Protecting critical assets: Corrosion mitigation in the chemical industry

According to various reports, the Indian chemical industry aims to reach a US$1 trillion market value by 2040, driven by innovation, AI, and sustainability, positioning India as a global leader in the sector

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Corrosion is a significant problem in the chemical industry, damaging equipment and causing environmental harm. Chemicals like sulfuric acid, hydrochloric acid and hydrogen peroxide are used in many chemical processes, which are inherently corrosive. Aggressive substances like aqueous solutions with different concentrations of salts can corrode equipment. Besides, pH, oxygen and dissolved gases, hardness, and temperature also promote corrosion. Corrosion in the chemical industry is the gradual destruction of materials due to chemical reactions with their environment. It can occur in a variety of forms, including galvanic corrosion, crevice corrosion, corrosion under insulation, pitting corrosion, and uniform corrosion, amongst others.

This results in decreased equipment life, environmental damage, plant shutdowns, product contamination, damage to adjacent equipment, and hazardous conditions, amongst others.

Corrosion mitigation in the chemical industry involves using coatings, inhibitors, and other methods to prevent metal deterioration. Paint or oil can be used to protect metal; sealers, overlays, and barrier systems can be used to prevent moisture, chloride ions, and carbon dioxide from entering structures.

Corrosion inhibitors are substances that slow down corrosion reactions. They are added to acids, steam, and cooling waters to reduce corrosion. Inhibitors can be used internally in carbon steel pipes and vessels.

Cathodic protection is another method of corrosion control that can be used to protect metal surfaces. Using alloys that are less reactive than the base metal can help prevent corrosion

Other methods include changing the environment, changing the material, and placing a barrier between the material and its environment. Proper ventilation or dehumidification can also help prevent corrosion.