Program Magister Teknik

Departemen Metalurgi dan

Material Flow
Universitas Indonesia 2014
Accelerated
Corrosion
Iman Sugihartoto
NPM 1406582556
Definition
 Corrosion mechanism in which a normally protected
oxide layer on a metal surface dissolves in a fast
flowing water. The underlying metal corrodes to re-
create the oxide, and thus the metal loss continues
 FAC has to be distinguished from particular erosion
corrosion because the fundamental mechanisms for
the corrosion model are different. FAC does not
involved impingement of particles, bubbles, or
cavitation which cause the mechanical (often crater-
like) wear on the surface.
 FAC involves dissolution of normally poorly soluble
oxide by combined electrochemical, water chemistry
and mass transfer phenomena
Simplified Mechanism of FAC
 Reaction between dissolved oxygen and metal
surface form a protective oxide layer (rust)

Flow
Pipe ID
Protective oxide
layer

Pipe OD
Simplified Mechanism of FAC
 The oxide layer is dissolved into the flow stream

Flow
Pipe ID

Pipe OD
Simplified Mechanism of FAC
 The oxide layer is replenished as the base metal
is converted into more oxide

Flow
Pipe ID

Pipe OD
Simplified Mechanism of FAC
 The oxide layer is again dissolved into the flow
stream. The base metal again has to form a new
protective oxide layer. The cycle repeats,
thinning the pipe wall until a rupture occurs

Flow
Pipe ID

Pipe OD
Type of FAC
 Single-Phase FAC
Occurs when the fluid is in the liquid water phase.
Damage is characterized by a bumpy “orange
peel” surface
 Two-Phase FAC

Occurs when the fluid is in the saturated “wet”

steam phase.
Damage is characterized by a shiny black surface
Two-phase FAC is more aggressive than single-
phase FAC due to the hyper turbulent nature of
wet steam versus water.
Main Reactions
 Fe Fe2+ + 2e-
 2H O + 2e- 2OH- +H
2 2

 Fe + 2H2O  Fe(OH)2 + H2
 3Fe(OH) Fe3O4 + H2 + 2H2O
2
Affecting Factor
Wall Loss depends on :

 Material
Composition
 Environment
 Water Chemistry
 Flow velocity
 Hydrodynamics
 Pipe roughness
 Piping geometry
 Steam Quality
Basic Modelling of FAC
Phenomena
Sanchez Caldera Mechano-Electrochemical
Model Model

 Dm/dt  wall thinning

 Wc-e = weight loss involved
 Equilibrium concentration of iron
 Ø1 = Material Intrinsic Properties
species  Ø2 = Hydrodynamic Parameters
 Θ = porosity  Ø3 = Surface Oxide layer
 Kd = Mass Transfer Properties
 K = A exp (-E/RT)
 d = magnetite thickness
 D = Diffusion coefficient of Iron
cation
Case Study