Corrosion Control in Industry

Corrosion Control in Industry
Corrosion is a worldwide crucial problem that strongly affects natural and industrial
environments. Today, it is generally accepted that corrosion and pollution are interrelated
harmful processes since many pollutants accelerate corrosion and corrosion products such as
rust, also pollute water bodies. Both are pernicious processes that impair the quality of the
environment, the efficiency of the industry and the durability of the infrastructure assets.
Therefore, it is essential to develop and apply corrosion engineering control methods and
techniques.
Other critical problems, that impact on infrastructure and industry are climate change, glob‐
al warming and greenhouse emissions, all interrelated phenomena.
It’s important to know aspects of corrosion in industrial infrastructure, its causes, impacts,
and control, protection and prevention methods.
Materials in industry
• Metallic materials play a key role in the development of a country and its sustained
growth in the context of the global economy.
• During the course of the metal production it undergoes various types of processes:
mining of minerals, manufacturing and application and generation of gases, liquids
or solids that are released into the environment.
• In the industrial development, production and use of materials in general,

economic cycles are due to take effect that influence the environment.
• The selection of a pre‐dominant group of materials depends on the particular

industries; they determine to a greater or lesser extent the pattern of consumption
of a given product, inducing the market to adapt itself to this new reality.
• The materials industry follows two general strategies: re‐ search the materials and
the available technology recommended for their.Recycled materials typically
require less capital and energy consumption, but need more manpower, for
primary processing.
• Also, the costs of pollution control are lower than those required for primary
processing of minerals. Recycling becomes more intense, as economies tend to be
more sophisticated, since viable quantities of recycled material must be available
for reuse.
Material Main properties Uses
Metals and alloys Mechanical resistance Cars, aircraft, tanks,
infrastructure
(carbon and stainless steels, non hardness Reinforcement.
ferrous
alloys)
Plastics Low density and Process components, tubes,
corrosion vessels,
(Synthetic polymers, rubbers) resistance Coatings, paints.
Ceramics High hardness, high Cutting tools, motor
temperature components,
(Metallic carbides, silica, glass, and corrosion resistance refractory bricks, ovens, etc.
alumina)
Composites Light weight, high Car bodies, aircraft
strength and components,
(glass and carbon fibers Hardness. Vessels, construction.
reinforced plastics,
plastic matrixes reinforced with
metallic
particles)
Table 1. Materials in industry: Types, main properties and uses.
• One of the most common corrosion problems in pipes, ducts, tanks, pre‐heaters,
boilers and other metal structures, insulated heat exchange systems, is the wear and
corrosion occurring on metal (steel, galvanized steel, Al, SS, etc.), below a deposit
or in its immediate neighbor‐ hood. This corrosion is known as corrosion under
deposit.
• The deposit may be formed by metal corrosion products and / or different types of
coating applied for protection. For ex‐ ample, in the case of a calcareous deposit,
formed in the walls of galvanized steel pipes which carry water with a high degree
of hardness (dissolved salts), it might develop corrosion under deposit.
• These shells may be porous, calcareous deposit and / or partially detached from
the metal surface, so that direct contact between metal, water and oxygen (the
oxidizing agent in the corrosion process) allows the development of metal
corrosion.
• For this reason the pipes could be damaged severely in these locations up to
perforation, while in parts of the installation corrosion might occur at a much lower
level.
• There is a considerable amount of factors in the design, construction and

maintenance, which can be controlled to avoid the effects of deterioration of metal
by corrosion under de‐ posit.
• In general, under these conditions the metal is exposed to frequent cycles of

moisture, corrosivity of the aqueous medium or failure in the protective coatings
(paint, metal, cement, fiberglass, etc.).
Figure 9. Corrosion of a carbon steel pipe under insulation.
• Seven factors can be controlled on the ground, to prevent this type of corrosion:
design of equipment, operating temperature, selection of the insulation, protective
coatings and paints, physical barriers from the elements, climate and maintenance
practices of the facility.
• Any change in any of these factors may provide the necessary conditions for the
corrosion process to take place. The management knowledge of these factors help
explain the causes of the onset conditions of corrosion under deposits, and it will
guide a better inspection of existing equipment and the best design.
Equipment design
• The design of pressure vessels, tanks and pipes, generally includes accessories for
support, reinforcement and connection to other equipment.
• Details about the installation of accessories are the responsibility of the engineers or
designers, using building codes to ensure reliability of both insulated and non
insulated equipment.
• The protective barrier against the environment surrounding the metal structure in
such designs often breaks donor due to an inappropriate insulation, loss of space
for the specified thickness of insulation or simply by improper handling during
installation of the equipment.
• The consequence of a rupture or insulation failure means greater flow water ingress
to the space between metal and coating hot‐cold cycle, generating over time a
buildup of corrosive fluid, increasing the likelihood of corrosive damage.
Moreover, wet insulation will be inefficient and also cause economic losses.
• The solution of this factor is to meet the thickness specifications and spacing, as
indicated in the code or equipment‐building specifications and characteristics of the
coating used.
• The operating temperature is important for two reasons: a high temperature favors
the water is in contact with the metal for less time, however, also provides a more
corrosive environment, causes fast failures of coatings. Usually a team operating in
freezing temperatures is protected against corrosion for a considerable life time.
• However, some peripheral devices, which are coupled to these cold spots and
operating at higher temperatures, are ex‐ posed to moist, air and steam, with cycles
of condensation in localized areas, which make them more vulnerable to corrosion.
For most operating equipment at freezing conditions, the corrosion occurs in areas
outside and below the insulation.
• The temperature range where this type of corrosion occurs is 60 °C to 80 °C;

however, there have been failures in zones at temperatures up to 370 °C. Also, in
good water‐proof insulation, corrosion is likely to occur at points where small
cracks or flaws are present, so that water can reach the hot metal and evaporate
quickly. On the other hand, in machines where the temperature reaches extreme
values, as in the case of distillation towers, it is very likely to occur severe corrosion
problems.
Selection of insulation
• The characteristics of the insulation, which have a greater influence on the
corrosion processes deposits, are the ability to absorb water and chemical
contribution to the aqueous phase. The polyurethane foam insulation is one of the
most widely used;
• However, in cold conditions they promote corrosion due to water absorption

present. The coatings of glass fiber or asbestos can be used in these conditions,
always when the capacity of absorbing water do not becomes too high.
• Corrosion is possible under all these types of coating, such insulation. The selection
of insulation requires considering a large group of advantages and disadvantages
regarding the installation, operation, cost, and corrosion protection, which is not an
easy task.
• The outside of the insulation is the first protective barrier against the elements and
this makes it a critical factor, plus it is the only part of the system that can be readily
inspected and repaired by a relatively inexpensive process.
• The durability and appearance, melting point fire protection, flame resistance and
installation costs are other important factors that must be taken into account
together with the permeability of the insulation. Usually the maintenance program
should include repairs to the range of 2 to 5 years. Obviously the weather is
important and corrosion under thermal insulation will more easily in areas where
humidity is high. Sometimes conditions of microclimate can be achieved through
the use of a good design team.

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• In the industrial development, production and use of materials in general,

• The selection of a pre‐dominant group of materials depends on the particular

Table 1. Materials in industry: Types, main properties and uses.

• There is a considerable amount of factors in the design, construction and

• In general, under these conditions the metal is exposed to frequent cycles of

Figure 9. Corrosion of a carbon steel pipe under insulation.

• The temperature range where this type of corrosion occurs is 60 °C to 80 °C;

• However, in cold conditions they promote corrosion due to water absorption

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