Abstract
A simple galvanic sensor was developed to determine the onset of iron corrosion under conditions similar to those used for removing the iron oxide (magnetite) layer from steam boilers with a hy-drochloric acid solution. Since the potentials of magnetite and iron are different, the initiation of the dissolution of the magnetite layer without corroding the base metal can be determined by moni-toring the potential of a sensor made of magnetite layers of different thicknesses that can be placed directly on the iron surface. Moreover, the time at which the addition of corrosion inhibitors is required to protect the base metal can be specified using this sensor. It has been shown that the time required for the iron base metal to start was dependent on the magnetite layer thickness in the sensor. With this sensor, the onset of the steel corrosion during the cleaning can be detected in re-al-time which makes the oxide removal process less harmful to the base metal.
Highlights
Steam, generated from boilers of different sizes and types, is used in many industrial plants for process applications and power generation
Steam boilers are made of carbon steel and the inner side of the boiler tubes are in contact with water
To simulate the actual operating conditions in a steam boiler, we suggest incorporating the prepared sensor as part of the internal boiler surface
Summary
Steam, generated from boilers of different sizes and types, is used in many industrial plants for process applications and power generation. Steam boilers are made of carbon steel and the inner side of the boiler tubes are in contact with water. The formation of solid deposits on that side of the tubes is a progressive and inevitable process, even when the water and steam chemistry is carefully controlled, leading to reduced boiler efficiency and increased fuel consumption. Steam at a certain temperature can react with iron, forming iron oxide and magnetite (Fe3 O4 ) when the environment inside the boiler is reductive. Thick magnetite layers may lead to deposit corrosion, reduce the water circulation inside the boiler, and overheat the tubes. The inner surface of the boiler tubes must be cleaned and kept free of unwanted deposits to ensure that the temperature of the tube wall will not cause damage to the boiler.
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