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Materials and Corrosion Control in Desalination Plants

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 Materials and D
Corrosion
Control in
Desalination
Plants
M. Schorr, B. Valdez, J. ocaMpo, and a. So, the desalination industry is evident by the
University of Baja California, México activities of the various professional as-
a. eliezer, Sami Shamoon College of Engineering, Israel sociations, research and development
Te desalination industry is based on the principles
of water chemistry, chemical engineering, and
energy efficiency. Desalination plants have a high
level of corrosion since they process saline waters
under severe operating conditions. Corrosion
resistance is the main requirement to be considered
in the selection of materials; therefore,
inhibitors and corrosion-resistant alloys
are used in these plants.
56 MATERIALS PERFORMANCE May 2012
ue to increased population and
the expectation of high living
standards, the demand for water
and electricity in desert and arid
regions of the world is increasing. De-
salination plants combined with power
generating units utilize the heat extracted
from the generation process to evaporate
seawater. The desalination industry is
undergoing an expansion and modern-
ization program to construct more effi-
cient and larger desalination plants that
will reduce production costs. This indus-
try is based on water chemistry, chemical
engineering, and efficient energy man-
agement. Modern desalination technol-
ogy is less energy-consuming and more
environmentally friendly. The most
widely utilized desalination technologies
are thermal and membrane, powered by
“green” solar energy that doesn’t rely on
fossil fuels.
The economic and social relevance of
institutions, and industrial enterprises.
The threat of bioterrorism has increased
efforts to preserve the available supply of
water.
Desalination Processes
and Plants
Desalination plants have a high level
of corrosion risk since they handle and
process aggressive saline water under se-
vere operating conditions, which include
filtration, heat exchange, distillation,
evaporation, agitation, and high-flow,
often turbulent velocities.1 There is no
universal desalination process—every
type of saline water requires a process
adapted to its physicochemical character-
istics and performance. Desalination
plants are fed with seawater, containing
35 g/L of total dissolved solids (TDS), or
brackish water taken from briny wells or
wells infiltrated by seawater, with TDS in
NACE International, Vol. 51, No. 5
 C H E M I C A L T R E AT M E N T

FIguRE 1

the range of 2 to 5 g/L. Many desalination

plants are located in desert/arid regions
with a harsh climate and limited rainfall.
About one-fifth of the desalination plants
operating in the Middle East are in Saudi
Arabia and produce half of the world’s
desalted water. Figure 1 shows a typical
modern membrane desalination plant.
Two main desalination technologies
(membrane and thermal) are imple-
mented worldwide (Table 1). The mem- A typical modern membrane desalination plant.
brane separation process, reverse osmo-
sis, operates under high pressure; the
water molecules contained in seawater
pass through a selective membrane while TAbLE 1
the dissolved salt ions do not pass through
Membrane and thermal desalination processes
the membrane (Figure 2). Some reverse
osmosis membranes are made from Process Characteristics
high-grade polymeric polyvinylidene Pressure is applied to the saline water, forcing it
Membrane
fluoride (PVDF) material to form a hol- Reverse osmosis through a semipermable plastic membrane that
low fiber membrane that is very durable separates brine from water.
and less prone to breakage than other Thermal Saline water is heated and the pressure
membranes. Multistage flash distillation is lowered in several stages so the water flashes
The thermal processes are based on into steam, which is cooled.
improved distillation, evaporation, and Multi-effect distillation Low-pressure steam, 60 °C, is handled in a
condensation technologies with the aim series of evaporative-condensers (effects) with
to save energy and obtain fresh water heat rejection condensers.
with a low level of TDS and at a low Mechanical vapor compression Distillation is effected by an electrically driven
operational cost. In general, the thermal centrifugal compressor mounted on the
evaporator.
processes are more expensive than re-
verse osmosis, but distillation produces
pure water independent of the quality
and salinity of the feedwater. The cost of
desalting brackish groundwater is gener- FIguRE 2
ally less than the cost of desalting seawater
due to a lower TDS content. The average
expense for desalting brackish water is
$0.50 m3 and for seawater, $1.50 m3.

