Corrosion is a complex electrochemical phenomenon that can significantly affect the safety, integrity and lifecycle cost of industrial assets. Traditional design often relies on conservative assumptions that may not represent real operating conditions. In process industries and energy infrastructure, managing material loss from corrosion is critical to long-term asset integrity.
The power of multiphysics simulation
Advanced multiphysics modelling, such as electrochemistry coupled with fluid flow and species transport, lets engineers simulate galvanic corrosion, localised pitting and atmospheric degradation before critical failures occur. Understanding how electrolyte currents are distributed and how fast material is lost allows teams to design robust Cathodic Protection (CP) systems, optimise anode placement and extend asset life.
Core pillars of the corrosion modelling lifecycle
- Mechanistic hazard and scenario identification. Environmental exposure, electrolyte dynamics and material pairings are evaluated to model galvanic, pitting, crevice and atmospheric corrosion.
- Electrochemical current distribution modelling. Primary, secondary and tertiary current distributions are simulated together with species transport to quantify localised metal dissolution and passivation behaviour.
- Cathodic protection system design. Impressed Current Cathodic Protection (ICCP) and Sacrificial Anode Cathodic Protection (SACP) are simulated to evaluate current density, potential distribution and protection coverage on complex geometries such as pipeline networks and offshore jacket structures.
- Deforming geometry and dynamic degradation. Moving mesh and level-set methods track surface deformation, wall thinning and structural degradation under changing operating conditions.
What simulation lets you do
- Predict corrosion rates and current distribution.
- Optimise ICCP and sacrificial anode systems.
- Assess coating defects and protection effectiveness.
- Evaluate complex geometries and environmental conditions.
- Reduce the risk of costly redesigns and premature failure.
Why it matters
Managing corrosion is a cornerstone of asset lifecycle management. Adding predictive corrosion modelling to risk assessments means barriers are placed where they are needed, assets last longer and unplanned downtime falls.
How EnTech can help
EnTech Engineering Solutions supports corrosion risk evaluations, technical safety assessments and advanced corrosion simulation and protection design. Contact us at info@EnTech-Solution.com.