The Silent Menace: Understanding and Mitigating Corrosion in Industrial Systems

Let’s understand - What is CORROSION?

The natural process of corrosion is the slow breakdown or deterioration of materials—mostly metals—caused by chemical reactions with their surroundings. The most prevalent kind of corrosion is rusting, which is the result of an oxygen and moisture reaction with iron or steel that produces iron oxides. Corrosion, however, can impact a variety of materials, such as metals, ceramics, and polymers, each of which has a unique set of degradation mechanisms.  

Corrosion types:

• Uniform Corrosion: Has an equal impact on the material's whole surface.
• Pitting Corrosion: A focused attack that leaves the substance with tiny holes or pits.
• Crevice Corrosion: Occurs in confined spaces where the environment differs from the bulk environment, like under gaskets or seals.
• Galvanic Corrosion: Happens when two dissimilar metals are in electrical contact in the presence of an electrolyte.
• Intergranular Corrosion: Takes place at a material's grain borders.
• Corrosion Under Stress Cracking: The outcome of tensile stress and a corrosive environment working together.

Corrosion is a Significant Concern for Various Industries:

• Economic Impact: Corrosion leads to significant direct costs due to the need for repairs, replacements, and maintenance of corroded components. This can run into billions of dollars annually for industries. Also include production downtime, loss of efficiency, and the potential need for premature retirement of infrastructure or equipment.
• Safety Hazards: Corrosion can weaken structures, making them prone to catastrophic failures. This is especially critical in industries such as construction, aerospace, and automotive. In the oil and gas industry, corroded pipelines can lead to leaks, causing environmental pollution and posing severe health risks.
• Operational Efficiency: Corrosion can reduce the efficiency of machinery and equipment, leading to increased energy consumption and operational costs. The need for unexpected repairs can disrupt production schedules, leading to significant operational losses.
• Environmental and Regulatory Compliance: Corrosion-induced failures can result in spills and leaks, causing environmental damage that may lead to hefty fines and remediation costs. Industries must comply with strict regulations regarding safety and environmental protection. Non-compliance due to corrosion issues can result in legal liabilities and reputational damage.
• Public Health and Safety: In water treatment and distribution systems, corrosion can lead to contamination of water supplies, posing health risks to the public. Public infrastructure such as bridges, highways, and railways are susceptible to corrosion, which can compromise their safety and reliability.

Solenis' Maintenance Solutions:

At Solenis, we have a three-step process to ensure that the correct steps are being taken to prevent machinery corrosion:

• Prepare: The most important step of this process is to ensure that any loose rust is identified and removed. Once this is completed, apply the Solenis industrial degreaser to remove any contaminants in preparation for step 2.
• Treat: Solenis has a variety of anti-corrosion products that you should apply to completely remove or ensure long-term protection from rust.
• Protect: This process must be done regularly to prevent rust from returning unless it has been encapsulated. The Solenis aerosol products are a fast and effective way of doing this.

Useful Links: https://www.nchasia.com/en-in/product/x-rust-gel/ https://www.nchasia.com/en-in/product/salvage-2/ https://www.nchasia.com/en-in/product/chelade/

Solenis is dedicated to helping commercial businesses create safe, efficient working environments and working with you to promote a healthy water environment for any commercial property. Contact us today to find out more about how we can support your business.