Corrosion-resistance Corrosive environments

Atmospheric corrosion results from a metal s ambient-temperature reaction, with the earth s atmosphere as the corrosive environment. Atmospheric corrosion is electrochemical in nature, but differs from corrosion in aqueous solutions in that the electrochemical reactions occur under very thin layers of electrolyte on the metal surface. This influences the amount of oxygen present on the metal surface, since diffusion of oxygen from the atmosphere/electrolyte solution interface to the solution/metal interface is rapid. Atmospheric corrosion rates of metals are strongly influenced by moisture, temperature and presence of contaminants (e.g., NaCl, SO2,. ..). Hence, significantly different resistances to atmospheric corrosion are observed depending on the geographical location, whether mral, urban or marine. 

Electric Submersible Oil Well Pump Cable. These cables are rated up to 5 kV and are designed for highly corrosive oil wells that besides oil also contain brine and other harsh chemicals as well as gases under high pressure and high temperatures (6). Insulations can be based on polypropylene for low temperature wells or on ethylene—propylene mbber which is compounded with special ingredients in order to resist the environments of high temperature wells (Fig. 4). 

Molybdenum improves the corrosion resistance of stainless steels that are alloyed with 17—29% chromium. The addition of 1—4% molybdenum results in high resistance to pitting in corrosive environments, such as those found in pulp (qv) and paper (qv) processing (33), as weU as in food preparation, petrochemical, and poUution control systems. 

Other alloys have been developed for use in particular corrosive environments at high temperatures. Several of these are age-hardenable alloys which contain additions of aluminum and titanium. Eor example, INCONEL alloys 718 and X-750 [11145-80-5] (UNS N07750) have higher strength and better creep and stress mpture properties than alloy 600 and maintain the same good corrosion and oxidation resistance. AHoy 718 exhibits excellent stress mpture properties up to 705°C as well as good oxidation resistance up to 980°C and is widely used in gas turbines and other aerospace appHcations, and for pumps, nuclear reactor parts, and tooling. 

Packed vs Plate Columns. Relative to plate towers, packed towers are more useful for multipurpose distillations, usually in small (under 0.5 m) towers or for the following specific appHcations severe corrosion environment where some corrosion-resistant materials, such as plastics, ceramics, and certain metaUics, can easily be fabricated into packing but may be difficult to fabricate into plates vacuum operation where a low pressure drop per theoretical plate is a critical requirement high (eg, above 49,000 kg/(hm ) (- 10, 000 lb/(hft )) Hquid rates foaming systems or debottlenecking plate towers having plate spacings that are relatively close, under 0.3 m. 

Corrosion Resistance. The environment to which a plated part is to be exposed should be a part of any definition of corrosion resistance. Problems arise in testing a part in its intended environment in part because of the long time period required. In many plating processes, corrosion resistance is direcdy proportional to the plate thickness, so a specification on plate thickness is a much faster method of indirectiy measuring corrosion resistance. In specifying a corrosion resistance requirement for the production of plated goods, accelerated tests are used especially if plate thicknesses caimot be related to corrosion protection. 

Biological Corrosion The metabohc activity of microorganisms can either directly or indirectly cause deterioration of a metal by corrosion processes. Such activity can (1) produce a corrosive environment, (2) create electrolytic-concentration cells on the metal surface, (3) alter the resistance of surface films, (4) have an influence on the rate of anodic or cathodic reaction, and (5) alter the environment composition. 

Usually, in practice, the resistance is measured as a ratio between the actual measuring element and a similar element protected from the corrosive environment (the reference), and is given by R /Rr where subscript M is for measured and R is for reference. 

Note from the Sec. 28 editors to the readers of this handbook Historically, previous editions of Perrys Chemical Engineers Handbook carried an extensive series of so-called corrosion resistance tables [listing recommended materials of construciion (MOC) versus various corrosive environments]. This practice goes back, at least, to the Materials of Construction Sec. 18, 1941, 2d ed. Unfortunately, if valid at all, these data are only usable as indicators of what will not work for. sure, the.se listings should not be used as recommendations of what materials are con o.sion resistant. The section editors have elected to no longer include these data tabulations. 