Corrosion, Scaling,
and Fouling
Frequently, corrosion, scaling, and
fouling phenomena appear simultane-
ously in desalination plants, where they
interact and influence each other. Scaling
and fouling are often associated with
saline and salt water velocities. These
factors originate in the saline water, Flow diagram of the reverse osmosis desalination process.

NACE International, Vol. 51, No. 5 May 2012 MATERIALS PERFORMANCE 57

C H E M I C A L T R E AT M E N T
TAbLE 2
Equipment for desalination plants
Pipes, Tubes, and Ducts
Saline water pumps, vertical and centrifugal
Valves, diverse types
Gasketed plate-and-frame heat exchangers
Filters, diverse types
Fittings and flanges
Steam and gas turbines
Compressors
Control and flow instrumentation
TAbLE 3
CRAs used for manufacture of equipment in desalination
plants
Alloy
Aluminum-magnesium
Austenitic chromium-nickel steels
High-alloyed austenitic
Austenitic, casting
Duplex: ferritic-austenitic
Nickel-based alloys
Titanium
depending on the water’s chemical and
biological composition and interaction
with the equipment surfaces. Plant oper-
ating conditions such as pH, flow regime,
temperature, and pressure also affect
corrosion.
Unless prevented, corrosion and the
buildup of scale and biological fouling
impact the desalination plant operation
and, in extreme cases, even lead to equip-
ment shutdown. Corrosion and scale in-
hibitors and biocides are applied as
needed.
Highly concentrated saline water
tends to form thick scales by deposition
of dissolved and suspended solids such as
carbonates, silicates, and hydroxides. As
saline water is circulated, the last com-
58 MATERIALS PERFORMANCE May 2012
Materials and Corrosion Control in Desalination Plants
Evaporators
Vapor condensers, diesel engines
Flash chambers
Demisters
Steam generators
Condensers
Deaerators
Chlorinators
Storage tanks
UNS Designation
A15052, A95054
S30400, S31600, S31700
S31254, N08020, N08028
J92500, J92800, J95150
S32250, S31803
N06600, N08825, N06030
R50250, R52400
pound that tends to come out of the water
is calcium carbonate (CaCO3). To pre-
vent CaCO3 scaling, the feedwater is
treated with sulfuric acid (H2SO 4) to
convert the carbonate to carbon dioxide
(CO2), which escapes from the water.
When phosphates and phosphonates are
applied to provide corrosion protection,
careful control is implemented to avoid
scaling by calcium phosphate [Ca3(PO4)2].
Organic polymers containing carboxilic
acids are added for control of Ca3(PO4)2
deposition. Some alkaline chemicals (e.g.,
soda ash) neutralize the acidity found in
some brackish waters, which helps reduce
corrosion and extend the life of equip-
ment. Scaling is controlled by introducing
additives to inhibit crystal growth, and by
reducing temperatures and salt concen-
tration to avoid deposits of colloidal
particles (e.g., silica or silicic acid [SiO2]).
Pollution and corrosion are interre-
lated processes since many atmospheric
pollutants (e.g., sulfur oxide [SOx], nitro-
gen oxide [NOx], COx, and hydrogen
sulfide [H2S]) accelerate corrosion, and
corrosion products such as rust-pollute
water bodies. Both pollution and corro-
sion are pernicious processes, which im-
pact environmental quality and structural
durability.2
The pH values of saline water vary
from 5 to 8 and the concentration of dis-
solved oxygen (DO), the main corrodent,
varies from 4 to 6 mg/L as a function of
temperature and flow regime. Saline
water contaminated with H2S is slightly
acidic and corrosive toward some corro-
sion-resistant alloys (CRAs), therefore
H 2S is eliminated by mechanical or
chemical methods.
Corrosion inhibitors slow down an-
odic or cathodic reactions, or both, and
reduce the extent of corrosion by inter-
acting with corrosive ions or forming a
thin, protective film on the metallic sur-
face. Atmospheric corrosion in desalina-
tion plants installed in coastal zones is
caused by the effect of marine aerosols
containing particles of sodium chloride
(NaCl).
