ABSTRACT:
Corrosion in submerged metal structures is a major issue in marine and industrial environments. This project focuses on designing and simulating a buck-boost converter to deliver a stable DC voltage for a cathodic-protection system. The converter efficiently regulates output voltage irrespective of input or load variation, ensuring continuous corrosion prevention and system reliability.
INTRODUCTION:
The degradation of metals due to corrosion results in huge economic losses and structural failures. Cathodic protection systems use a small DC current to polarize metal surfaces, reducing anodic reactions that cause corrosion. However, the stability of this DC source is critical. Fluctuations in supply voltage or environmental conditions can alter the current and potential required for protection, reducing system effectiveness. The buck-boost converter solves this issue by providing both step-up and step-down capability, maintaining a consistent DC output suitable for submerged metal corrosion protection.
OBJECTIVES:
• To design a buck-boost converter suitable for cathodic-protection voltage ranges.• To simulate and analyze the converter using Proteus software.• To validate performance metrics such as output voltage regulation, efficiency, and ripple factor.
LITERATURE SURVEY:
Recent studies demonstrate continuous improvements in DC-DC converters and their applications:[1] A. Fekik, M. Mahdal, M. L. Hamida, M. Ghanes, S. Vaidyanathan, A. Bousbaine, and H. Denoun, “Hardware Implementation of a Solar-Powered Buck-Boost Converter for Enhanced Cathodic Protection Using Texas Instruments C2000 Board, ” IEEE Access, vol. 12, pp. 74831–74842, 2024.
[2] H. Jbara and E. Altürk, “Develop a Cathodic Protection System (CP) Using a Mix of Green Energy Sources, ” MINAR International Journal of Applied Sciences and Technology, vol. 7, no.2, pp.186–197, Jun. 2025.
[3] A. A. Hassan, H. M. Farghally, A. E.-S. A. Nafeh, N. M. Ahmed, and F. H. Fahmy, “Design and Optimized Control of a Photovoltaic/Battery-Powered Cathodic Protection System, ” Energy and Power Engineering, vol. 16, pp. 373 393, Jan. 2024.
[4] A. O. M. Maka, T. N. Chaudhary, G. Alaswad, and O. Elsayah, “Applications of Solar Photovoltaics in Powering Cathodic Protection Systems: A Review, ” Clean Technologies and Environmental Policy, vol. 26, pp. 2755–2776, Feb. 2024.
[5] N. Karabacak and A. Karakaya, “Using solar energy in galvanic anode cathodic protection systems, ” International Journal of Energy Applications and Technologies, vol. 10, no. 1, pp. 6–13, Jun. 30, 2023.
While many converter designs exist, few address corrosion-control applications specifically. This project bridges that gap by tailoring the converter design for submerged metal protection, ensuring efficient, renewable-energy-compatible operation.
DESIGN PLANNING:
The converter consists of:• A PWM-driven MOSFET switch controlled by the microcontroller.• An inductor and diode for energy storage and polarity inversion.• An output capacitor for voltage smoothing.• Feedback loop simulation within Proteus for output regulation.
SIMULATION PARAMETERS:• Input voltage: 6–12 V (variable)• Output voltage: 5–15 V (regulated depending on load)• Load resistance: equivalent to submerged metal structure impedance• Switching frequency: 25–50 kHz
SIMULATION AND RESULTS:
The Proteus simulation validates the following results:• Stable output voltage regulation over input variations.• Output ripple below 2%, ensuring smooth DC output.• Efficiency exceeding 90% under rated load.• Minimal overshoot and quick transient recovery.
DISCUSSION:
The simulation results show that a properly tuned buck-boost converter can effectively meet the voltage and current requirements for cathodic protection systems. Control stability is achieved by optimizing the duty cycle through the microcontroller’s PWM output, ensuring smooth transitions between buck and boost modes. This makes the system flexible enough for use with renewable energy sources such as solar panels or batteries.
CONCLUSION AND FUTURE SCOPE:
The project successfully demonstrates the feasibility of using a buck-boost converter for corrosion control applications. Future extensions include:• Real-time hardware implementation and testing with submerged electrodes.• Integration of renewable sources (solar/wind) for self-powered corrosion systems.• Adaptive control algorithms using sensors to monitor corrosion potential and adjust output automatically.
REFERENCES:
[1] A. Fekik, M. Mahdal, M. L. Hamida, M. Ghanes, S. Vaidyanathan, A. Bousbaine, and H. Denoun, “Hardware Implementation of a Solar-Powered Buck-Boost Converter for Enhanced Cathodic Protection Using Texas Instruments C2000 Board, ” IEEE Access, vol. 12, pp. 74831–74842, 2024.
[2] H. Jbara and E. Altürk, “Develop a Cathodic Protection System (CP) Using a Mix of Green Energy Sources, ” MINAR International Journal of Applied Sciences and Technology, vol. 7, no.2, pp.186–197, Jun. 2025.
[3] A. A. Hassan, H. M. Farghally, A. E.-S. A. Nafeh, N. M. Ahmed, and F. H. Fahmy, “Design and Optimized Control of a Photovoltaic/Battery-Powered Cathodic Protection System, ” Energy and Power Engineering, vol. 16, pp. 373 393, Jan. 2024.
[4] A. O. M. Maka, T. N. Chaudhary, G. Alaswad, and O. Elsayah, “Applications of Solar Photovoltaics in Powering Cathodic Protection Systems: A Review, ” Clean Technologies and Environmental Policy, vol. 26, pp. 2755–2776, Feb. 2024.
[5] N. Karabacak and A. Karakaya, “Using solar energy in galvanic anode cathodic protection systems, ” International Journal of Energy Applications and Technologies, vol. 10, no. 1, pp. 6–13, Jun. 30, 2023.
TEAM MEMBERS:Gokul V J, Gowthami B, Kamali D, Keerthana S, Dept of ECE, Coimbatore Institute of Technology, Coimbatore
GUIDED BY: Dr. K. M. Priya, Assistant Professor, Dept of ECE, Coimbatore Institute of Technology, Coimbatore
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