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The document describes the components and operation of a mixed bed ion exchange unit used to treat water. It contains: 1) Multiple resin beds for cation and anion exchange that can be independently regenerated using counter-current flows of acid, caustic soda, and rinse water. 2) Piping and valves to direct the flows of acid, caustic soda, water and regenerants during service runs and regeneration cycles. 3) A degasser to remove carbon dioxide from the water upstream using counter-current contact of water and air to reduce the carbon dioxide level. 4) Design considerations for lowering carbon dioxide and oxygen levels in treated water to minimize corrosion downstream.

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Rahul Shandilya
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0% found this document useful (0 votes)
26 views

Adobe Scan 02-May-2023

The document describes the components and operation of a mixed bed ion exchange unit used to treat water. It contains: 1) Multiple resin beds for cation and anion exchange that can be independently regenerated using counter-current flows of acid, caustic soda, and rinse water. 2) Piping and valves to direct the flows of acid, caustic soda, water and regenerants during service runs and regeneration cycles. 3) A degasser to remove carbon dioxide from the water upstream using counter-current contact of water and air to reduce the carbon dioxide level. 4) Design considerations for lowering carbon dioxide and oxygen levels in treated water to minimize corrosion downstream.

Uploaded by

Rahul Shandilya
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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37 SIGHT WINDOW,

WATER INLET ACID


DOWN FLOW RINSE ANION LEVEL
INLET BEFORE MIX
MANHOLE ING
CATION LEVEL
AIR RELEASE BEFORE MIX
ING

WEDGE WIRE STRA!NR

PVC.DISTRIBUTOR

BACK WASH OUTLET


COSTIC SODA
INTET CALSO USED AS
WATER INLET )

COST IC SODA
DRAIN DOWN
SPREADERS. CONNECTION

ACID INLET
BACK WASH RUBBER LINED
INLET CAUST VESSEL
IC SODA OUT
LET CAUSTIC
SODA RINSE
OUTLET SIGHT WINDOW

SUPPORT
HEADER

P.V.C.LATERA
LS WITH TREATED WATER
STRAINER OUTLET BACI.WASH
BUTTONS 2 INLET ACID OUT
LET ACID RINSE
OUTLET FINAL RIN
SE OUTLET AIR
INLET
BUFFER FLOW DUR
ING CAUSTIC SODA
STEEL DIVISION PLATE REGENERATION
BOTTOM MANHOL E
CONCRETE
Fig.2(f): Mixed bed unit
water, P=Partial pressure of the gas in o
This CO, can be removed in Degasser very cheaply.
The capital cost of a Degasser is very less and running
water. H- constant at that temperature. contact wiN
cost also. Otherwise this CO, is to be removed in anion
Further solubility offthe gases
exchanger. Hence Degasser actually reduces load in temperature of the solvent is increased. decreases:s
When
the
Anion exchanger. reachessit saturationtemperature all the wate,
The theory ofdegassification is mainly based on
gases are theoretically insoluble in it uncombi
and maynedbe
removed.
following gas laws.

DELTON'S LAW Hence solubility of agas may be decreased


effect more complete from water in several ways.
The total pressure exerted by amixture of several
gases is equal to the sum of the partial pressures of By lowering the partial pressure by inserting
individual gas. Again according to charles law the partial another gas in contact with water (Degassifier).
pressure of each gas is determined by the amount of
that gas in the mixture. By decreasing the pressure (cold water
deareation).
HENRY"S LAW
(i) By lowering the partial pressure by heating te
The solubility of the gas, in water is directly water to boining point corresponding to thc
proportionalto the partial pressure of that gas in contract pressure of the steam introduced (Hot water
with water X P/H, X= amount of gas dissolved in deareation).

BACKWASH CAUSTIC
0UT IN

SPENT
CAUSTIC
OUT

BACKWASH
IN
AIR OUT

ACID IN

SPENT
ACID IN AIR IN

Fig.2(g,h,ij)
24
Incase of removing CO, from cation effluent The spray and packings devide the water intodroplets
principal is normally adopted. or thin films, exposing new surfaces to the gas phase.
Packing materials also provide agitation and thus allows
Dry air contain around 0.03% CO,(300 ppm) the dissolved gases to leave the water readily. Packings
at atmosphere pressure. It has a partial pressure 300 x also provide adequate detention time for near approach
10 ats. to equillibrium solubility ofthe gas in water.
From Henry's law constant for CO, (Table-2) The height required for packing material increase
Say at 10°C thus is in equilibrium with 0.7 ppm CO, in when the amount of influent CO, is higher, when the
water or at 25°C this is in equilibrium with 0.45 ppm amount ofeffluent C0, derived is lower and when the
Co, (Table-2). water temperature is lower.