Saline water provides an ideal envi-
ronment for macro and microorganisms
to thrive. Unless properly controlled
through the use of biocides, bacteria,
algae, fungi, and mollusks will grow on
metallic surfaces. These organisms se-
crete polymeric substances, which form
a film that generates acids and other
harmful corrosion-inducing compounds.
Furthermore, they establish oxygen con-
centration cells that cause localized and
pitting corrosion. To prevent the forma-
tion of biological fouling, biocides such
as gaseous chlorine (Cl2), sodium hypo-
chlorite (NaOCl), chlorine dioxide
NACE International, Vol. 51, No. 5

(ClO 2), and bromide salt (NaBr) are
applied.
Acidic and alkaline cleaning are
mechanochemical operations easily im-
plemented in CRA equipment to remove
biological fouling and mineral scale that
alter the equipment surface performance
and induce corrosion.
Equipment and Materials
For effective operation, a diversified
assembly of equipment is employed in
desalination plants that includes many
storage tanks, pumps, heat exchangers,
and pipes (Table 2). Electric steam gen-
erators, made of Type 304 or 316 stain-
less steel (SS) (UNS S30400 or S31600),
are ideal for producing clean steam. An
electrical conductivity sensor is used to
maintain steam conductivity from 1 to 10
mS/cm.
Carbon steel (CS), galvanized or
cadmium-plated steel, and cast iron pip-
ing should not be used in desalination
plants in contact with process fluids due
to risk of corrosion and consequent con-
tamination by corrosion products.3-4
Pumps are essential for water transporta-
tion, treatment, and seawater desalina-
tion plants. Pumps should have low-
energy consumption and optimized hy-
draulic performance over a wide range
of flow. They are manufactured from
duplex and super duplex SS (Table 3) to
avoid pitting and crevice corrosion.5
Flash evaporators, low-pressure turbines,
evaporators, and condensers operated in
contact with steam are particularly prone
to corrosion by salts. Corrosion inhibitors
are used to avoid or minimize corrosion
of steel and other alloys.
Corrosion-Resistant
Alloys
The equipment in desalination plants
is fabricated from engineered materials,
metallic and nonmetallic, that display
a reasonable resistance to the fluids
NACE International, Vol. 51, No. 5
(liquids, vapors, and gases) handled and
processed in the plant installations and
environments.6
The prime factor when considering
materials is their corrosion resistance.
CRAs used in the desalination industry
are classified into two large groups:
• Ni-containing alloys (e.g., Ni-based
alloys, SS,7 and Cu-Ni alloys)
• Titanium and aluminum alloys (e.g.,
UNS A95052)
Their UNS designations are displayed
in Table 3. Nonmetallic materials such as
plastics (polyethylene [PE]), polypropyl-
ene [PP], and polyvinylchloride [PVC]),
and composites (in particular, fiber-rein-
forced plastic [FRP]-based on polyester
or epoxy resins) are employed mainly for
piping and storage vessels.
Ni-based alloys are among the most
important because they resist corrosion
in a wide variety of environments, includ-
ing saline water rich in chlorides. These
alloys are divided into two groups: those
composed mainly of Ni and those com-
posed of Cr as a major alloying element.
They are used for the fabrication of high-
pressure pumps and brine concentrators
in thermal desalination plants. ASTM
Standard B5528 contains specifications of
seamless and welded Cu-Ni tubes for heat
exchangers.
Ti has good corrosion resistance in
strong oxidizing environments, but not
with reducing acids like hydrochloric acid
(HCl). Ti can be readily shaped and
formed, and is available in conventional
shapes. It shows excellent resistance to
seawater and saline water but it does not
tolerate even trace amounts of fluorides,
which cause severe corrosion. Alloying of
Ti with palladium (Pd) and other noble
metals yields corrosion-resistant alloys.
The aluminum oxide (Al 2O 3) film
imparts corrosion resistance to Al equip-
ment in contact with saline water, includ-
ing seawater.9 In thermal desalination
equipment, Al tubes are utilized in huge
C H E M I C A L T R E AT M E N T
heat exchangers for condensation of
water-cooled vapor with seawater.
