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What serious consequences can underscale corrosion lead to?

2026-07-19View Original

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Given the previous background related to industrial equipment such as steam generator heat transfer tubes and boilers, under-scale corrosion can lead to several serious consequences: equipment perforation and leakage. The rapid rate of local corrosion results in a rapid thinning of the metal tube walls, causing perforations and leaks in pipes, heat exchangers, and the heating surfaces of boilers, which in turn leads to unplanned shutdowns of the equipment. Heat transfer efficiency plummets: The thermal conductivity of scale is only about 0.1% of that of metal, which significantly reduces the efficiency of heat exchange. For every 1 mm of scale that forms on a boiler, fuel consumption increases by approximately 10%, resulting in substantial energy waste. Causing safety accidents: When pressure-bearing equipment such as boilers and steam generators suffers from under-scale corrosion, the strength of their tube walls decreases significantly, leading to bulging, tube rupture, or even explosions. In China, there have been cases where boilers had to be shut down 6 times within half a year due to under-scale corrosion that caused perforations. Significantly reduces the lifespan of equipment: Corrosion causes an irreversible reduction in the effective thickness of metals; in severe cases, it requires the replacement of large areas of tubing, and may even lead to the premature disposal of key equipment such as steam generators, thereby greatly increasing operational costs. Blockage of piping systems: The accumulation of corrosion products and scale reduces the cross-sectional area available for fluid flow, increasing the flow resistance; in severe cases, it can completely block the heat exchange tubes and disrupt the normal water circulation in the equipment.

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