X= P/H Normally degassifier is designed to reduce C0,


where P-partial pressure of C0, in atrmosphere at the level of 5 ppm,operating design temp. selected
X-concentration of C0, dissolved in water. for such CO, content, is normálly above 10°C. If
temperature falls below the slight increase in CO, may
Temperature Value of H to give be taken care by anion exchange unit.
°C Xin ppm CO,
0.30 x 10-3 By degassifier CO, level of water can be very
10 0.43 x 10-3 easily reduced to 5ppm. Problem with degasser is that
20 0.58 x 10-3 while blowing CO, out it saturate the water with oxygen.
25 0.67 x 10-3
50 1.16x 10-3 This is undesirable as oxygen finds way into
condensate with make up water which is more or less
Hence by bringing water and air in contact, CO,in free from oxygen.
water can be reduced to a very low level.
Though air filter is supposed to take care of any
This can be achieved when air and water air dust or dirt in the air, still it sometime finds entry into
broughtto near equillibriumwhich is done in adegassifier. water.

There are different types of degasser. The unit From the oxygen/corrosion point of viewcold
essentially consists of a tower mounted on a tank to water deaeration based on principle (ii) is a better choice
hold 1-2 minutes supply of degassified(decarbonated) though more expensive.
water. Degasser internal packing of wooden slat trays
or ceramic raschig rings or ceramic/ plastic ball rings Here CO,2 and oxygen level is reduced and thus
etc.over which water trickles down from a spray pipe make up water does not increase the condensate oxygen
(corrosion resistant) at the top. Filtered air is blown in level.
at the bottom and rises counter current to the downward
water.
Theion exchange unit fconventional layout.
is of
COUNTER FLOW REGENERATION resin bed in acylinderical vessel ab0ve
It consists ofa usual 50%- 100%
whichthere is the rising space. The
service
In the conventional ion exchanger during resin top and bottom ofthe
unit are fitted with inlet:nd outlet
through the however there in
runwater flows from top to bottom same direction. distributors. In addition to these,
bed and the regeneration is done in the third - buried collector lyingjust below the upper leyel
or
nozzles mesh
ofthe resin bed, and fitted with strainer
Since like operation, Regeneration is not l00% covered holes through which resin
cannot pass.
During
the bottom part of the bed contains more ions. the bed
service run when the final treated water leaves These units are run in normaldownflow service
bed
it passes through less regeneratedportion of the When the resin is exhausted, regenerant is pumped into
and thus picks up more ions for example in case of the bottom distributor and passes upwards through the
cation exchanger sodium slip will be more. bed. At the same time, air or water enters the top
But if the regenerant is injected from bottom to distributor and flows through the very small depth of
top then the bottom portion of the bed will be better the bed which lies above the buried collector. Both the
regenerated. During service when treated under leaves two flows leave the unit through this buried collector.
the bed it passes through the better regenerated bottom The upflow ofregenerant tends to make the resin lift
position and ion pick up is less, say for cation exchanger and mix, but this tendency is overcome by the force
R-Na concentration is very very less at the bottom past exerted on the bed by the down flow through the upper
thus Na slip will be very less. This gives abetter quality layer.
of water and Regenerate level is also low.
This basic principle has been used in several
The CFR design has to meet all the requirements variations. The liquid which enters the top distributor
of conventional exchangers with some additional during regeneration may be water, (Fig.3a).Or the
atachments.
downflowmay be of spent regenerant (Fig.3b) which
avoids the waste of water but needs an expensiVe
The requirements ofCFRare as below: corosion resisting pump. The most successful variation
uses air vwhich avoids the dilution problem, air blowe
(1) The exchanger should have normal arrangement for air mixing at M.B. and this blower can double up to
for down flow service.
the CFR duty at no extra cost
(2) Back washing is required time to time to regrade
(Fig.3c).
the bed and remove dirt and fines. For this 50 The resin above the buried collector is nevel
100% free expansion space is to be provided. regenerated and plays no part in the ion exchang
3) Resin must be free to shrink and swell during the process. On the contrary if this totally exhaustedresit
cycle. should accidentally get into the working portionofth
bed, it could have a on CFRoperation
(4) Arrangement is to be made to hold the bed damaging Theeffectburied
Alayer of the bed (Fig.3d). collector ma)
packed and immobile during up flow be of the
regeneration. header and
may be placed outsidelateral typewith(Fig.3e)
the bed
orthe collecto
long individualdow
Most common design is shown in comers dipping into the bed, each down comer-being
(Fig.3).
fitted with a standard nozzle
(Fig.3t).
26
27
Fig.3
FIG
3d. FIG-
RESIN
EXChANGE 1ON
SECTION
AA- SIN INERT_
RE
3e
FIG-
FIG-3c. -3b FIG
IG=3a FIG-3
required. isfew at washtends
FOULING
RESINS Water. with the the aredirection isregenerated.
wherespend the frompossible byoutcomeregeneration
improved cach
by condition Noticeable
pH, exchange precipitate
irreversibly heavy used
following bed, wanted treatedHCI.The regeneration from
treatment conductivity, degassed regenerant they
the With regeneration filtertoAny
It This metals, Certain and for bottom to is the
is this, as obtain by suspended
capacity
or
changes where least, the
came, water sulphuric
that buried out
only resins is by on PROBLEMS service. regenerant In object CFR.
100% characterised the high
inorganic water it CFR, of chemical at
possible the theywhich will thbeing a when back
rinse as or resins e last the very On distributor the
takes molecular
surface of
