Caustic embrittlement

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Caustic embrittlement is the phenomenon in which the material of a boiler becomes brittle due to the accumulation of caustic substances. [1]

Contents

Cause

A tube damaged by caustic embrittlement. White caustic deposits can be seen inside. Boiler scale 5.JPG
A tube damaged by caustic embrittlement. White caustic deposits can be seen inside.

As water evaporates in the boiler, the concentration of sodium carbonate increases in the boiler. In high pressure boilers, sodium carbonate is used in softening of water by lime soda process, due to this some sodium carbonate maybe left behind in the water. As the concentration of sodium carbonate increases, it undergoes hydrolysis to form sodium hydroxide.

Na2CO3 + H2O → 2NaOH + CO2

The presence of sodium hydroxide makes the water alkaline in nature. This alkaline water enters minute cracks present in the inner walls of the boiler by capillary action. [2] Inside the cracks, the water evaporates and the amount of hydroxide keeps increasing progressively. The concentrated area with high stress works as anode and diluted area works as cathode. At anode, sodium hydroxide attacks the surrounding material and then dissolves the iron of the boiler as sodium ferrate forming rust. This causes embrittlement of boiler parts like rivets, bends and joints, which are under stress.

Prevention

This can be prevented by using sodium phosphate (Na3PO4) instead of sodium carbonate as softening reagents. What happens is that its molecules will get inside the hair-line crack and block it, as a result of which sodium hydroxide, even if it is there, will not be able to come in contact with iron, and no reaction will be there. Adding tannin or lignin to boiler water blocks the hair-line cracks and prevents infiltration of NaOH into these areas. [1] Adding Na2SO4 to boiler water also blocks the hair-line cracks. [3]

Related Research Articles

In chemistry, an alkali is a basic, ionic salt of an alkali metal or an alkaline earth metal. An alkali can also be defined as a base that dissolves in water. A solution of a soluble base has a pH greater than 7.0. The adjective alkaline, and less often, alkalescent, is commonly used in English as a synonym for basic, especially for bases soluble in water. This broad use of the term is likely to have come about because alkalis were the first bases known to obey the Arrhenius definition of a base, and they are still among the most common bases.

<span class="mw-page-title-main">Hydroxide</span> Chemical compound

Hydroxide is a diatomic anion with chemical formula OH. It consists of an oxygen and hydrogen atom held together by a single covalent bond, and carries a negative electric charge. It is an important but usually minor constituent of water. It functions as a base, a ligand, a nucleophile, and a catalyst. The hydroxide ion forms salts, some of which dissociate in aqueous solution, liberating solvated hydroxide ions. Sodium hydroxide is a multi-million-ton per annum commodity chemical. The corresponding electrically neutral compound HO is the hydroxyl radical. The corresponding covalently bound group –OH of atoms is the hydroxy group. Both the hydroxide ion and hydroxy group are nucleophiles and can act as catalysts in organic chemistry.

<span class="mw-page-title-main">Sodium hydroxide</span> Chemical compound with formula NaOH

Sodium hydroxide, also known as lye and caustic soda, is an inorganic compound with the formula NaOH. It is a white solid ionic compound consisting of sodium cations Na+ and hydroxide anions OH.

<span class="mw-page-title-main">Base (chemistry)</span> Type of chemical substance

In chemistry, there are three definitions in common use of the word "base": Arrhenius bases, Brønsted bases, and Lewis bases. All definitions agree that bases are substances that react with acids, as originally proposed by G.-F. Rouelle in the mid-18th century.

<span class="mw-page-title-main">Potassium hydroxide</span> Inorganic compound (KOH)

Potassium hydroxide is an inorganic compound with the formula KOH, and is commonly called caustic potash.

The Bayer process is the principal industrial means of refining bauxite to produce alumina (aluminium oxide) and was developed by Carl Josef Bayer. Bauxite, the most important ore of aluminium, contains only 30–60% aluminium oxide (Al2O3), the rest being a mixture of silica, various iron oxides, and titanium dioxide. The aluminium oxide must be further purified before it can be refined into aluminium metal.

<span class="mw-page-title-main">Calcium hydroxide</span> Inorganic compound of formula Ca(OH)2

Calcium hydroxide (traditionally called slaked lime) is an inorganic compound with the chemical formula Ca(OH)2. It is a colorless crystal or white powder and is produced when quicklime (calcium oxide) is mixed with water. It has many names including hydrated lime, caustic lime, builders' lime, slaked lime, cal, and pickling lime. Calcium hydroxide is used in many applications, including food preparation, where it has been identified as E number E526. Limewater, also called milk of lime, is the common name for a saturated solution of calcium hydroxide.

<span class="mw-page-title-main">Hard water</span> Water that has a high mineral content

Hard water is water that has high mineral content. Hard water is formed when water percolates through deposits of limestone, chalk or gypsum, which are largely made up of calcium and magnesium carbonates, bicarbonates and sulfates.

