Corrosion in condensers

Carbon dioxide CO, Severe corrosion in condensate lines Aeration Deaetation Alkalies (neutralization) Filming and neutralJZiUion amines... 

Oxygen corrosion in condensate pipelines is recognizable as large pits and are a typical result. Where the condensate pH level is low (say, due to the presence of carbonic acid), the pits may be particularly large, but as the pH level rises (say, due to the use of neutralizing amines), the layer of iron oxide corrosion product becomes more protective and the resulting pits tend to be smaller. 

Vapor phase inhibitors (VPIs), also called volatile corrosion inhibitors (VCIs), are compounds that are transported in a closed system to the site of corrosion by volatilization from a source. In boilers, volatile basic compounds such as morpholine or octadecylamine are transported with steam to prevent corrosion in condenser tubes by neutralizing acidic carbon dioxide (Boles et al. 2009). Compounds of this type inhibit corrosion by making the environment alkaline. In closed vapor spaces, such as shipping containers, volatile solids such as the nitrite, carbonate, and benzoate salts of dicyclohexylamine, cyclohexylamine, and hexamethyleneimine are used. 

Statistical Analysis of Pitting Corrosion in Condenser Tubes [16]... 

A statistical technique known as extreme value analysis for assessing pitting corrosion in condenser tuhing is broadly... 

Ault, J. P., and Gehting, G. A., Statistical Analysis of Pitting Corrosion in Condenser Tubes, Corrosion Testing in Natural Waters Second Volume, ASTM STP 1300,1997, pp. 109-121. 

Alkalinity Bicarbonate (HCOji, carbonate expressed as CaCOj Foaming and carry over of solids with steam. Embrittlement of boiler steel. Bicarbonate and carbonate produce CO, in steam, a source of corrosion in condensate lines. Lime and lime soda softening. Acid treatment. Hydrogen zeolite softening. Demineralization. Dealkalization by anion exchange. 

Foaming and carryover of solids with steam. Embrittlement of boiler steel. Bicarbonate and carbonate produce CO2 in steam, a source of corrosion in condensate lines... 

A recently developed drying appHcation for zeoHtes is the prevention of corrosion in mufflers (52,55). Internal corrosion in mufflers is caused primarily by the condensation of water and acid as the system cools. A unique UOP zeoHte adsorption system takes advantage of the natural thermal cycling of an automotive exhaust system to desorb the water and acid precursors. 

Gas leaving the converter is normally cooled to 180—250°C using boiler feedwater in an "economizer." This increases overall plant energy recovery and improves SO absorption by lowering the process gas temperature entering the absorption tower. The process gas is not cooled to a lower temperature to avoid the possibiUty of corrosion from condensing sulfuric acid originating from trace water in the gas stream. In some cases, a gas cooler is used instead of an economizer. 

Admiralty Brass and Naval Brass are 30 and 40% zinc alloys, respectively, to which a 1% tin addition has been added. Resistance to dezincification of Cu—Zn alloys is increased by tin additions. Therefore, these alloys are important for thein corrosion resistance in condenser tube appHcations. In these, as weU as the other higher zinc compositions, it is common to use other alloying additives to enhance corrosion resistance. In particular, a small amount (0.02—0.10 wt %) of arsenic (C443), antimony (C444), or phosphoms (C445) is added to control dezincification. When any of these elements are used, the alloy is referred as being "inhibited." For good stress corrosion resistance, it is recommended that these alloys be used in the fiiUy annealed condition or in the cold worked plus stress reHef annealed condition. 

Iron is added in small (usually 0.5—1.0 wt %) amounts to increase strength. More importantly, iron additions also enhance corrosion resistance, especially when precautions are taken to retain the iron in solution. Precipitation of the iron—nickel-rich phase does not result in strengthening and can cause degradation of corrosion resistance (47). A small (up to 1.0 wt %) amount of manganese is usually added to both react with sulfur and deoxidi2e the melt. These copper alloys are most commonly applied where corrosion resistance is paramount, as in condenser tube or heat exchangers. 

An interesting and novel use of a soHd desiccant, the reduction of cold condensate corrosion in automotive exhaust systems, illustrates a hybrid closed—open system. Internal corrosion occurs in mufflers when the water vapor in the exhaust condenses after the engine is turned off and the muffler cools. Carbon dioxide dissolves in the condensate to form an acidic soup. In an essentially closed static drying step, an acid- and heat-resistant desiccant located in the muffler adsorbs water vapor from the exhaust gas as it cools to prevent formation of corrosive acidic condensate. When the engine is restarted, the system becomes open, and the desiccant is regenerated by the hot exhaust gas to be ready for the next cooldown step (19). 

In many cases, cold spots on the reactor shell will result in condensation and high corrosion rates. Sufficient insulation to maintain the shell and appurtenances above the dew point of the reaction gases is necessary. Hot spots can occur where refractory cracks allow heat to permeate to the shell. These can sometimes be repaired by pumping castable refractoiy into the hot area from the outside. 

Carbon Dioxide CO2 Corrosion in water lines and particularly steam and condensate lines Aeration, deaeration, neutralization with alkalies, filming and neutralizing amines... 

The first vessel in the blowdown system is therefore an acid-hydrocarbon separator. This drum is provided with a pump to transfer disengaged acid to the spent acid tank. Disengaged liquid hydrocarbon is preferably pumped back to the process, or to slop storage or a regular non-condensible lowdown drum. The vented vapor stream from the acid-hydrocarbon separator is bubbled through a layer of caustic soda solution in a neutralizing drum and is then routed to the flare header. To avoid corrosion in the special acid blowdown system, no releases which may contain water or alkaline solutions are routed into it. 

Dehydration to dew points below the temperature to which the gas will be subjected will prevent hydrate formation and corrosion from condensed water. The latter consideration is especially important in gas streams containing CO2 or H2S where the acid gas components will form an acid with the condensed water. 

Gas-Fired water heaters are also made more efficient by a variety of designs that increase the recov-ei y efficiency. These can be better flue baffles multiple, smaller-diameter flues submerged combustion chambers and improved combustion chamber geometry. All of these methods increase the heat transfer from the flame and flue gases to the water in the tank. Because natural draft systems rely on the buoyancy of combustion products, there is a limit to the recovery efficiency. If too much heat is removed from the flue gases, the water heater won t vent properly. Another problem, if the flue gases are too cool, is that the water vapor in the combustion products will condense in the venting system. This will lead to corrosion in the chimney and possible safety problems. 

The main corrosion processes that occur in these items arise from condensing liquids on the internal surface. Although often lagged, heat loss frequently causes internal skin temperatures to fall below the dewpoint of one or more components of the gas stream, albeit locally, such as at support points. Even at temperatures above its dewpoint a gas can dissolve in condensed water. Rapid corrosion can then occur in this thin film of corrosive liquid. 

Bimetallic corrosion in atmospheres is confined to the area of the less noble metal in the vicinity of the bimetallic joint, owing to the high electrolytic resistance of the condensed electrolyte film. Electrolytic resistance considerations limit the effective anodic and cathodic areas to approximately equal size and therefore prevent alleviation of atmospheric galvanic corrosion through strict application of the catchment area principle. 

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