recovery well poor and Forwould deposit slow
is pushed to unit CFR much the acid
comes bed wash
tmatter
op
requirements cause and this avoid
to place anion at
injection rinse so regeneration,
other of
remove operating astreated isefficiency is iswill
oforganic IN cationcause thefresh that lower
to backwashed; not
contained the
is in by fouling. organic exchanger treated back ions into keep hand
bed
not physicalwater the
ION-EXCHANGE
ionsjust must the
remove
drop exchanger high itself. to lealkage needed.
possible. bulk etc. impurities
bed contact
removed unwanted resin
itcan and
parameters quality compounds leakagewater bethe does in
of and in or If, zones in with the it. anthe
the with where raw the of hardly But For
chemical operation absorbed is outlet by
is
which cations
make overall double upward water
For
fouling or such D.M. rinsed during water same from fully ions after this
they
this like both. etc. as of
the
it be
28
converted unsoluble iron, 5. 4. 3. encountered 2. 1. pre-treatment prevention
pretreatment exchange resistant acid. iron resin
as thiocyanate. sulphuric as occurWhere Oxygen METALFOULING HEAVY
contain colloidal this
fouling in Silicafouling foulingOrganic Oil fouling metal Following
Heavy
In
In sample Iron acid as the Well precipitation CaSO, fouling
iron However HClHCIif and When
case bed.lining case fouling acid allowedto from
is
when formwater
in of
plant
matters can with
A less ellutes ion ion fouling
plant
which Resin ofblood regeneration used offerrous
of treatmentsoftener, be HCl effective soluble
exchange oxidised may exchangers.types
surface by it
can the as is
is is are removed better by
taken aeration. antifoulant red acid regenerant
accumulate contain
better alsO be iron to in proper
colour andeasily in insoluble resinbicarbonate. of
water
up which cation or contact proposal.
available may by then elluting ferric
fouling
by tto
he significant design,
anion
organic to indicates
soaking detected the it absorbs
remove remove be
may adding resin is
ferric chloride.
problem dificult form with
in given This are well
exchange the not may iron oxygen.
matter resin
ammonium by quantities
salt
iron market. iron out havepresence by ion. normally operated
treating beBut doesdissolved to
become
as of in fouled with remove. which
eresins at
wethacv Hu 0 not
is of
NaO treat this. of diffe done co1S Some (3) (2) (1) releas are carbo
c arethrou:
gr uphumiirreve
by ORG onepre-trediscus
NaOH).treated
with this.
difference done.
ofcollected is
Some (3) (2) (1) are through
carboxylic
release humic
are irreversibleup ORGANIC onediscussed
FOULINGpre-treatment
chemical convertedgradually by valency
Anion Before When timesResinthrough. break high Decrease
Deterioration magnitudeyellow
fouling). of foulingThe is NaOH
Increase anion and Organic
the later,
alkaline willjustify organic
requirement and foul conductivity acid fulvic
pores absorption
exchange form
exchange and becomes
laboratory odour torinse to lost.
due groups fouling may carry
after in sodium but acid. and
operation even to Further take over
brine the fouling comes dark of (Rinse
characterised by:
hydrolysis. can does
resin brine treated
or purple attached resin.Since of of place of
can plant scale salt. not anion
big
treatmentfouled in high at not
aluminium
also scale washsuspected, is out. capacity. effluent the come This organic
they but
colour water
pH depending During to exchanger create
be
alkaline the time out. bag are aluminium
by treatment.
operating or
organicestablished
(10% is organic molecule serious
and prematurequality. coloured operation Exchange of molecule being due
brine resin opaque regeneration
acid is to
NaCl+2%matter capacity
Amount washsample upon molecule due problem. improper
has
Such mostly to
from and silica straw they sites entertaken only
is as the the
is
Oil wil FOULINGOIL subsequent regeneration
MB bed
separated against fouledby ion.organic they
groups better NaOH
betterregeneratedexhausted treatingbefore is
acid. tested
fouled form effluent This comes are
Ifoil
MB organic Macroporous
In
Macroporous of used WBA choice
matters
Alkaline result. at In alkaline the Before
for
resins afilm results ifa organic WBA 40-50°Cis alkaline
contaminated form resin
and service the small in cation toare where with iron.
giving
or fouling protect brine Then brine
may resin also inorganic contact matters. (Ammines) are seldom double for (in Ifiron
run amount and brine
be drop low WBA resin easily water
treatment after passed an exhausted wash. alkaline
cleaned bed it anion of SBA hour. wash is
water pH, matter offouled
redissolved with SBA fouled has quality present
preventing in has eluted normal Removal brine
capacity. high resins can have from a Overnight through brine
byenters isacid units. big byhistory at form)
precipitated. be high fouling. of treatment
first
non-ionic conductivity anion are pores because organic regular alkali.
releasing at used rinse solution by
ofiron
diffusion ion not affinity of the iron
exchanger, the resin soaking 10%
detergent.
completely as and
functional Frommatter fouling. interval the resin
HCl
is
is fouled
mineral time in a are with removed
done
ofDuring cation of WBA bed
of guard gives bed
ions. the of not OH and is is
2% acid. by resin
it a is
HClregeneration is
regenerated
slow
CaSO, CaSO, FOULING
precipitate
quantitytemperature acid,
accumulation
If Though This low
precipatation
the results In
of sulphuric
unit water can flow
of may
with step the
DUE
after be due
and HCI, and regenerant. rate to foul
of upremoved acid TO
CaSO, some CaSO, there
regeneration then injection the
during
CaSO, regeneration CaSO,
regeneration is soaking resin.
fouling will in
always by
the regeneration
back PRECIPATATION
ofhigh The
be bed.followed is with
remnoved
can some wash insoluble
precipitation
HCl concentration
be with
avoided. chance
to acid. with or CaSO,
during H,SO avoid large high
30 of of
50°C.WBA 3 2regeneration.
thorofare
precipitate
1. fouling low through
regeneration).
regenerant This SBA is the FOULING SILICA