Corrosion resistance is inferior to that of austenitic stainless steels, and martensitic steels are generally used in mildly corrosive environments (atmospheric, fresh water, and organic exposures). 

Elastic modulus Resistance to environ- Corrosion resistance, thermal... 

Although transformers suitable for other industrial installations are generally suitable for producing applications, certain options may be desirable— primarily due to environmental considerations. At locations subject to harsh environmental conditions, and particularly at locations subject to washdown with high-pressure hoses, non-ventilated enclosures are desirable, if not necessary. Likewise, at locations subjected to salt water and salt-laden air, it often is desirable to specify copper windings and lead wires. Most manufacturers provide standard units with aluminum windings and lead wires. Even if aluminum coils are used, it is almost always desirable to require stranded copper lead wires. This will lessen corrosion and loose terminal problems when transformers arc interconnected to the facility electrical system with copper conductors. If the transformers are to be installed outdoors in corrosive environments, cases should be of corrosion-resistant material (e.g., stainless steel) or be provided with an exterior coating suitable for the location. 

Material Properties. Materials possess various mechanical and chemical properties, and, therefore, it is possible to select materials appropriate for severe corrosion conditions. For example, if the equipment is under cyclic loading, a material with high fatigue strength is desired. Similarly, it is desirable to have corrosion-resistant materials for the corrosive environments. There are several sources for obtaining information on materials properties. Some are listed in Table 4-173. 

Steel is the most common constructional material, and is used wherever corrosion rates are acceptable and product contamination by iron pick-up is not important. For processes at low or high pH, where iron pick-up must be avoided or where corrosive species such as dissolved gases are present, stainless steels are often employed. Stainless steels suffer various forms of corrosion, as described in Section 53.5.2. As the corrosivity of the environment increases, the more alloyed grades of stainless steel can be selected. At temperatures in excess of 60°C, in the presence of chloride ions, stress corrosion cracking presents the most serious threat to austenitic stainless steels. Duplex stainless steels, ferritic stainless steels and nickel alloys are very resistant to this form of attack. For more corrosive environments, titanium and ultimately nickel-molybdenum alloys are used. 

Copper has excellent resistance to some corrosive environments, including fresh waters and fluoride-containing atmospheres. Alloying is necessary to achieve good strength, but copper limiting with steel for strength is an alternative (BS 5624). Copper and some of its alloys are susceptible to crevice corrosion, but the mechanism is different from that which affects stainless steels. 

The use of anodic films on aluminum alloys is only applicable to some mildly corrosive environments, including architectural purposes and where abrasion resistance is required. 

The improvement in rust resistance achieved through low-alloy additions obviously depends on the nature and amounts of the alloying elements — incidentally their effects are not additive — and to an even greater degree on the nature of the corrosive environment. To make a broad generalisation, weathering steels show to maximum advantage when they are freely exposed to the open air in industrial environments but, even then, their performance... 

Since the formation of the silica film does not depend on any particular property of the corrosive environment, high-silicon irons can resist attack by a very wide range of environments. Solutions which are capable of dissolving silica, even in a small degree, are, however, inimical to silicon irons, and there are also a few ions capable of penetrating the silica film, which can cause relatively serious corrosion of the metal. The presence of chromium... 

In practice, pitting of nickel and nickel alloys may be encountered if the corrosive environment contains chloride or other aggressive ions and is more liable to develop in acidic than in neutral or alkaline solutions. In acidic solutions containing high concentrations of chloride, however, passivity is likely to break down completely and corrosion to proceed more or less uniformly over the surface. For this reason nickel and those nickel alloys which rely on passivity for their corrosion resistance are not resistant to HCl. 

Since stainless irons and steels (Section 3.3) are widely used for resisting corrosive environments, it is relevant to consider the welding of these alloys in some detail. There are three groups of stainless steels, each possessing their own characteristic welding problem ... 

A metal s resistance to fatigue is markedly reduced in a corrosive environment. Many welded structures are subjected to fluctuating stresses which, with the superimposed tensile residual stress of the joint, can be dangerous. In addition to this a welded joint is a discontinuity in an engineering structure containing many possible sites of stress concentration, e.g. toe or root of the joint, weld ripple. 

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