Localized corrosion deposition erosion

Galvanic corrosion may also occur by transport of relatively noble metals, either as particulate or as ions, to the surface of an active metal. For example, ions of copper, perhaps resulting from corrosion or erosion-corrosion at an upstream site, may be carried by cooling water to the surfaces of aluminum, steel, or even stainless steel components. If the ions are reduced and deposit on the component surfaces, localized galvanic corrosion may result. 

The major concern in respect of surface modification is the integrity and resistance to erosion. It could be a serious problem if cracks or local peeling occur that might facilitate localized corrosion or the buildup of deposits. It has to be remembered also that the presence of a film or coating on the heat exchanger surfaces could be regarded as a fouling layer that by itself imposes a resistance to heat transmission. 

Fig. 10.16 Types of localized corrosion initially associated with the environment, (a) Crevice corrosion, (b) Deposit corrosion, (c) Waterline attack, (d) Filiform corrosion (e) Erosion corrosion, (f) Drop corrosion, (g) Turbulent-flow corrosion, (h) Fretting.

Shells, clams, wood fragments, and other biological materials can also produce concentration cell corrosion. Additionally, fragments can lodge in heat exchanger inlets, locally increasing turbulence and erosion-corrosion. If deposits are massive, turbulence, air separation, and associated erosion-corrosion can occur downstream (see Case History 11.5). 

Often coal ash deposit effects are inter-related. For example, slagging will restrict waterwall heat absorption changing the temperature distribution in the boiler which in turn influences the nature and quantity of ash deposition in downstream convective sections. Ash deposits accumulated on convection tubes can reduce the cross-sectional flow area increasing fan requirements and also creating higher local gas velocities which accelerate fly ash erosion. In-situ deposit reactions can produce liquid phase components which are instrumental in tube corrosion. 

Heavy fuel deposits were expected in boiling systems, and therefore the initial studies of deposition and activity transport for power reactors concentrated on the CANDU-BLW concept until the fields at Douglas Point became a concern. The deposit thickness was proportional to iron concentration in the coolant and to the square of the heat flux (69) deposition was reversible and quickly reached a steady value set by the local conditions. The corrosion products initially deposit by hydrodynamic and electrostatic effects then boiling accelerates deposition by drawing water and its contained iron into the deposit to replace the steam that leaves. Local alkalinity gradients within the deposit determine whether iron crystallizes to cement the deposit or dissolves to weaken it, and erosion processes then define the equilibrium thickness (70), This model works well in explaining deposition under boiling conditions. 

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