caustic. time
resinSilica WBA.Dilute Discard
then through WBABefore Silica
either
with pass out regeneration of
fouling the fouling
thethorofare ofandWhen
10% SBA it passed
throughinitial the fouls
can outlet following this is
caustic regeneration with throughnormally
high solution
be WBA. the
removed caustic silica WBAresin. regenerant
solution passino
after
steps contain thobserved e
and discharge enters
pass WBA
at by pass are high
some observed WBA To
treating
around avoid (thorofae in
it from silica
through caustic WBA.
45the SBA silica silica and
in A
CORROSION porous
FORMATION be product. withwhichforms aluminiumget Corrosion.
Butcorrosive
atmosphere of go and pure (low
compound. deterioration
reaction
impervious aluminium fortunately thatspend back
lessmetal.
Ifwe The does an For metal onstable energy ln M+ Corrosion
ENV=CORR.
unprotective impervious to nature
oxide notimmediatelymetal. example ore its Hence We with
place
to to ore than state). its of
allow the from the
ELECTR0Zn protective layer and go get form metallic spend every environment.
PROCEEDS corrosion we backmetals, metal can
rod (Fe,O,, formed further Aluminium
metalprotective Alumina. its
Metals thing
spend (corrosion). ore. lot
ina oxidised to by be
is higher So of chemical
solution (Al, form wants Product
CHEMICAL Fe0,
oxygen product
onprotected lot its
metals energy are
simply
Crthe layer So
ofelectrical ore
to is
containing WITH etc.).oxides metal to aluminium
when
aluminium form willHigher highernormally to attain
to
or
by aluminium on has
reduce defined
came the be electro
surface the exposed bythe
tendency energy a
Fe,O,) basemetal in th e stable
CELLCELL corrosion energy means
tendency found
metal chemical
CORROSION
Zn contact oxide. very is energy as
may oxide state state
ion or to of the
31
to to to as
() into )flowjoined
assume rod Cd Fe Zn MnALM, Base
End potential
determined potential".
electrode the the noandpotential.
that behindsome
ve
potential the fromn isdipped further
solutionequillibrium it
potential with equillibrium. wil
solution a
Here (Standard electrons Zn
Znelectrodepotential -0.2770.402 -0.44 0.740.762-0.876 -1.18 -1.66 -2.37-3.045 or loss balance After
wil a into in Electro to wil
low case of
of construct standard ofwil some go
drop asresistance
Zn standard potential The Zn the oninto
Znt+ +0.34. of Motive
Cuttelectrode to Zn Series
EMF
Table-3 potentialestablish.
Zn++
asdriving time the
the
ion Cu it a strength Zn
solution
If is table (-)ve solution
ion andelectrode. wire these -0.76 Force of rod.
hence Au Pt
A Cu H Pb SnMo Ni ion force CHAPTER-2
from in (Fig.4a) different
of
between Thereafter
ofits andit potential Zn
Cuelectrode Zn twosimilarly
of standard
(E.M.F.) for and
solution This copper +0.799+0.337
0 N ions Zn rod
will electrodes L B 0.000-0.1260.136 0.20.255
+1.68+1.19
the willZnt+
start current
will metals is wil there form towill
will salt ifa (Table-3).
Electrode "standard remain
metal have
reduce copper beleaving
start sincegoing will are wil it are and in be
wil Zntt such
-ve
beandCORROSION
acceptedby are CELLFaraday's
Law.by
determined
fromthe resistance
potential(protected). chemical
enters
Cathode: andplace.telectrode
heanode
InAnode: Zinc staking
IS
replaced
dissolution Continuous.
Zn
Anode
Ifin reaction
Rate Amount of NoCuTT Here from At Zn’ is electrode
-’
the difference
in reduction anode thatwhere electron
Zn of loss Cathode
Cu solution. In
by
above
electrical
above
electrode
on
H+
at of dissolution + is an will
(Danniel
+2e hydrochloric of cathode loss Anode
t+ and
Zinc flowing
current 2e from
electro
current metals takes Or is in continue. deposit
(Fig.4). will cell cell
Cathode ’
cathode between
circuit/ +2e
2H Zn Cu cathode that metal is: where (+)
(Fig.4a) cell)
continue of and place. current
chemical
+2e and flowing takes electrode
acid. Zinc solution. the cathode (corrosion) chemical
copper.so as
Cu is is