The chloralkali process is an industrial process for the electrolysis of sodium chloride (NaCl) solutions. It is the technology used to produce chlorine and sodium hydroxide, which are commodity chemicals required by industry. Thirty five million tons of chlorine were prepared by this process in 1987. The chlorine and sodium hydroxide produced in this process are widely used in the chemical industry.

<span class="mw-page-title-main">Alkaline fuel cell</span> Type of fuel cell

The alkaline fuel cell (AFC), also known as the Bacon fuel cell after its British inventor, Francis Thomas Bacon, is one of the most developed fuel cell technologies. Alkaline fuel cells consume hydrogen and pure oxygen, to produce potable water, heat, and electricity. They are among the most efficient fuel cells, having the potential to reach 70%.

<span class="mw-page-title-main">Boiler water</span>

Boiler water is liquid water within a boiler, or in associated piping, pumps and other equipment, that is intended for evaporation into steam. The term may also be applied to raw water intended for use in boilers, treated boiler feedwater, steam condensate being returned to a boiler, or boiler blowdown being removed from a boiler.

<span class="mw-page-title-main">Boiler feedwater</span>

Boiler feedwater is an essential part of boiler operations. The feed water is put into the steam drum from a feed pump. In the steam drum the feed water is then turned into steam from the heat. After the steam is used, it is then dumped to the main condenser. From the condenser, it is then pumped to the deaerated feed tank. From this tank it then goes back to the steam drum to complete its cycle. The feedwater is never open to the atmosphere. This cycle is known as a closed system or Rankine cycle.

The Castner–Kellner process is a method of electrolysis on an aqueous alkali chloride solution to produce the corresponding alkali hydroxide, invented by American Hamilton Castner and Austrian Carl Kellner in the 1890s. Due to lower energy cost and fewer environmental concerns, the Castner–Kellner process is being replaced gradually with membrane electrolysis.

<span class="mw-page-title-main">Alkali soil</span> Soil type with pH > 8.5

Alkali, or Alkaline, soils are clay soils with high pH, a poor soil structure and a low infiltration capacity. Often they have a hard calcareous layer at 0.5 to 1 metre depth. Alkali soils owe their unfavorable physico-chemical properties mainly to the dominating presence of sodium carbonate, which causes the soil to swell and difficult to clarify/settle. They derive their name from the alkali metal group of elements, to which sodium belongs, and which can induce basicity. Sometimes these soils are also referred to as alkaline sodic soils.
Alkaline soils are basic, but not all basic soils are alkaline.

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<span class="mw-page-title-main">Concrete degradation</span> Damage to concrete affecting its mechanical strength and its durability

Concrete degradation may have many different causes. Concrete is mostly damaged by the corrosion of reinforcement bars due to the carbonatation of hardened cement paste or chloride attack under wet conditions. Chemical damages are caused by the formation of expansive products produced by various chemical reactions, by aggressive chemical species present in groundwater and seawater, or by microorganisms. Other damaging processes can also involve calcium leaching by water infiltration and different physical phenomena initiating cracks formation and propagation. All these detrimental processes and damaging agents adversely affects the concrete mechanical strength and its durability.

<span class="mw-page-title-main">Alkaline anion exchange membrane fuel cell</span>

An alkaline anion exchange membrane fuel cell (AAEMFC), also known as anion-exchange membrane fuel cells (AEMFCs), alkaline membrane fuel cells (AMFCs), hydroxide exchange membrane fuel cells (HEMFCs), or solid alkaline fuel cells (SAFCs) is a type of alkaline fuel cell that uses an anion exchange membrane to separate the anode and cathode compartments.

<span class="mw-page-title-main">Residual sodium carbonate index</span>

The residual sodium carbonate (RSC) index of irrigation water or soil water is used to indicate the alkalinity hazard for soil. The RSC index is used to find the suitability of the water for irrigation in clay soils which have a high cation exchange capacity. When dissolved sodium in comparison with dissolved calcium and magnesium is high in water, clay soil swells or undergoes dispersion which drastically reduces its infiltration capacity.

Chemical drain cleaners or openers are pure or mixtures of chemicals used to unclog drains that are blocked by hair, food, or other organic materials. They are often accompanied by other mechanical drain cleaners for the optimal effect. Chemical drain cleaners are available through hardware stores, although some may be intended for use by licensed plumbers. They may contain either strong acids or strong alkalis. These cleaners contain chemicals that dissolve at least some of the material causing the clog.

References

  1. 1 2 Krishnamurthy; et al. (1 August 2007). Engineering Chemistry. PHI Learning Pvt. Ltd. p. 146. ISBN   978-81-203-3287-4 . Retrieved 11 September 2013.
  2. Dr. B.K. Ambasta (1 January 2006). Chemistry for Engineers. Laxmi Publications. p. 94. ISBN   978-81-7008-123-4 . Retrieved 11 September 2013.
  3. Sivasankar (2008). Engineering Chemistry. Tata McGraw-Hill Education. p. 513. ISBN   978-0-07-066932-1 . Retrieved 11 September 2013.

Further reading