Study on galvanic corrosion caused by coating failure in heat exchangers for chemical cooling water systems
Cooling water heat exchangers are essential components in chemical production processes, requiring long-term stability under corrosive circulating cooling water conditions. Coating protection technology has become increasingly widespread for mitigating corrosion in these systems. However, prolonged...
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| Format: | Article |
| Language: | English |
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Frontiers Media S.A.
2025-05-01
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| Series: | Frontiers in Materials |
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| Online Access: | https://www.frontiersin.org/articles/10.3389/fmats.2025.1580067/full |
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| author | Zeyu Zuo Zeyu Zuo Zhenhua Yu Zhenhua Yu Qingle Hou Kai Ren Kai Ren Jie Zhang Chengjun Zhang Ruiyong Zhang Wolfgang Sand Zhao Hu Xilei Chen Jizhou Duan Baorong Hou |
| author_facet | Zeyu Zuo Zeyu Zuo Zhenhua Yu Zhenhua Yu Qingle Hou Kai Ren Kai Ren Jie Zhang Chengjun Zhang Ruiyong Zhang Wolfgang Sand Zhao Hu Xilei Chen Jizhou Duan Baorong Hou |
| author_sort | Zeyu Zuo |
| collection | DOAJ |
| description | Cooling water heat exchangers are essential components in chemical production processes, requiring long-term stability under corrosive circulating cooling water conditions. Coating protection technology has become increasingly widespread for mitigating corrosion in these systems. However, prolonged immersion in cooling water during operation can result in coating degradation and detachment. This study examines the corrosion behavior associated with coating damage in cooling water heat exchangers under varying immersion times. Coated carbon steel specimens were coupled with artificially stripped specimens to simulate large cathode and small anode systems in a cooling water environment. The results reveal that the corrosion rate of the small exposed anode increases as the exposure area decreases. Simultaneously, the adhesion between the coating and the substrate of the large cathode weakens with immersion time, leading to the formation of voids regardless of the exposure area. The findings indicate that in practical applications, smaller areas of coating delamination drive localized corrosion at the exposed substrate, whereas larger areas promote internal corrosion beneath the coating, ultimately leading to complete coating failure. |
| format | Article |
| id | doaj-art-bbfbdf0d009a43b784da271a1bdfc848 |
| institution | OA Journals |
| issn | 2296-8016 |
| language | English |
| publishDate | 2025-05-01 |
| publisher | Frontiers Media S.A. |
| record_format | Article |
| series | Frontiers in Materials |
| spelling | doaj-art-bbfbdf0d009a43b784da271a1bdfc8482025-08-20T01:50:00ZengFrontiers Media S.A.Frontiers in Materials2296-80162025-05-011210.3389/fmats.2025.15800671580067Study on galvanic corrosion caused by coating failure in heat exchangers for chemical cooling water systemsZeyu Zuo0Zeyu Zuo1Zhenhua Yu2Zhenhua Yu3Qingle Hou4Kai Ren5Kai Ren6Jie Zhang7Chengjun Zhang8Ruiyong Zhang9Wolfgang Sand10Zhao Hu11Xilei Chen12Jizhou Duan13Baorong Hou14Key Laboratory of Advanced Marine Materials, Institute of Oceanology, Chinese Academy of Sciences, Qingdao, ChinaCollege of Environment and Safety Engineering, Qingdao University of Science and Technology, Qingdao, ChinaQingdao Municipal Center for Disease Control and Prevention, Qingdao, ChinaQingdao Institute of Preventive Medicine, Qingdao, ChinaWanhua Chemical Group Co., Yantai, ChinaKey Laboratory of Advanced Marine Materials, Institute of Oceanology, Chinese Academy of Sciences, Qingdao, ChinaCollege of Environment and Safety Engineering, Qingdao University of Science and Technology, Qingdao, ChinaKey Laboratory of Advanced Marine Materials, Institute of Oceanology, Chinese Academy of Sciences, Qingdao, ChinaWanhua Chemical Group Co., Yantai, ChinaKey Laboratory of Advanced Marine Materials, Institute of Oceanology, Chinese Academy of Sciences, Qingdao, ChinaInstitute of Biosciences, University of Mining and Technology, Freiberg, GermanyKey Laboratory of Advanced Marine Materials, Institute of Oceanology, Chinese Academy of Sciences, Qingdao, ChinaCollege of Environment and Safety Engineering, Qingdao University of Science and Technology, Qingdao, ChinaKey Laboratory of Advanced Marine Materials, Institute of Oceanology, Chinese Academy of Sciences, Qingdao, ChinaKey Laboratory of Advanced Marine Materials, Institute of Oceanology, Chinese Academy of Sciences, Qingdao, ChinaCooling water heat exchangers are essential components in chemical production processes, requiring long-term stability under corrosive circulating cooling water conditions. Coating protection technology has become increasingly widespread for mitigating corrosion in these systems. However, prolonged immersion in cooling water during operation can result in coating degradation and detachment. This study examines the corrosion behavior associated with coating damage in cooling water heat exchangers under varying immersion times. Coated carbon steel specimens were coupled with artificially stripped specimens to simulate large cathode and small anode systems in a cooling water environment. The results reveal that the corrosion rate of the small exposed anode increases as the exposure area decreases. Simultaneously, the adhesion between the coating and the substrate of the large cathode weakens with immersion time, leading to the formation of voids regardless of the exposure area. The findings indicate that in practical applications, smaller areas of coating delamination drive localized corrosion at the exposed substrate, whereas larger areas promote internal corrosion beneath the coating, ultimately leading to complete coating failure.https://www.frontiersin.org/articles/10.3389/fmats.2025.1580067/fullcooling water heat exchangersorganic coatingschemical process safetycorrosioncoating breakage |
| spellingShingle | Zeyu Zuo Zeyu Zuo Zhenhua Yu Zhenhua Yu Qingle Hou Kai Ren Kai Ren Jie Zhang Chengjun Zhang Ruiyong Zhang Wolfgang Sand Zhao Hu Xilei Chen Jizhou Duan Baorong Hou Study on galvanic corrosion caused by coating failure in heat exchangers for chemical cooling water systems Frontiers in Materials cooling water heat exchangers organic coatings chemical process safety corrosion coating breakage |
| title | Study on galvanic corrosion caused by coating failure in heat exchangers for chemical cooling water systems |
| title_full | Study on galvanic corrosion caused by coating failure in heat exchangers for chemical cooling water systems |
| title_fullStr | Study on galvanic corrosion caused by coating failure in heat exchangers for chemical cooling water systems |
| title_full_unstemmed | Study on galvanic corrosion caused by coating failure in heat exchangers for chemical cooling water systems |
| title_short | Study on galvanic corrosion caused by coating failure in heat exchangers for chemical cooling water systems |
| title_sort | study on galvanic corrosion caused by coating failure in heat exchangers for chemical cooling water systems |
| topic | cooling water heat exchangers organic coatings chemical process safety corrosion coating breakage |
| url | https://www.frontiersin.org/articles/10.3389/fmats.2025.1580067/full |
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