CORROSION ISSUE IN WASTE WATER TREAMENT PLANT

Wastewater treatment plant (WWTP) components generally experience both atmospheric and immersion corrosion. The corrosion intensive components include buried piping, handrails, gratings,ladders, electrical junction boxes, clarifier rake arms, concrete walls, etc. Hydrogen sulfide, which is usually present, has wide-ranging effects in wastewater systems, most notably causing corrosion and odor problems.Severe immersion corrosion of WWTP components were recently identified in and around the primary and secondary clarifiers at two Army Installations. The corroding components included: rake arms, weir and other metallic components, such as skimmers and valve handles. Also the concrete clarifier structure itself has shown sign of deterioration. In addition, steel lamp posts within the vicinity of one of the wastewater treatment plant were found to be corroding due to hydrogen sulfide in the atmosphere, in addition to moisture and high humidity.The corrosion problems have been mitigated by a combination of strategies, including judicious selection and implementation of emerging corrosion resistant coatings, corrosion resistant materials selection, and cathode protection. For example, impressed current cathodic protection using ceramic anodes has been employed for protection of the immersed metallic components in several clarifiers.Non-volatile, 100% solids, environmentally compatible coal tar epoxy coatings are being used on lamp post within the WWTP, and corrosion resistant steels alloys are being substituted as corrosion resistant Alternatives for low carbon steel in valve handles and electrical junction boxes and polymers are being implemented in electrical junction boxes. The benefits of the implementing corrosion control Technologies at the wastewater treatment plants are restoration of the plant to optimum operating condition, reduced maintenance, and increased safety.

CAUSES OF CORROSION AT WASTEWATER TREATMENT PLANTS Raw sewage is a source of hydrogen sulfide, and has wideranging effects. Hydrogen sulfide is released from the surface of the wastewater, enters the atmosphere of the sewer and is oxidized on the surface of the of the wastewater treatment plant components. The oxidation of hydrogen sulfide results in the production of sulfuric acid as follows: H2S + 2O2 H2SO4

As a result of this reaction, moist areas become acidic, and corrosion of metallic components proceeds rapidly. Steel and other ferrous alloys and copper are especially susceptible to this form of corrosion.Normal oxidation (rusting) of ferrous materials may be accelerated in the presence of sulfuric acid, up to 10 times the calculated corrosion rate due to oxidation alone. The sulfuric acid attacks concrete structures by dissolving cement bonding materials, forming a pasty mass, which falls away and exposes more material to be attacked. Corrosion rates depend on sulfide concentration in the sewer, rate of release of H2S from the surface of the wastewater stream,and turbulence, which promotes higher than normal off-gassing conditions. Turbulence in Headworks and grit tanks can cause mist or splash to occur on the wall area immediately above the water surface.The mist zone is most susceptible to corrosion. Areas above this zone are usually kept dry, ifventilation is provided, or if the facilities are open to the atmosphere. Areas of turbulence and splash, for example, weirs and troughs are often corroded in primary clarifiers. Secondary clarifiers are typically not subject to H2S corrosion, because sulfide concentrations in them are very low, usually unmeasurable.

Sulfide Production Rate

The rate at which sulfide is produced by a slime layer on collection pipes depends on the following environmental conditions:
y y y y y y y y

Concentrations of organic matter and nutrients Sulfate concentration Dissolved Oxygen (DO) pH Temperature Stream Velocity Surface area Retention time

Corrosion mechanism in waste water treatment plant

As one would suppose, the environment of a sewage collection system is one of the least sterile imaginable.Perversely, it is the very lack of sterility that at once makes the system workas efficiently as it does and that is the cause of myriad problems. The process begins with decomposition of solid wastes in the sewage. To travel from any particular home or building on the system to the wastewater treatment plant (WWTP) requires several days, on average. During this time, anaerobic bacteria, which function in an airless environment, are present in the solid wastes, along with water-aided dissolution and agitation due to flowing and tumbling through the pipeline. These factors cause the waste solids to break up. The microbes release hydrogen sulfide (H2S) as they form sulfate-containing organic compounds: The bacterial digestion of the solids forms polythionates and other sulfates,

Water Waste solids + microbes = H2S + polythionates + sulfates Agitation some of which are deposited on the concrete.In the air spaces above the sewage,water vapor (H2O) and carbon dioxide(CO2) are ubiquitous. Collecting on theconcrete, the condensed H2O dissolves both the CO2 and H2S, resulting in a solution of H2S and carbonic acid (H2CO3).Metals are also used in various ways throughout wastewater treatment systems. Concrete usually contains metallic reinforcement (rebar). Ladders, sluice gates, and other metallic substrates offer opportunities for corrosion. Microbiologically influenced corrosion (MIC) on metals is no different than any other electrochemical attack. The microorganisms involved can cause the same sort of corrosion problems seen in other environments.They may accelerate corrosion from other sources, such as industrial discharges. Corrosion phenomena such as pitting, gaseous concentration cells, crevice corrosion, exfoliation,and selective de-alloying are all found with MIC.

