Technical Information Guide

Corrosion
The Corrosion Process
Metal corrosion is a chemical reaction between the metal and its environment, as far as water
treatment is concerned this is usually an aquatic environment but not exclusively so. We will
concern ourselves predominantly with the wet environment where corrosion occurs through the
removal of atoms from the metal surface. The metal atoms at the surface loose electrons and
become actively charged ions that leave the surface and enter the water phase, the atoms join with
oppositely charged ions from another chemical to form a new more stable compound, often an
oxide.

In some cases this oxide production may be of benefit, ie the formation of a magnetite film within a
boiler system which shields the metal surface from further attack.
Differential Aeration Effects
The corrosion process needs oxygen and where oxygen is present the metal is cathodic and where
oxygen is depleted the metal is anodic and corrodes. The parts of the metal in contact with the
highest concentrations of oxygen become cathodic and are protected, areas of low oxygen will see
corrosion and this effect is the principal cause of pitting corrosion in cooling systems and is
particularly noted in under deposit corrosion. The same principal is apparent in crevice corrosion
which is most likely to be observed in steam boilers should a small crack occur any where in the
water side construction.

AKVO Ltd, Unit 3A Davian Works Storforth Lane Chesterfield S40 2TU

T: 0844 2448726

E:office@akvo.co.uk

Technical Information Guide

Corrosion
Bacterial corrosion
This occurs when certain acid producing bacteria are present in a cooling water system, eg sulphate
and nitrate reducers which produce sulphuric and nitric acids respectively. Any corrosion displayed
will be very localized and surfaced will have a shiny appearance.
Galvanic Corrosion
Galvanic corrosion can occur when two dissimilar metals are adjacent to each other in a water
bearing system under such conditions the more anodic material will corrode, the further apart the
metals are in the galvanic series then the more rapid the corrosion of the most anodic material will
be, the galvanic series is as follows:
Cathodic
Graphite
Platinum
Titanium
Austenitic Stainless, passive
Chromium Steels, passive
Inconel
Nickel
Monel
Bronze, Gunmetal
Copper
Alpha Brass
Naval Brass
Tin
Lead
Austenitic Stainless, active
High Nickel Cast Iron
Chromium Steels, active
Cast Iron
Mild Steel
Aluminium alloys
Cadmium
Aluminium
Zinc
Magnesium
Anodic
It should be noted that the processes detailed above are not the only types of corrosion likely to be
encountered, but they are the most common.
AKVO Ltd, Unit 3A Davian Works Storforth Lane Chesterfield S40 2TU

T: 0844 2448726

E:office@akvo.co.uk

Technical Information Guide

Corrosion
Controlling Corrosion
Corrosion control involves hindering the natural chemical reactions occurring between the metal and
its environment. From a water treatment perspective the most likely methods are to modify the
environment, eg remove oxygen, as we do in a steam boiler system, or install a protective film over
the metal surfaces as we do in a cooling / heating water system with film forming corrosion inhibitors
which can be either cathodic or anodic in nature.
Measuring Corrosion Rates
There are two common methods of monitoring corrosion rates, the simple coupon method which
involves the suspension of a small metal coupon of known weight and size in the system under
scrutiny. From the weight loss, in relation to the number of days the coupon has been suspended,
the corrosion rate in mpy can be calculated from the following equation:
Corrosion rate mpy =
______143,700 x Weight loss (grams)
Metal density (g/cm3) x Coupon area (cm2) x Time (days)
The number 143,700 is constant relating to the coupon area and for a calculation to give the rate in
mpy, should you wish to have the result expressed in mm/year then a different constant would be
used. AKVO can supply the coupons. We have a table of metal densities and will make the
calculations on your behalf.
Contact AKVO for expert advice on minimization of corrosion in your water system. Visit
www.akvo.co.uk, or call 0844 2448726.

AKVO Ltd, Unit 3A Davian Works Storforth Lane Chesterfield S40 2TU

T: 0844 2448726

E:office@akvo.co.uk

Technical Information Guide

Corrosion

Acceptable Rates of Corrosion

What is deemed to be acceptable will depend upon the type of system and the ability to apply
suitable corrosion protection and the materials of construction. For normal industrial installations
the following tables give an indication of what would be acceptable, corrosion rates are stated in
mpy and apply to general corrosion rates. If the analyst reports that pitting has been observed then
action may need to be taken at levels much lower than stated below

DESCRIPTION
Excellent
Very Good
Good
Moderate to Fair
Poor
Very poor

OPEN RECIRCULATING COOLING SYSTEMS

CARBON STEEL
COPPER ALLOYS
<1
<0.1
1 to 3
0.1 to 0.25
3 to 5
0.25 to 0.35
5 to 8
0.35 to 0.5
8 to 10
0.5 to 1.0
>10
>1

CLOSED RECIRCULATING COOLING/CHILLED/HEATING WATER SYSTEMS

DESCRIPTION
CARBON STEEL
COPPER ALLOYS
Excellent
<0.2
<0.1
Good
0.2 TO 0.5
0.1 TO 0.25
Moderate
0.5 TO 0.8
0.25 TO 0.35
Poor
0.8 TO 1.0
0.35 TO 0.5
Very poor
>1
>0.5
Contact AKVO for expert advice on minimization of corrosion in your water system. Visit
www.akvo.co.uk, or call 0844 2448726.

AKVO Ltd, Unit 3A Davian Works Storforth Lane Chesterfield S40 2TU

T: 0844 2448726

E:office@akvo.co.uk