Simeon C. Nwanonenyi, A.A. Daniyan, Mustapha Balarabe Idris, O.O. Ige
Corrosion costs the global oil and gas industry over $1.372 trillion annually, necessitating effective cathodic protection systems. This comprehensive review examines Aluminium alloy sacrificial anodes for oil and gas applications, analyzing their superior performance characteristics compared to traditional zinc and magnesium alternatives. Aluminium anodes demonstrate exceptional current capacity (2,000-2,800 Ah/kg), representing 3.5 times the capacity of zinc anodes, with enhanced environmental resistance and controlled reactivity. Strategic alloying with zinc, indium, tin, and gallium prevents oxide layer formation while maintaining consistent electrochemical performance throughout operational life. Manufacturing techniques including casting, extrusion, forging, and coating technologies are systematically evaluated alongside four structural designs (rod-shaped, plate-shaped, wire-shaped, and insert-type) optimized for diverse applications. Five Aluminium activation mechanisms are identified: dissolution-redeposition, negative potential shift, surface free energy modification, preferential dissolution, and ion resistance reduction. Despite challenges including passivation and environmental sensitivity, Aluminium alloys offer superior electrochemical performance, cost-effectiveness, and environmental sustainability. Future research priorities focus on uniform corrosion morphology, optimized alloy compositions, and integration of advanced monitoring technologies to enhance asset integrity and reduce operational costs across global energy infrastructure.