(corrosion) two that Znenters the
H2.......... Current
and sulphate through depends
uponthe place
(2) current
where() (1) electrode cell
loss Now
electrons electrodes reaction electrode oxidation the
in takes anode
will the solution of
Zinc the
solutions cathode
(3) circuit can is where place. is process
will flow and anode takes is
from
be that
32 or
DIFFERENT
1. doneofIron
corrosion can from Nowforms
reaction(5) theifand proceed.
reaction
cathode
medium
ultimatelyreduce pHin control).
corrosion control) can Nowslowed
we
if and
(mixed
ofthe the wil
(Fig.4b).
Difference inanode. either flow
metallic Potential Fet+ 4e' corrode. any If
power reaction:
Cathode the above
it electrolyte
Ifresistance
or entire then Hence
down FeAnodeIfinstead
At
+O, current -’ and
Fe(OH), ion corrosionis anode slow want to
oxygen cathode
solution
Maintaining rate
station). cell iron Fereaction
or in (E) TYPES can and+2H,0 (resistance down
galvanic
metals: (Fig.4b) addwe is
reaction control will +2e of
difference (whichß precipitate
cathodically
controlled be can OH which rate.reaction then increased the ofact Zn
OF reduced be the will rod
Bimetallic diffuses But H+ reaction
rate as
2H*+2e CathodeAt
cellCORROSION pH
deaerated ’40H takes (H" ions control) (anodic cathode loss
aboveanode bewe
as can and in that of put
to
(corrosion neutral will
already be removingcontrol through up te NaOH to will reaction ron half(from an
cell electrons i.e. ’
obtained be control) willbe iron
them ......5.) ’ less. loss also (corrosion) cell H2
or and E.M.E
discussel
diss1mia losscathode
product), each H reaction ......... rod
CELL alkaline This
increaseofiron.reduce (cathodi reduced Sb
by oxyge other to ate as cur
of help both table)
( Fe and wil If the we is( (4)
COPF
tus z
COPPE R SuSTION'ZSO 4

