Corrosion extent

For a given bulk environment and a given crevice eonfiguration, the repassivation potential becomes independent of the corrosion extent as soon as some critical damage size is exceeded [8] (Fig. 28). 

High-temperature oxidation and corrosion behaviors of Ni-Fe-Cr alloy as inert anodes for aluminum electrolysis have been studied in oxygen and molten electrolyte. The oxidation and corrosion scales on the anodes tested were analyzed using XRD and SEM-EDS. The oxidation rate is found to increase with increasing temperature from 700 °C to 950 °C, which can be approximately described by an inverse power rate function. The oxidation scales at 750 °C, 920 °C and 950 °C contain Cr-rich phase along with FeCr204 and (Eeo.eCro.4)203. The corrosion extent of Ni-Fe-Cr anodes in electrolyte is dominated by temperature, which can make the scales thickness double from 700 °C to 750 °C or from 920 °C to 950 °C. Cr and Fe in the scales on the anode in electrolysis corrode preferentially into the molten electrolyte, while the nickel oxides could better sustain the corrosive environment in electrolysis. The results can be useful for developing inert anode material for potential application in aluminum electrolysis. 

It is obvious that the corrosion extent of the alloy anodes can be reduced at lower testing temperatures in KF-AIF3 electrolyte than in NaF-AlFs electrolyte at higher ones. Here the chemical difference in electrolyte may have some impact on the corrosion rate, but it is the temperature that can play even more important role in the scale development during electrolysis... 

The corrosion extent of Ni-Fe-Cr alloy in aluminum electrolyte is dominated by temperature, and the thickness of the scales is increased double from 700 C to 750°C or from 920°C to 950°C. 

This is essentially a corrosion reaction involving anodic metal dissolution where the conjugate reaction is the hydrogen (qv) evolution process. Hence, the rate depends on temperature, concentration of acid, inhibiting agents, nature of the surface oxide film, etc. Unless the metal chloride is insoluble in aqueous solution eg, Ag or Hg ", the reaction products are removed from the metal or alloy surface by dissolution. The extent of removal is controUed by the local hydrodynamic conditions. 

Gaseous Hydrogen Chloride. Cast Hon (qv), mild steel, and steel alloys are resistant to attack by dry, pure HCl at ambient conditions and can be used at temperatures up to the dissociation temperature of HCl. The corrosion rate at 300°C is reported to be 0.25 cm/yr and no ignition point has been found for mild steel at 760°C, at which temperature HCl is dissociated to the extent of 0.2%. 

Montedison and Mitsui Petrochemical iatroduced MgCl2-supported high yield catalysts ia 1975 (7). These third-generation catalyst systems reduced the level of corrosive catalyst residues to the extent that neutralization or removal from the polymer was not required. Stereospecificity, however, was iasufficient to eliminate the requirement for removal of the atactic polymer fraction. These catalysts are used ia the Montedison high yield slurry process (Fig. 9), which demonstrates the process simplification achieved when the sections for polymer de-ashing and separation and purification of the hydrocarbon diluent and alcohol are eliminated (121). These catalysts have also been used ia retrofitted RexaH (El Paso) Hquid monomer processes, eliminating the de-ashing sections of the plant (Fig. 10) (129). 

Feedwater treatment is designed to protect the feedwater system and, to some extent, the boiler. Most systems contain carbon steel piping. Carbon steel corrosion (Fig. 23a) is considerably slower at a pH between 9.0 and 11.0. In aH-ferrous feedwater systems, the preferred pH range is therefore 9.2 to 9.6, although some systems are operated at a pH as high as 10. In systems where copper alloys are present, high concentrations of ammonia accelerate corrosion of the copper alloys. In those systems the preferred pH is 8.8—9.2. 

Health nd Safety Factors. Thionyl chloride is a reactive acid chloride which can cause severe bums to the skin and eyes and acute respiratory tract injury upon vapor inhalation. The hydrolysis products, ie, hydrogen chloride and sulfur dioxide, are beheved to be the primary irritants. Depending on the extent of inhalation exposure, symptoms can range from coughing to pulmonary edema (182). The LC q (rat, inhalation) is 500 ppm (1 h), the DOT label is Corrosive, Poison, and the OSHA PEL is 1 ppm (183). The safety aspects of lithium batteries (qv) containing thionyl chloride have been reviewed (184,185). 

Boiler Deposits. Deposition is a principal problem in the operation of steam generating equipment. The accumulation of material on boiler surfaces can cause overheating and/or corrosion. Both of these conditions frequentiy result in unscheduled downtime. Common feed-water contaminants that can form boiler deposits include calcium, magnesium, iron, copper, aluminum, siUca, and (to a lesser extent) silt and oil. Most deposits can be classified as one of two types scale that crystallized directiy onto tube surfaces or sludge deposits that precipitated elsewhere and were transported to the metal surface by the flowing water. 

Purification actually starts with the precipitation of the hydrous oxides of iron, alumina, siUca, and tin which carry along arsenic, antimony, and, to some extent, germanium. Lead and silver sulfates coprecipitate but lead is reintroduced into the electrolyte by anode corrosion, as is aluminum from the cathodes and copper by bus-bar corrosion. 

Knowledge of the composition of coal ash is usehil for estimating and predicting coal performance in coke making and, to a hmited extent, the folding and corrosion of heat-exchange surfaces in pidverized-coal-fired furnaces. 

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