavy metals or organic pollutants, which is then easier to filter out or render harmless. Zinc electrodes can treat effluent from industries like oil and gas, mining, and food processing that discharge high-pollutant water.
When outfitting electrochemical systems or cathodic protection applications, it becomes crucial to understand the various characteristics of zinc anodes. Here are some common features and specifications:
The lifespan of a zinc electrode is determined by several factors, including the level of corrosion in the specific environment, water temperature, salinity (for marine applications), and current density (for galvanic cells or batteries). In marine settings, such as on ships and offshore platforms, zinc anodes can last between 6 and 24 months, depending on the level of the aforementioned factors. In other environments, such as alkaline batteries, zinc electrodes can last several years with appropriate maintenance and operating conditions.
The shape of a zinc electrode can take various forms depending on the specific needs of the application in question: cylindrical, rectangular, block, rod, or anode wire. For example, a ship may have a shaft zinc anode in a cylindrical shape that gets fitted on internal rotating machinery. In a pipeline cathodic protection system, zinc anodes may be cast into a block or cylinder shape and randomly fitted inside a vault or buried in a trench beside the pipeline. Zinc electrodes are highly customizable for electroplating baths and research systems, ranging from small laboratory-scale cylindrical electrodes to large industrial electroplating baths.
In cathodic protection systems, zinc electrodes will sometimes need to be inspected periodically, typically by divers or remotely operated vehicles (ROVs) in the marine environment, to see if they need replacement. Onshore installations, such as underground pipelines or storage tanks, may require excavation or other non-destructive testing methods to visually inspect zinc anodes. In alkaline and other zinc-based batteries, zinc electrodes may require occasional maintenance, such as electrolyte replenishment.
The electrical conductivity of zinc electrodes is required to enable effective cathodic protection or electrochemical reactions to take place. Zinc has a conductivity value of approximately 28 × 10-6 S/m (siemens per meter), lower than copper but still appreciable enough for most sacrificial anode applications. Jiang and others found that Zn electrodes perform most efficiently when corroding quickly to establish a galvanic potential between the anode and the protected structure. This process also generates a current that drives away susceptible organisms in the surrounding environment. Corrosion occurs when the anode material (zinc, in this case) dissolves into the environment via electrochemical reactions, forming zinc ions. There are two types of corrosion: desirable corrosion and undesirable corrosion. The previously mentioned type is the bite that zinc anodes are meant to experience so that zinc ions can be released to protect cathodic structures like steel piers or machinery.
When purchasing zinc electrodes, various factors come into play. Here are some of the factors:
Aspects such as the type of electrolyte and environment, the design of the electrochemical cell, and the nature of the system requiring protection should all be considered and be found in zinc electrodes and their conducive environment to ensure maximum performance. Applicable examples include using a galvanized (zinc-coated) metal frame on a segmental bank of zinc graphite composite electrodes for an electroplating process, using a cylindrical zinc wear plate on a stirred petridish filled with zapped yeast for microbiological research, and positioning a zinc block anode inside a dumpy level to cathodically protect all the internal metallic components from corrosion. Target industry offers a broad range of zinc electrodes, including rods, tubes, blocks, wires, and composites, to help create ideal environments for their marine, mining, and mechanical manufacturing.
In zinc anodes, higher zinc purity typically results in better electrical conductivity, slower corrosion rates, and enhanced protection. Look for zinc electrodes with 99.99% purity to ensure optimal performance. Quality refers to the manufacturing process's care and detail, affecting the final product's performance and resilience. High-quality electrodes corrode uniformly without defects, facilitating steady currents in the electrochemical process or cathodic protection.
The specific needs of the target application should inform the choice of zinc electrode. Such needs include the scale of the system, the current density required, and the environment. For instance, a ship overbuilding a corrosion problem would need larger zinc anodes with a higher zinc quantity than a small laboratory electrochemical cell which may be in a more controlled environment, such as saline solution.
Look closely at attributes like the corrosion rate (how quickly the anode material sacrifices itself), surface area, and electrical resistance. These factors greatly influence how effectively the zinc electrode provides cathodic protection or facilitates electrochemical reactions. Specifically, an ideal zinc anode should have a moderate corrosion rate to ensure the material lasts long enough to protect the system while continuously providing zinc ions.
A1. A zinc electrode is an electric conductor that supports the electric current flow within a system or medium. It is performed and based on one of the electrolysis types known as cathodic protection. It is the electric current that causes electrolysis, an electrochemical process that helps deposit a layer of metal onto a conductive surface. Important elements of the zinc electrode include the electrolyte solution containing zinc ions, the electric current applied, and the object (cathode) where zinc ions travel to deposit and coat.
A2. Zinc electrodes are used in alkaline and zinc-air batteries. In Zn-air, for instance, zinc is the anode or negative electrode, while oxygen is the cathode or positive electrode. Zn-air batteries have various applications like hearing aids, remote controls, and other low-power gadgets and technologies that require a compact energy source. Zinc is the electrolyte in alkaline batteries, which involves an aqueous solution of sodium hydroxide, potassium hydroxide, or other alkali for zinc-air battery construction.
A3. Zinc electrode purity plays a critical role in performance. The higher the zinc purity, the more it strongly and effectively protects other metals within its environment from corrosion by sacrificing itself through a more efficient electrolytic process. At 99.99% purity, the zinc ions released during corrosion are less likely to contain impurities that cause precipitation on the surface of the anode or interrupt current flow in electrochemical cells. Consequently, better-quality zinc electrodes enhance battery efficiency, increase energy output, and maximize cathodic protection.
A4. Zinc electrodes enable the removal of positive contaminants like heavy metal cations and negatively charged organic pollutants during electrochemical wastewater treatment. Such removal involves contaminant precipitation or transformation, making the contaminant easier to filter and simply render it harmless. Zinc's affinity for these types of contaminants enables it to be a critical component for treating effluent with high pollution concentration, such as those found in the mining industry.
A5. Although efficient, zinc electrodes can be replaced with other materials like magnesium or aluminum, depending on the specific needs of the cathodic protection system. However, since magnesium is more electrochemically active than zinc, it preferentially protects the metal identity of the structure at all costs through efficient sacrificial corrosion. The same goes for aluminum, which, although it is not as electrochemically active as magnesium, is more so than zinc. However, hybridized with other metals like zinc.