RELATIVE POTENTIAL
OH
RELATIVE
TIME
POTENTIAL
CATHODE ANDOE
FECOH)2
RUST
Corrusion
Fig.4b:
Cell OH
1 POTENTIAL Z11 Cu
t1 (G)
Fig.4d:
3
NAt FE+
CL
POROUS
PAPTITION
(-)
Dip
in
potential IRON
CUSO, -COPPEP
SOLUT1ON
difference Fig.4a
33
Danniel :
with CATHODE
HIGH 2O IRON
time uJ Fig.4c Cell
due
4 7INC
|ANODE
TEJNTIAL Concentration :
PO
RE
to
LAT|VE
polarisation CATHODE
POTENTIAL TOLYTIE
ELEC S
2 difference

TI cell PERTIT
IONROUS PO
3
ME due (e)
4 O,
concentration
ANODE -LOWO2
ROM I
COPEi
cATHOo asenvironment
formation). homogenous
perfectly 100% cathodemetal
solvent in METAL
CORROSIONOF
difference 4.
3. 2.
Fig.4c Ht-HH2
H-Ht
anode contact SINGLE
STEAL In homogenous one It In
EAnode Difference Fig.
cell (Fig.4c).
It cell. Difference
temperature inDifference
Fig. composition, due is Corrosion
current: a is
Cor. : and part for not solution in
to evident
4c but developing
the necessary
IM
= E°
of -ANO0E oxide we may and values
Steal H*+FE
++CL itdifference in
see is it ofresistance
Bcathode
practically act that in
composition:
Metal
Local
is
scale metal generally cold
asurface.
RSOL Ec-EA
i.e. temperature
concentration:
break as
potential to all
HCL anode have
WATERHCL N
as working in above
do are
at cathode. millin composition.
not not two (R.SOL).different.
Breck difference.
and
possiblecorode etc. dissimilar situations concentration
scale another :
SCALE
-0XI0E
in Differential
Millscal
CCATH
OOE )
(Localwhich If
in Mill
to metal a In
unifom
make part metals a create
scale single action
cell acts cell
a is as
34
2. 8
1. corrosion
control.
FORMS of Cathode down
anode. POLARISATION
cathode,
gradually (4a') freelyCommon
the local speed) clectrolyte
accumulation
concentration. lower velocity
Atplacethe
metals presence
Corrosion
Galvanic
Corrosion
Uniform Polarisation
Some the Initially exposed corrosion
Difference wil than
polarisation potential
corrosion the causes
TALME local A
OFtendency corrosion
potential be velocity the
of CANODE)
rPIT difference
CORROSION metals corrosion metal a Corrosion
Fig.4e:
Pitting cathode. High ofarea corrosion
deposit for
where in Metal
polarises at is differential oxygen metal where is
Cathode called rate. product
drift surface. CURRENT
ROSIONCOR
ions higher of
This at low electrolyte the cell
polarisation. towards starts concentration
one oxygen
iresults
on
more is change build concentration electrolyte. whee3. nl may
metioais
isusually with aeration
area
very than each inlowwhe
speedis also
up of area higher
concentration 1
in
higher develop
other, at
importantothers. more Anode anode
ancell causes
otherwise attackanode.is
RROSIONhat
PRODUCT co
CAlHODE
OMmo
CO