CS is the main material used for erecting
plant structures, water storage vessels, tanks,
and pipelines. Due to its limited corrosion
resistance, CS should be protected by coat-
ings and, where in contact with water or
soil, by cathodic protection (CP).
Corrosion Control
Practical methods that minimize or
eliminate corrosion include the selection
of suitable CRAs, application of coatings
and linings to CS, and CP. The technical
selection process has three main stages:10
1) Analysis of the requirements and
collection of the relevant informa-
tion about the conditions of the
desalination process and the corro-
sion resistance required by the
equipment
2) Selection and evaluation of candi-
date materials by screening the in-
formation collected in the first stage.
Laboratory and pilot plant corro-
sion tests are performed by exposing
suitable materials in the desalination
process fluids and environments
(ISO 84511 and ASTM standards
G412 and G3113)
3) Selection of the most appropriate
materials based on costs, availabil-
ity, ease of fabrication and repair,
maintenance, and safety
Laboratory tests are made by simulat-
ing desalination plant fluids and condi-
tions and also by exposing specimens in
a desalination plant. These are conducted
per ASTM standards G1,14 G4, G31,
G3,15 G5,16 G52,17 and NACE TM0169-
2000.18
Corrosion monitoring involves mea-
suring corrosion events and rate by con-
tinuously exposing material probes in an
operating desalination plant. Modern
electrochemical, electronic, mechanical,
nondestructive, and computational de-
vices such as potentiometry, multielec-
May 2012 MATERIALS PERFORMANCE 59
C H E M I C A L T R E AT M E N T
trode probes, electrical resistance, com-
munication networks, remote corrosion
monitoring, expert programs, and artifi-
cial neural networks are also used. Cor-
rosion monitoring techniques provide
daily warnings of costly corrosion dam-
age and other critical information. This
information is essential for making deci-
sions about the type, urgency, and cost of
preventive and curative measures to be
taken.
Conclusions
In recent years, desalination experts
have been playing an increasingly active
role in refining desalination processes,
saving energy resources, selecting long-
lasting CRAs, and improving the effi-
ciency of desalination plants. The world-
wide increase in population, rising
standards of living, and the extension of
water pollution have evolved into a criti-
cal demand for potable water. Desalina-
tion technology is a good response to this
challenge.
References
1 P.R. Roberge, Corrosion Engineering,
Principles and Practice, Seawater (New York,
NY: McGraw-Hill, 2008), pp. 274-280.
2 “Carlsbad Desalination Project,” http://
www.carlsbad-desal.com (January 2012).
3 U. Malik, A. Saleh, Al-Forzan, “Corro-
sion and Materials Selection in MSF
Desalination Plants,” Corrosion Reviews
29, 10 (2011): pp. 153-175.
4 A. Malik, et al., “An Overview of the
Localized Corrosion Problems in
SWDPs—Some Recent Case Studies,”
Des. & Water Treatment (2010): pp. 22-34.
5 Dupont, J.P. Peri, “Newly Developed
Water Pumps,” Sulzer Technical Review 3
(2011): pp. 12-15.
6 K. Habib, et al., “Risk Assessment and
Evaluation of Materials Commonly
Used in Desalination Plants,” Desalination
139 (2001): pp. 249-253.
7 B. Valdez, M. Schorr, “Stainless Steel
for Corrosion Control in Desalination
Plants,” Stainless Steel World 5 (2000): pp.
40-44.
60 MATERIALS PERFORMANCE May 2012
View publication stats
Materials and Corrosion Control in Desalination Plants
8 ASTM B552-08, “Standard Specifica-
tion for Seamless and Welded Copper–
Nickel Tubes for Water Desalting
Plants” (West Conshohocken, PA:
ASTM International).
9 A. Eliezer, et al., “Corrosion of Naval
Aluminum in Seawater,” MP 49, 9
(2010): pp. 62-66.
10 “Encyclopedia of Desalination and
Water Resources, Materials Selection
and Corrosion,” http://www.desware.
net (March 20, 2012).
