Boiler Corrosion: The Silent Enemy
As the caretaker of a boiler system, you’re well aware of the constant threat of corrosion. The exposure of iron to water and oxygen is a recipe for disaster, leading to the dreaded formation of rust. But what exactly is the science behind this phenomenon?
The Chemical Reactions
When iron comes into contact with water, it combines to form ferrous hydroxide – a critical step in the corrosion process. The formation of ferrous hydroxide actually acts as a protective layer for the remaining iron, but that’s just the beginning.
The presence of dissolved oxygen further complicates the situation, as it combines with the ferrous hydroxide to create an insoluble compound known as ferric hydroxide, aka rust. This sets off a chain reaction that can ultimately dissolve the metal entirely, causing holes and leaks within the boiler system.
But not all corrosion is created equal. Let’s take a closer look at the various types of corrosion that can plague a boiler system.
Understanding the Different Types of Corrosion
[Need help fighting boiler corrosion? Download Rasmussen’s Boiler Safety: Annual Inspection Checklist to help rid your boiler of any unwanted corrosion.]
Caustic Corrosion: Caused by a concentrated caustic substance that dissolves the protective magnetite layer of a boiler, leading to potential leaks and breakdowns if left unchecked.
Acidic Corrosion: Arises from the mishandling of chemicals during acid cleaning or improper pH levels, resulting in the passivation of the boiler’s carbon steel surfaces.
Pitting Corrosion: The formation of small cavities in the metal, typically caused by the localized breakdown of the protective layer and leading to structural weaknesses in the boiler system.
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Boiler feedwater quality affects boiler operations. Pitting is a destructive type of boiler corrosion that can be hard to predict. It is a localized form of corrosion caused by oxygen in the feedwater, and can lead to leaks if not properly addressed. Proper operation and maintenance of the deaerator or feedwater system is essential to prevent pitting.Read More
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The corrosion of your boiler can be a serious issue, but there are ways to fight back. One common type is oxygen pitting, which occurs in systems with leaks. Crevice corrosion can also occur if the boiler has cracks that prevent proper circulation. Additionally, galvanic corrosion can be a problem when different metals are in contact in an electrolytic environment. To learn more about how to combat boiler corrosion, click the link above!