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Acid strength
depends on
its tendency to
dissociate into
hydrogen ion and
counter ion
H2 Evolution
begins
Fe Fe + + + 2 ( Anode )
2H + 2 H2 (Cathode)
4H+ + O2
4 2H2O
Oxygen effects are largest for weak and dilute inorganic acids
When acids are concentrated , H2 evolution is so great that Oxygen
cannot easily reach the corroding surface
The addition of oxygen has little or no effect on corrosion rates
in oxidizing acids
Effect of
Dissolved O2
on corrosion
of Mild Steel in
Acids Corrosion
Rate ( in./y )
Acid
acetic
H2SO4
0.04
1.2
Under O2 Under H2
0.55
0.006
Ratio
92
0.36
0.03
12
HCl
0.48
0.031
16
HCl
0.39
0.0055
71
HNO3
1.82
1.57
1.2
Fe + 2 Fe + + + 3 Fe + +
2- Stainless steel
Acidic attack on Stainless steels differs from
corrosion on steels in two important respects
First , nonoxidizing acid corrosion is usually more
severe in deaerated solutions
Second , oxidizing acids attack stainless steel far less
strongly than carbon steel
Hence , nitric acid solutions at low temperatures cause
only superficial damage , but hydrochloric acid causes
truly catastrophic damage
Stainless steels tend to pit in acid solutions
Pits form local areas of metal loss associated with
breakdown of a protective oxide layer
3 - Copper alloys
Copper corrosion by mineral and organic acids is controlled
to a large degree by the presence of oxidizing agents
nonoxidizing acids such as organic acids cause very little
corrosion if oxygen concentration is very low
Hence , just above boiling temperatures copper is virtually
impervious to attack
If cupric or other metallic salts that might be reduced are
present,attack may be severe,even in absence of
oxygen
Oxidizing acids such as nitric acid cause severe attack
4 - Aluminum
Aluminum corrodes at a fairly low rate between a pH
of 5.5 and 8.5 at room temperature
At concentrations between 50 % and 95 % sulfuric acid
causes rapid attack ; below 10 % corrosion is much less
Hydrochloic acid is quite corrosive in all but
dilute concentrations
The corrosion rate in hydrochloric acid increases 100
fold as temperature increases from 50 F ( 10 C ) to
176 F ( 80 C ) in a 10 % hydrochloric acid solution
Locations
any cooling water component contacting lowpH water may corroded
However,there are differences as to corrosion severity and initiation
times depending on alloy composition, kind of acid, and location
In general, the higher the residual or applied metal stress,
the more severe the corrosion at a given acidic pH
This explains why heat exchanger
tube ends are attacked so severely
Tube ends that have been rolled or
welded often contain high residual stress
crevices are sometimes present in which acidic species concentrate
Screens,rolled sheet metal,and other highly worked metals
( not stress relieved ) are also prone to attack
Alloys whose corrosion resistance depends on forming a protective
oxide layer,such as S.S are susceptible to severe localized attack if
pH falls due to nonoxidizing acid excursions
However, there is a period of immunity from attack corresponding
to the time necessary to breach the protective oxide layer
Hence,copper
heat
As low
Fe+++
So,S.steels experience
little attack during brief
pH excursions
exchanger tubes
concentration
handling
acetic
During long
acidic exposure, pits may begin increases
and grow at
ever acid
during
acid
can be more
increasing
rate . Surfaces containing pits , crevices
, and other
cleaning,the
seriously
shielded corroded
areas are more likely to be attacked
by lowpH
conditions
corrosion
rate
of steel
at low than at
rapidly
Occluded
sites allow concentration of acidic increases
materials and
high
temperatures
assist the so called Autocatalytic pitting process
Sulfuric
acid atacids
roomcan be highly sensitive to
Corrosion involving
nonoxidizing
temperature
is handledare more severely
flow.regions of high
flow and turbulence
inquiescent
carbon steel
drums,
attacked than more
regions
when water
concentration
is low,but
Weires, lips,and other
flow obstructions
increase turbulence and
it elbows,tees,
becomes extremely
thus corrosion.Pipe
and joints are frequently attacked
corrosive as water
locations,althoughconcentration
widespread,are
dependent on many factors,
increases
metallurgy,deposition,design,temperature,pH,flow and other factors
all influence attack
Dissolved O2,water,acid,and metalion concentrations can have
a pronounced effect on acid corrosion
For example,copper is attacked by acetic acid at low temperatures,
above boiling,no attack occurs because no dissolved O 2 is present
Critical Factors
1- Intermittent attack
Acid attack is caused by an upset, intermittently, consequently
periods of attack may be separated by intervals of no acid corrosion
2 - Mixed acids
corrosivity of solutions containing more than one acid may
be unrepresentative of the corrosivity of either acid alone
Such mixtures are used widely in a variety of industrial applications
3 Corrosion products
Acid attack causes damage directly by wastege and
indirectly by increasing and/or moving deposits
For example, during severe acid
excursion, large amounts of Fe,
Cu, zinc, or other materials may
be solubilized, resulting
corrosion products will be moved
and can foul heat exchanger
tubing, blockage of pipes,
screens may occur due to solid
material sloughed from corroed
and fouled surfaces .
