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Author: Giovanni Franchi-Chemical Engineer- Cooperation Contract -University UCBM – Rome (Italy) 1.Theme Description Corrosion is the destructive attack of a metal by chemical or electrochemical reaction with its environment. It’s called “anti-metallurgy” because it tends to bring the metals back to their state of being in nature, mixed with other elements (especially with O 2). Deterioration by physical causes is not called corrosion, but erosion, galling, or wear.There are different types of corrosion: uniform, pitting, crevice, intergranular, galvanic, etc., and are related to different sectors: infrastructure, utilities, production, manufacturing and transportation.Corrosion costs are due to lost production, health, safety and environmental issues. In the USA, referring only on direct costs, corrosion costs grew up from 276 billion US$ in 1998 to 1.1 trillion US$ in 2016.
Table 1 reports the Global Corrosion Costs referring to 2013. Table 1 – Global Corrosion Costs (2013) As can be seen, these costs reached 2.5 trillion US$ corresponding to 3.4% of Global Gross Domestic Product. The Nace International Institute has estimated that the application of techniques for preventing corrosion can save 375-875 billion US$ (15-35% of the total cost). The following sections described the most common types of corrosion in industrial processes such a soil and gas refining and corrosion due to water and in soil. Finally, methods to prevent and monitoring corrosion are described.
Corrosion in Industrial Processes 2.1 Corrosion in Oil and Gas Refining Corrosion is widespread in oil and gas refining; indeed, refining processes works at high level of pressure and temperature. In addition, due to harmful fluids, specific corrosions (sulfidic corrosion, naphthenic acid corrosion, sour water corrosion etc.) are related. The European Commission’s report on “Corrosion Related Accidents in Petroleum Refineries” highlights that the most sensitive equipment, in the 99 refineries analysed, is the distillation unit (23% of failures) followed by hydrotreatments equipment (20%); 17% of failures occurred in the pipeline for transport between units, 4% in tubes of heat exchanger and cooling equipment, 15% took place in storage tanks, whereas the rest involved other equipment component like trays, drums and towers.
2.2 Corrosion in Water Water is very aggressive natural electrolyte for many metals and alloys due to oxygen dissolved. Other elements that affect corrosion are: pH, chloride, Total Dissolved Solids (TDS), hardness and high temperature. Langelier Saturation Index (LSI) is one of the most common index used to evaluate the water corrosion: where. pH S = pH at saturation conditions.
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