slowingC rate areametal


Studvoma than lot due
(1ow6. io,.
Rustingnvironhickne an
be foüke t lace o and anG bul CONCHIGH is of mport
Corrosi classif 8. 7. t
place ORE EN
nd but ise Kis de. tof low ion here here
is
on to1e
for dy at ndng E) ON

Rustingthickness can
environmnent. like place CORROSION
Normally to GENERAL OXYGEN
LHIGH
TRATION
CONCEN important
Corosion,classification.
conditions
common that 8 7 6. 5 4.
place classification. 3.
be plain
This from Here
of taken on Other TheCorrosion
Stress
Corosion
Erosion
Leaching
Selective
Intergrannular
CorosionPitting
Corrosion
Crevice
iron, as iscarbon thisentire anodicthe for
Exfoliation, above
Example per at the is metal
corrosion
Crevice
Fig.4f: power than Corosion_
metal common CORROSION
mayMany
corrosion thesafest steel. surface be
and above are
in design form surface. CORROSION
CONCENTRATION CURRENI
OXYGEN
LOW station. other most
contact High : in cathodic High similar
casegives it Fatigue
ratestage of When Temperature distinguished
types yet
temperature
with corosion ofnon to
of sites
that by uniform loss OR Corrosion, each are
acid shifts there.
adding resistance ofUNIFORM other
etc. metal and Oxidation
oxidation,
measure corrosion.metals from It
excess
in Fretting manyfor coincise
is
that metal takes place found
are
35

(Fig.4e).
inadequally
localised PITTING may twlarge)
corrode, on ofwith area be
oslight may top corrosion
higher
rate.
(Table-4) corrosion
CORROSION
GALVANIC
corrosion
metals.
dissimilar
be copperanode. large than taken not in
Pitting While the In When
Whencorrosion. properly but cathode that be
galvanic Coupling
plate For that table wil occurs. Fig.4g:
protected is metals
ifcopper example
corrosion coupling always
anodic the
is two
give
a (cathode, of becomes
smallNomally one insulated cathode.
wil metals corrosion
true. potentialdissimilar
greaterwidely Stress STRESS
CRACKS1
of The
contact rivet two
anodemetal
is the wil ifgive
if large)
is severe we should dissimilar anode seperated drivingmetals
potential corrosion
resistant
gives
most possible. area take used have small A the
difference CORROSION
steel metal
surrounded
largebydestructive uptoplace. oncorrOSion steel and are
pitting steel rivet
have
anode metals corrode differencemetals Force in cracking
metals/alloys someWhile rivets higher normally galvanic
contact
plate wil betweenin for
and if care LOAD
corrosion extension
coupling(anode, (anodic) coupledsurface
severely but the
that Galvanic
form of failure should on series
this the this two
or
GRANNULAR
CORROSION INTER avoid concentration
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thwhich or corrosIon.
givesandExampleprotection
CREVICEenvironment
pitting. equipment. place cathbeode
SELECTIVE grannular
corrosion.
LEACHING
fromlostthpreferential
desineification
e is high depleted
improperly
the metal differential due less
exposedto grain bulk from but
Crevice toPitting
In strength grain Inter crevice Since occurs
environment. pitting
selective boundariesgiving in formation film,
stainless penetration
Pitssmall a
chromium grannular the cloride corrosion
aluminium boundaries.
heat in
brass.dissolution.
wet
of
areation
corrosion crevice corrosion
crevice layer also corrosion
condition
Resulting Brass.If leathing
treated acts area is
thus corrosion This or differential
ion steel of
For
cell
ishinders is breaks corrosion may giving
as hightakes
for brassMost one
alloys inter less may to is gives area
intense if
zinc resistant.example
avoid
formed. the initiating as
a element
(less are have which
rise exposed
concentration
down product take rise lossplace.
free longcommon crystalline is
crevicediffusion localised
also grainlocalised to is to
copper time than a The the
shielded
the place pointfailure Metofal
85%
Zincexample
of pronecrack.Attackstainless best passive inbreaks metal loss
an boundaries (Fig.4f).ofoxygen differentialcorrosion
looses copper) alloy
to is attack way
chloride cell when of
stress of
may be
interSome along steel from film etcdown
.
takes may
the
its has at to a
is
36