Identification
Attack by strong acids tends to produce intense localized wastage
Weak acids cause more general corrosion,however numerous
exceptions to these general rules exist
Fortunately, corrosion caused by acids has many unique
features that allow easy recognition in most cases
Strong acids
Pit growth
When most metals exposed to highly acidic conditions,
pitting results.a pit has a depth greater than its width
In strong mineral acid attack,not only is depth greater than width
but undercutting is pronounced. Cavernous chambers from just
below the surface because of segregation of aggressive anions
within the pits
When corrosion begins a small amount of positive ion is put
into solution at the corroding surface
So,pits
usually
contain
only small amount
of is
corr.
A
striking
feature
of mineralacid
corrosion
the Product,although,
directionality of
areas
surrounding
pits
may
contain
precipitates
formed
by normal
pit
growth.
Because
pits
entrap
metal
ions and acidic
anions
, the
pHprecipitation
process
oxidation
of than
ions leaking
out density
of pits
density of fluid within
canor
beby
much
greater
bulk water
Pits forming on roof or ceiling surfaces tend to drain by
convection that is stimulated by the density difference between
the fluid within the pit and the bulk water
This
Contents
process
leak
tends
out of
to pit
decrease
interiors
acidity
and depassivate
within pits, Thus
areas, pits
growing
immediately
in the
below
direction
the active
of gravity
corrosion
are favored
sites
Depassivation
by pit leak out
due to density
difference
Pits growth in
the direction of
gravity
Grooving
Weld attack Welds are more susceptible to corrosion than other areas
Welds may contain porosity,crevices,high residual stresses& other
imperfections that favor attack. C.S welds are ditched by acid attack
Severely attacked weld on
a large-diameter steel pipe
by an acid upset
Weak acids
( Carbonic Acid )
Jagged tree
pattern of
metal loss
caused by
condensing
steam with
high CO2 &
oxygen Con.
Organic Acids
Horseshoe-shaped
depressions due to
erosion corrosion
(( Cautions ))
Oxygen pitting and erosioncorrosion frequently
produce damage resembling acid attack
Erosion
corrosion
Prevention
Monitor water pH routinely
inspect acid feed equipment such
as pumps on a regular basis
Isolate & identify possible
sources of inleakage, such as
perforated heat exchangers
or makeup contamination
Eliminate windborne acidgas
contamination of cooling towers
and other water sources
Regularly ( at least monthly )
review all chemical feed and
handling equipment
Clean systems containing acidic
deposits frequently
Emergency
Begin BD or drain system if
possible & Suspend all acid feed
Monitor pH frequently at
appropriate locations
CONCLUSION
Corrosion is not yet completely understood, despite an enormus
amount of research over the last century and concentrated study
during the past twenty five years
Corrosion can be controlled if it is detected and diagnosed in time,
but unfortunately there is no universal remedy
There are at least a dozen form of corrosion which are affected
in different ways by metallurgical structure, composition, and
mechanical factors
The identification of cooling water system corrosion problem
begins with a knowledge of how to recognize such problem .
Knowing where particular forms of damage might occur, What
damage looks like, how critical factors influence attack and most
importantly, how such problem can be eliminated
Acid corrosion is usually caused by an upset.kind of the acid and the
kind of metal attacked have the largest consideration in control and
eliminate such type of attack in a cooling water system .
OPEN DISCUSSION