Areas in Wastewater Collection and Treatment Systems Prone to Corrosion

Manholes Lift Stations/Pumping Stations Grit Chambers Junction Boxes Drop Manholes Digesters Clarifiers Sludge Houses Wet Wells Aeration Basins

Cabinet, large valves, and vertical pumps located in the general area of the primary clarifiers, showing an example of general surface corrosion (WWTP)

Above ground piping located in the general area of the primary clarifiers. Note the rubber gasket material for the pipe flange set (WWTP).

Sludge thickener tanks rake arm. There was virtually no coating on the steel associated with the rake arm (WWTP) PRODUCTS FOR RESTORATION AND PROTECTION OF WASTEWATER INFRASTRUCTURES LININGS INFILTRATION AND CORROSION PROTECTION SewerGard Epoxy Systems Self priming, moisture tolerant epoxy systems that are completely resistant to the micro-biologically induced corrosion common to municipal wastewater applications as well as provide an infiltration barrier. They are available in aggregate filled trowel (No. 210T) and rotary spray (No. 210RS) versions, as well as a

fiber-filled airless spray version (No. 210S). The No. 210RS allows manholes to be efficiently lined from street level with minimal entry into the manhole. These products will bond to damp concrete and cure in the presence of moisture. An optional topcoat (210G) provides a more smooth surface for greater cleanability. This 100% solids product can be economically rolled or sprayed. SewerSeal No. F-170 Single component, high strength, 100% calcium aluminate based product for use in manholes and other wastewater structures. This material will restore structural integrity, prevent infiltration and resist mild acids and alkalies on concrete, brick, and steel structures. SewerSeal is designed for rotary and straight shot spray applications and can be applied at various thickness in one pass. H2OPruf No. F-190 Two component cementitious based negative side waterproofing system specifically designed to withstand hydrostatic pressures that cause water seepage in below grade structures. Two 1/16inch coats will withstand up to 70 feet of water head pressure. It can be applied by brush or spray, including rotary spray equipment used for manholes. SUBSTRATE REPAIR Underlayment and Repair Mortar No. F-120 Single component, high strength, rapid set Portland cement based repair mortar that is available in trowel, castable and gunite grades.The trowel grade can be applied vertically and overhead and can be topcoated with epoxy in 5 hours.

Substrate Resurfacer No. F-121 Single component, high strength, rapid set Portland cement based product for repairing, resurfacing, and waterproofing masonry structures.This material will restore structural integrity and prevent water infiltration into concrete and brick structures. It is designed for rotary and straight shot spray applications and can be applied at various thicknesses in one pass. Filler Compound No. 209 Three component, epoxy formulation that is specifically designed to fill voids, irregularities, and air pockets in concrete. No. 209 will provide a smooth surface ready for application of protective compounds in 3 hours. This material is also available in a fast setting grade that can be topcoated in 1 hour. Either formulation is suitable for application over damp or dry concrete. Application is performed with a rubber K&R trowel. ACTIVE INFLOW AND WATERSTOP PRODUCTS Manhole ChimneySeal No. F-88 Elastomeric lining composed of fiber-reinforced, asphalt-modified urethane. Two component, chemical resistant seal that can be applied by a gloved hand onto the chimney sections of manholes to prevent water inflow. As a high solids elastomer, Chimney Seal maintains excellent elasticity and adhesion over a temperature range of -30 F to 250 F while resisting acids, alkalies, and salts. InstaPlug No. F-180 Rapid setting hydraulic water plug that will seal active water leaks and allow continuous rehabilitation work on concrete structures. This material will set in 60 90 seconds and cure completely in

one hour. It is also used to fill small voids and for anchoring applications. Hydroactive Polyurethane Grout No. F-370 Catalyzed hydrophobic grout that reacts with moisture and expands to 20 times its volume to seal leaks, cracks, joints and voids. It bonds tenaciously to practically any substrate, wet or dry, it has excellent chemical resistance and it is safe for potable water. SPECIALTY PenePrime No. 500 Two component water-borne epoxy primer that is specially formulated to work in conjunction with other Sauereisen products. PenePrime penetrates deep into the concrete substrate to seal porous substrates and reduce off-gassing from concrete. This product is manufactured to ensure maximum adhesion of the specified protective coating. Application is performed by brush, roll or spray. .

