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PRESENTER
Corrosion
Scaling
Foreign Matter/Deposits
Biological Fouling
Corrosion
• Corrosion is an
electrochemical
process where metals
are converted to their
more stable form (i.e.
oxides)
• The process requires
an Anode, Cathode, and
an ionic conduction
path through an
electrolyte (i.e. water)
Corrosion Cell
Corrosion Mechanism
in Alkaline Environment
H
H Fe(OH)2
O H
H O Fe+3
H
H H
Fe+2 O
H O H H
O H
O Fe+3 Fe+2 O H
H Fe(OH)3
Fe+2 O H
O H Fe+2
H O O
Fe+2
Fe2O3
Fe+2
Anode e– Cathode
Cost of Corrosion
• Production loss
• Equipment damage and
replacement
• Increase in utility costs
• Increase in labor costs
• Increase in water treatment
costs
Scaling
• As little as 1/8 of scale can reduce the efficiency of a cooling
tower, heat exchanges by 40%
• Scale formation always causes higher energy consumption and
this applies all year round regardless of the load on system.
scale itself is not considered as a nutrient for a biological
growth, heavy scaling provides a breeding haven for micro-
organisms and can therefore add to the risk of biological
contaminations. The following reaction governs formation of
CaCO3.
Scale Thickness
Scale
Hard crystalline
deposits
Precipitation of
mineral salts
CaCO3, CaSO4,
SiO2
CaSiO3, MgSiO3,
etc.
Suspended Solids – Related Problems
• Fouling
Cathodic inhibitor
Precipitates at a pH above 8.0
Forms zinc hydroxide – zinc
carbonate film
Operating LSI is from – 0.5 to + 0.5
Toxic to marine life
Banned in some locations
Film Formation (Zinc)
Ionic Migration
Reduction of Ions
and Oxygen
Dissolution of
Metal Ions (Fe²¯)
3Zn(OH)2 – 2ZnCO3
Electron Migration
Cathode Anode
Stabilized Phosphate Programs
Calcium polyphosphate
Complex
Electron Migration
Cathode Anode
BIOLOGICAL FOULING
MICROBOILOGICALLY INFLUENCED
CORROSION (MIC)
EFFECTIVE SOLUTIONS FOR A COSTLY PROBLEM,
• It induces generalized or localized corrosion such as
pitting.
• Is a serious form of degradation of system materials
in several industries like:
• Power generation
• Oil refineries
• Chemical processing plants
• Nuclear industries
Micro Biological Fouling
THE HIGH COST OF (MIC)
Generating plants have been
forced to undertake material
replacement.
To make extensive repairs to
service water system at
enormous cost.
Effects reliability, safety and
maintenance cost.
Microbiological Control
Biocides
Generally classified as
Oxidizing Biocides
– Irreversibly oxidize protein groups of the cell,
resulting in loss of enzymes activity and rapid
death.
Loss of Efficiency
Higher fuel consumption
Blockage
Tube Failure
In server cases, Explosions !
Scale on Boiler Tubes
Scale Causes
High temperature & pressures
Bare Metal Surfaces
Under – deposit corrosion
Oxygen & CO2
Low pH excursions
High pressure systems – caustic
embitterment
Condensate corrosion
Condensate is an excellent source of feed water
Condensate is typically of better quality then normal Make up
Water boiler water c/c and be increased and Blow Down can be
reduced
It result in a reduction of heat loss through Blow Down, which
reduces the amount of heat (Fuel) required t maintain operation
pressures.
As condensate what is hot, again less heat (Fuel) is required to
maintain operation pressures.
Re-using condensate water if treated represents a valuable
investment that can be utilized over.
Condensate water if not treaded/badly treated can become a
maintenance nightmares.
Most common problems associated with condensate is corrosion
of the piping that returns it to the feed with system and ultimately
the boiler.
Almost all problems associated with condensate is corrosion can
be trace to gasses Co2 and O2.
Carbon dioxide
Alkalinity is the form of carbonate and bicarbonate ions under
pressure and high Temperate is below decompress as
2HCO3CO3 + CO2 + H2O -----1
CO3 + H2O2OH + CO2 -----2
Reaction 1st achieves 100% Completion and reaction 2nd achieves
80% or more completion at pressure over 150psig.
CO2 is carried along with the steam.
After the steam has done its work and condenses CO2 will dissolve
in the condensate forming H2CO3.
CO2 + H2O H2CO3
H2CO3 causes low pH based corrosion in condensate line.
H2CO3 acid corrosion typically manifests its self as general thinning
of metal.
H2CO3 acid corrosion result in high iron content in boiler feed water
resulting in boiler tube failure as iron precipitate out on to the boiler
tube.
This deposition can cause galvanic as well as under deposit
corrosion, accelerating the corrosion rates to the point of failure.
CONDENSATE LINE TREATMENT
It depends on a number of factors that include:
Complexity, size and age of the system.
The quantity and source of condensate and the raw
water characteristics.
Generally two types of chemical are used for condensate
line treatment: neutralizing amines and filming amines.
Neutralizing amine neutralize H2CO3 reducing the
potential for low pH.
Common neutralizing amine include—Morpholine,
cyclohexylamine, diethylaminoithanol (DEAE).
Filming amine function by laying down a monomolecular
film on metal surfaces providing protection against
H2CO3 acid attack.
The two most common filming amines are octa-
decylamine (ODA) & ethoxylated soya amine (ESA)
Corroded condensate pipe
Priming
1. Priming Caused by:
Rapid drop in boiler pressure
Rapid increase in steam load
2. Both lead to:
Increase in specific volume of steam
Increase in steam velocity
Boiler water in “Sucked Out” of the boiler
Foaming
Phosphate (precipitation)
Oxygen Scavenger
Amines
Phosphate Program
3Ca++ + 2PO4– 3 Ca3(PO4)2↓
Phosphate reserves of 40 – 80 ppm as
PO4, must be maintained in boiler water,
equivalent to 70 – 100 ppm of Na3PO4.
Phosphate precipitate out in the boiler
water and is removed by blow down (not
continuous Blow down). Dispersant
(known as sludge conditioner) required
for Calcium Phosphate, which Otherwise
will form a sticky deposit.
Oxygen Scavengers
Sulphite
Na2SO3 + ½ O2 Na2SO4
Bisulphite
NaHSO3 + NaOH Na2SO3 + H2O
Metabisulphite
Less Bisulphite are required than Sulphite,
per ppm of oxygen in the water (5.9 for
Metabisulphite, 6.5 for Bisulphite, and 7.88
for Sulphite.
Oxygen Scavengers
• Hydrazine
N2H4 + O2 N2 + H2O
as oxygen scavenger, dose rate
1:1
usually dose is excess; 1.5 – 2:1
normally use catalyzed hydrazine
for BWT feed water pH > 9.5
suitable for up to 2,500 psig
Passivates metal surface
Condensate Protection
Neutralizing Amines
Filming Amines
Combination & Blends
Objective of Boiler Water Treatment
Molybdate
Nitrite
Molybdate
Works best with other inhibitors
Nitrite
Phosphate
Phosphonate
Azole copper inhibitor
Improves strength of oxide layer
Low toxicity
Expensive per kg. but cost effective
Nitrite
Similar mechanism to chromate –
promotes formation of protective
gamma iron oxide.
100% Anodic
Less toxic than chromate
Usually used as part of mixed inhibitor
Buffer
Copper Inhibitor
Aluminum Inhibitor
Closed System Biocide
Non oxidizing
Thermally stable
Non – corrosive
Compatible
Effective against anaerobic
bacteria
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