Corrosion In Industries

A Presentation By:Hrishikesh Shastri

Introduction

Derived from the Latin word corrodere, meaning to bite to pieces. A chemical or electrochemical reaction between a material, usually a metal, and its environment that produces a deterioration of the material and its properties.

Types of Corrosion

Corrosion, why Bother?

A very serious problem involving

Personal injuries Fatalities and Unscheduled shutdowns

Favourable Environments

Moist air Hot air

Polluted air
Acids

Hot water
Salt water

Industries suffering Corrosion

Infrastructure (16.4% of total) Utilities (34.7% of total)
Highway Bridges Hazardous Materials Storage

Electrical Utilities Telecommunications

Transportation (21.5% of total)

Production and Manufacturing (12.8% of total) Government (14.6% of total)

Ships Aircraft

Petroleum Refining Chemical, Petrochemical & Pharmaceutical

Defense Nuclear Waste Storage

Corrosion problems in Aircraft industries

Affects flight safety High maintenance costs, and Reduce the plane's service period

1988 - The Aloha Incident

Structural failure of a 19 year old Boeing 737. This aircraft lost upper fuselage at 24,000 feet Multiple fatigue cracks were detected in the remaining aircraft structure Disbonding, Corrosion and cracking problems in the lap joints Build-up of corrosion products inside the lap joints or Pillowing

Aircraft industries (contd.)

Type- Fatigue corrosion and Corrosion pitting present Parts - Engine, master connecting rod, Fuselage etc.
Serious, Fatal danger

Marine Corrosion
Electrochemical reaction & is greatly accelerated in salt, brackish waters, or in waters with a high mineral content. Boat engine, Boat exhaust system and Sterndrive

Corrosion in Buildings
On the exterior as cladding, roofing and flashings Those incorporated in the construction as structural and reinforcing steel Piping, storage tanks for hot water, drains and heating ducts Those buried in the ground.

Two most common causes of reinforcement corrosion are (i) localized breakdown of the passive film on the steel by chloride ions and (ii) general breakdown of passivity by neutralization of the concrete, predominantly by reaction with atmospheric carbon dioxide.
Systems supplying fresh water contains dissolved oxygen and dissolved salts which acts as a factor in corrosion.

Corrosion Impact on Food Industries

The Corrosion environment involves moderately to highly concentrated chlorides, often mixed with significant concentrations of organic acids.

Sulfiting agents producing sulfur dioxide used to treat foods are corrosive to foodprocessing equipment.

Corrosion Impact on Food Industries (contd.)

Under-deposit corrosion (type of crevice corrosion) occurs in cooling systems where scales or foulants exist & caused by using water in boilers, rotary cookers, and hydrostatic sterilizers. Al alloys and Stainless steels susceptible to, as well as deep pitting. Anodic, cathodic, and filming inhibitors are used to combat corrosion.

Corrosion Impact on Food Industries(contd.)

Galvanic corrosion in hydrostatic sterilizers the flight bars are made from Al or Stainless steel, the transport chain is made from carbon steel, and both are exposed to hot water and steam. The less noble metal of the couple is susceptible to galvanic corrosion.

Corrosion Impact on Food Industries(contd.)

Stress corrosion cracking (SCC) Occurs at temperatures higher than ambient in the presence of chlorides. stainless steel piping and tanks is a problem in water lines in brewery applications.

Pulp and Paper Industry Corrosion

In the wet process equipment. Pitting, Crevice corrosion, SCC, Microbiological attack, Corrosion of welds, Corrosion fatigue

Factors Temperature chemical constituents Concentration size and quality of the wood fibers, and metals used in components

Oil & Gas Industries

Corrosion in linings of the oil plants that occurs during hydrocarbon refining process. Water droplets causes pitting corrosion Steel becomes brittle from the exposure of heat and impurities from hydrogen and sulphide attack causing stress corrosion

Electronics Industry

Integral part of all technology-intensive industry products These systems are fabricated by a number of complex processes and consist of a variety of dissimilar materials. So exposed to a variety of environmental conditions. Corrosion is insidious and can not be readily detected. So often dismissed as just a failure and the part or component is replaced.

Nuclear Plants

The nuclear industry systems are complex and subjected to corrosive environments, high temperatures, and high pressures.

Davis-Besse nuclear plant

The reactor core at the Davis-Besse nuclear plant . The reactor vessel has carbon steel walls nearly six inches thick to provide the necessary strength. Because of the water cooling the reactor contains boric acid that is highly corrosive to carbon steel, the entire inner surface of the reactor vessel is covered with 3/16-inch thick stainless steel. But water routinely leaked onto the reactor vessel's outer surface.

Davis-Besse nuclear plant(contd.)

Outer surface lacked a protective stainless steel coating, boric acid ate its way through the carbon steel wall until it reached the backside of the inner liner. High pressure inside the reactor vessel pushed the stainless steel outward into the cavity formed by the boric acid. Cooling water remained inside the reactor vessel not because of thick carbon steel but due to a thin layer of stainless steel.

Way Ahead

Initial cost Best estimate of expected life Length of typical shutdown for emergency repair Cost of planned maintenance during scheduled shutdowns Effect of failure on total plant operation The portion of the total corrosion cost that could be avoided if better corrosion control practices were used