Microbiological Influenced Corrosion

What is MIC?
There are biological organisms (microbes) which influence corrosion. The primary, and to many, the only concern is that this "influence" often results in an extremely accelerated rate of corrosion. It affects most alloys, such as ductile iron, steel (including stainless and galvanized), and copper, but it doesn't seem to affect titanium. The affect does vary between the different alloys with ductile iron corroding slower than steel. There was also a case where MIC caused the water in copper

pipe to turn blue. MIC is not caused by a single microbe, but is attributed to many different microbes. These are often categorized by common characteristics such as by-products (i.e., sludge producing) or compounds they effect (i.e. sulfur oxidizing). In a general sense, they all fall into one of two groups based upon their oxygen requirements; one being aerobic (requires oxygen) such as sulfur oxidizing bacteria, and the other being anaerobic, (requires little or no oxygen), such as sulfate reducing bacteria. General corrosion affects the entire surface or at least the wetted surface. MIC, on the other hand, is very localized. It creates a nodule and a pit beneath the nodule. There can be only a few nodules or there can be many. Within these nodules microbes rarely work alone but operate as a mixed community of differing types and groups. The different microbes perform different functions within the community. This interaction allows a community to thrive in environments that are actually hostile to some of its members. For example, in an aerobic environment, anaerobic bacteria are generally inhibited or killed. But within a community the aerobic bacteria reside in the outer layer of the nodule consuming the oxygen in the water as it penetrates the nodule. Thus, the inner portion of the nodule experiences a reduced oxygen level allowing anaerobic bacteria to thrive.

Types of microorganism that produce MIC

y Acid Producing Bacteria (APBs-Aerobic or Facultative Anaerobic) y Sulfate-reducing Bacteria (SRBs) y Iron or Manganese Bacteria y Slime Formers

How MIC Works

As already identified, MIC operates as an individual nodule covering a pit. The development of this process occurs in three phases, which are:
y y y

Attachment of microbes. Growth of nodule and initial pit. Mature pit and nodule.

Phase One Obviously, for MIC to occur the microbes must be introduced into the sprinkler system. Even though a nodule can contain many different bacteria, they do not necessarily arrive and/or thrive simultaneously. In order for microbes to attach themselves to the inner wall of the pipe, the bacteria must find a desirable site. Such sites are defined as containing absorbed nutrients and having a metallurgical feature that the microbes can attach to. These features seem to be critical for MIC to occur and consist of irregularities in the pipe surface such as from welded connection, pipe seams, pre-existing corrosion, inclusions, etc. After successfully attaching to a location, Phase Two starts, a lot occurs at this stage. (Actually, only a fraction of the activity is shown, since there can be an immense amount of chemical interaction occurring). Among the microbe's by-products are sticky polymers which retain organic and inorganic materials aiding in the creation of the nodule. Once the nodule is formed, it allows the underlying conditions to become chemically dissimilar to the surrounding surface. This is the start of accelerated corrosion, which initially leads to crevice corrosion. Some of the characteristics of the community at this phase are: microbes are located throughout the nodule and the pH level is lowered (acidic) within the crevice, but it is still above 4. This lower pH adds to the corrosiveness of the environment, as well

as stimulating the growth of certain types of bacteria. The increased acidic level is commonly initiated by acid-producing bacteria which produce organic acids as a by-product. This acid provides a nutrient source for other bacteria whose by-product results in a buildup of hydrogen protons and an even lower pH level. In the final phas there is continued formation of the nodule over a mature pit. Such a pit not only increases in depth but also produces a tunneling characteristic. A significant condition is that the pH is less than 4. One of the factors which can contribute to the high acidic level is the weak organic acids discussed in Phase Two. These can be converted to a stronger acid by combining with chloride from the water, thus producing hydrochloric acid. As a result of the high acidity in the pit area, live bacteria are present only in the outer portion of the nodule. At this point, the bacteria could be eliminated and the corrosion would continue as a traditional electrochemical corrosion process. Because of a better understanding of the final phase, whereby the presence of the bacteria is not required, the name was changed from microbiological "induced" corrosion to microbiological "influenced" corrosion.

How to identify MIC

Experts need to use all three of the following confirmation tests to identify MIC. Chemical-Test directly for pH, organic acids and test indirectly (test byproducts) for iron sulfide. Biological-Several methods available. The most common are the MIC Field Kit and/or microbiological culturing. (Requires 28 days or more to produce results.)

Metallurgical-Visually identify shiny metal underneath corrosion products.

Minimizing MIC
Routine inspections Clean environment Design of the barge Barrier System Chemical Treatments Through Green Chemistry Maintain the Coating System Other methods