11 ISO 845:2006, “Cellular plastics and
rubbers—Determination of apparent
density” (Geneva, Switzerland: ISO).
12 ASTM G4, “Standard Guide for
Conducting Corrosion Coupon Tests
in Field Applications” (West Con-
shohocken, PA: ASTM).
13 ASTM G31, “Standard Practice for
Laboratory Immersion Corrosion
Testing of Metals” (West Conshohocken,
PA: ASTM).
14 ASTM G1, “Standard Practice for
Preparing, Cleaning, and Evaluating
Corrosion Test Specimens” (West
Conshohocken, PA: ASTM).
15 ASTM G3, “Standard Practice for Con-
ventions Applicable to Electrochemical
Measurements in Corrosion Testing”
(West Conshohocken, PA: ASTM).
16 ASTM G5, “Standard Reference Test
Method for Making Potentiostatic and
Potentiodynamic Anodic Polarization
Measurements” (West Conshohocken,
PA: ASTM).
17 ASTM G52, “Standard Practice for
Exposing and Evaluating Metals and
Alloys in Surface Seawater” (West
Conshohocken, PA: ASTM).
18 NACE TM0169-2000, “Laboratory
Corrosion Testing of Metals” (Houston,
TX: NACE, 2000).
M. SCHORR is a professor (Dr. Honoris Causa) at the
Institute of Engineering, Universidad Autónoma de
Baja California. He has a B.Sc. in chemistry, a M.Sc.
in materials engineering from the Technion-Israel
Institute of Technology, and 40 years of experience
in industrial corrosion control. From 1986 to 2004,
he was the editor of Corrosion Reviews. He has
published 262 scientific and technical articles in
English, Spanish, and Hebrew on materials and
corrosion. He has worked as a corrosion consultant
and professor in Israel, the United States, Latin
America, Spain, and South Africa. During the IMRS
Congress in August 2010, he received a Distin-
guished Career Award from the NACE Central
Mexico Section. He has been a NACE member for
18 years.
B. VALDEZ is the director of the Institute of
Engineering, Universidad Autónoma de Baja
California, Blvd. Benito Juarez y calle de la Normal
s/n, Colonia Insurgentes Este. CP. 21280, Mexicali,
Baja California, Mexico. He has a B.Sc. in chemical
engineering, a M.Sc. and a Ph.D. in chemistry, and
is a member of the Mexican Academy of Sciences
and the National System of Researches in Mexico.
He was the guest editor of Corrosion Reviews, in
which he produced two special issues on corrosion
control in geothermal plants and the electronics
industry. He is a full professor at the University of
Baja California. His activities include corrosion
research, consultancy, and control in industrial
plants and environments. He has been a NACE
International member for 20 years.
J. OCAMPO is a professor at the Engineering School,
Universidad Autónoma de Baja California. He has a
B.Sc. in mechanical engineering, a M.Sc. in
thermodynamic engineering, and a Ph.D. in
mechanical engineering, and is a member of the
International Geothermal Association. He has
published 70 scientific and technical articles in
English and Spanish on energy, scaling, materials,
and corrosion. He is a full professor at the
University of Baja California. His activities include
energy and material research and consultancy.
A. SO is a mechanical engineer. He received his
diploma from the Faculty of Engineering and his
M.Sc. from the Institute of Engineering, both at the
Universidad Autónoma de Baja California, Mexico.
He is currently involved in a postgraduate study
program at the Institute of Engineering to obtain a
Sc.Dr. degree in corrosion control in the gas
industry.
A. ELIEZER is the director of the Corrosion Research
Center, Nano-Bio & Advanced Materials, as well as
a faculty member of both civil engineering and
mechanical engineering at the Sami Shamoon
College of Engineering, Israel. Recently, he was
appointed as the Director of the Research and
Development Authority. He is active as a NACE
International Europe Area board member, a member
of the World Corrosion Organization Board of
Directors, an EFC member, and CAMPI chair, as well
as a faculty advisor of the NACE Israel Negev
student section.
NACE International, Vol. 51, No. 5