grannular Furtherthem static


concentration faiCORROSION
corrosive l CRACKING STRESS formCAVITATION of velocity directional Combined anddecrease.
grooves,
determental
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also CORROSION e ductility
examplArsenic
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corrosion
transgrannular) or environment
stress oxide place with
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high is th an
effect
abbrassive formed corrosion
is graphite strength. as
and metal corrosion metal a corrosion any layer time
it a
corrosion. damage
velocity holes layer
of oxidation is poison
the yield build high ever due corrosion
takes I under etc.erossion of wil and on
crack concentrate
point
fo
that
r
turbines, due solids is
t h em.
form solids increasing. the takes
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to lA
cracking stress which base and polarisation
place
with andresults at metal, to increased Itand place dezincification. amountof,
propagat e s themetal contents, can present S.H. fcast of
eventual exposed
formation are
andmetal th en
and causin! the
(Fig.4g). it propellers, corrosion be this tube
srinesses may smooth
identified wilinflue rate For rate iron
st i
failure. againstreslocal surface ultimatey to etc. by wil surface but of
(either and hig h be of example corrosion (
(see Antimeny
isexposed oxidation
a and continue. if
speci fic collapse
etc. gas
due erosion coolingAnother
inter fa i l ure under isa fluid have
the
by
more
wil to an or
low faigue
ifexposed limit endurance
limit infinite
FATIGUE Table-S)
(see Misteel
lkald loys Metal
Copper
HOW comosion
fatigue.
whatever
COrosion
environment.
modify
the CHANGING
THEENVIRONMENT
S. 4. 3. 2. 1. Some CORROSION Austenctic
Changethe There In metal When
This Of ChangeChange
environment
Cathodic tdesign. Use alloys
he of resistant of TO
corrosive cycle
in is the the COMBAT to do wil or stainless
steel
of comosive fatigue a
liquidwidely above suitable alloy but approaches are not tail. metal
of
various
stress
protection some exist.Hence operation
metal,
someuse environment This limit. is
media. used let also environment
may under
us paints, times CORROSION failure But
practical gives are ways
There consider be. cyclic
if
protective it listed a ifitexceeds Environnment
amnonia/oxygen chloride
SCCfor
become
localised to
This metal purely
is the caustic
Hig h
are
method fight endurance stressstress,
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different resistant
suitable failure wilunder
and expensive with mechanical. the
coating
corrosion. definitelyfail,
cyclic iscan it
of (5). corrosion. is endurance under
controlling
ways due stress
limit underg0
etc.
and to or the
to
37
volatile result REMOVECO,
carbondioxide
ammines. (Fig. on control OXygen
Sa). deaeration
Oxygen
Oxygen of ()
corrosion. be don iscorrosionsevere pH
milshown the
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Carbondioxideis CorzSION AL TE, corrOSion
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very is can Fig.5a
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not
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Stability
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at ammonianeutrallised pH in Effect : OXYGEN,
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RA reduced
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e (below4.5) morpholene acid
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RIOUS proper the
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of
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speed
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.05 25 .351
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30
Inhibitors
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TEMPERATURE rate
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at
metal the offer
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and the thus liquid hashelps with higher
38
So
a ofthe
corrosion.
inhibitoron
Fig. film the
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cathodic
Fig.5e: Fig.5d: cathode
Fig.5c (5c) Some
or
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Effect Effect POTENTAL to ofpotential
POTENTIAL POTENTIAL
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DENSITY
CURRENT CURRENT
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CORROSION IMAX, I
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EXTENT
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Supplying dezincification
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POLARIZATION is therefore,
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CORRA

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NECESSARY
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be taken
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as of of
39 OCOR.
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3) 2) GORRO0lNG
t Fig.5g: METAL
a
Should minimum.
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Current cannot from
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Both
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CURRENT -
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1
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Corrossion Net
Fig.5h :
afforded in mayexcess solution. to of
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40
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